Clunk after shifting from n to 1 - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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post #1 of 7 (permalink) Old 07-08-2019, 01:37 AM Thread Starter
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Clunk after shifting from n to 1

Hi First time here I just got a new to me a 2006 Honda foreman ES,
when I shift from N to 1st and after it engages and I press the go pedal i sometimes hear a clunk or a pop and it feels like it went into gear again, I can leave it in 1st and it's fine the rest of the gears are good, like what's going on it only as 2300 km's and is in great shape.

any help would be great
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post #2 of 7 (permalink) Old 07-08-2019, 09:54 AM
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Welcome to the site!


Sounds like the first gear problem with the 2004-2008 year models. ( I believe that is the year range but don't quote me). The gear has 4 ears on it to catch, the newer replacement gear has been beefed up and has 6. From what I know, the motor will have to come off and replacing the timing chain is recommended while you're at it. I have the same problem with mine and need to replace it also. All this information came from a very well known and respected member on here that helped me out many times.

Yesterday I was told by someone that had replaced their top end that you could get to the transmission gear from the front cover without removing the motor, but not too sure about that.
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2014 Foreman 500FM
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post #3 of 7 (permalink) Old 07-08-2019, 11:50 AM
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05-08 500's have a weak first gear.


What Wibur said pretty much covers it. Your dogs on first gear are slipping.


You definitely have to split cases to replace the gear. Whoever told you it can be done without removing the motor didn't know what they were talking about.


If you look at my thread here. Post #50 shows the new gear.


https://www.hondaforeman.com/130-for...-cleaning.html
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2005 Foreman Rubicon Camo
Perfex, 27" Mudbugs
Heated grips and Thumb , HID's
5K Viper Max winch

2009 Foreman 500FM Green
Perfex with HL springs
27" Execs on Rubicon rims
Heated Grips and Thumb, HID's
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2006 Foreman 500FM Green
28" Mugbugs, stretched, Perfex, HLsprings
3K Superwinch winch

2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
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post #4 of 7 (permalink) Old 07-08-2019, 01:07 PM
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I figured as much Jeep, this guy that told me that is more full of bull than the cows grazing in the pasture with their tails in the air.
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2007 Foreman 500FM
2014 Foreman 500FM
Service Manuals Link: https://drive.google.com/drive/folde...7LP-eZp2jMRVJU
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post #5 of 7 (permalink) Old 07-13-2019, 10:52 PM Thread Starter
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thanks guys for your help I pull the engine and bringing it to the shop to get it fixed...
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post #6 of 7 (permalink) Old 07-14-2019, 07:54 PM
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Newfie,

If you have enough snap to pull the engine then the rest is not that hard. I need to do mine also and have to admit that I haven't done it but from what I have been told it's not that difficult. I thought about taking mine in too just for the convenience but I'm just a little bit more of a miser. If you have the money the hassle is not worth it but if you're scratching then everybody here is more than willing to walk you through the questions you have during the process.
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2007 Foreman 500FM
2014 Foreman 500FM
Service Manuals Link: https://drive.google.com/drive/folde...7LP-eZp2jMRVJU
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post #7 of 7 (permalink) Old 07-15-2019, 12:51 PM
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Not that hard if you're careful.


I put a big piece of cardboard on the floor, lay the bits in order as I remove them.


If you're careful when you split cases you can set the engine with stator/ flywheel down and pull the top crankcase half off and the transmission will stay in place. The 1st gear set you need to replace is right on top so you don't have to remove the transmission.

2005 Foreman Rubicon Camo
Perfex, 27" Mudbugs
Heated grips and Thumb , HID's
5K Viper Max winch

2009 Foreman 500FM Green
Perfex with HL springs
27" Execs on Rubicon rims
Heated Grips and Thumb, HID's
4K Viper Max winch

2006 Foreman 500FM Green
28" Mugbugs, stretched, Perfex, HLsprings
3K Superwinch winch

2009 475 Rancher AT Tan
26" Mudbugs on Rincon rims
Warn winch. Foreman pod light with HID, SRA gear reduction
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