[NB_Small Engines]

Let me start off by introducing myself, Im Nick, I'm 33 and work on small engines as a hobby/side job. Have a decent amout of experience with atvs, dirt bikes, small engine repairs. But I am new to this hondamatic transmission, never worked on one or serviced one before.

A friend of mine brought me his 2003 Foreman Rubicon 500 that has what appears to be transmission/clutch issues. ATV runs fine, but won't move no matter what gear you select with the lever, wether it be in D1, D2, or ESP. He claims he rode it into his shed, shut it down, and the next time he went to use it he started it up and could barely get it into gear using the shift lever, and then once he got it in gear the lever wouldn't move back out... (It came to me still in reverse but I managed to get the lever back to neutral). Its been maintained relatively well from what I can see, and the engine oil was very clean and up to spec on dipstick.

I scouted this forum for a while, and have seen some threads mostly talking about oil pressure failure due to the oil pump chain coming off. After researching a bunch I figured out that the hondamatic obviously needs sufficient oil pressure to operate correctly. I also saw some videos on how to retrieve "Codes" from the dash indicator, so I went ahead and did that and only got a Code 11 (which could be a number of things, ECM Relay Code). That could be a weak battery, who knows how long that code could have been stored. After reading countless forums I decided to start with checking the oil pressure check valves and springs. Took both oil pressure bolts out of the engine and only could get the springs out. Is there a secret to getting the oil check valves out?? Anyway, the springs looked good so I reinstalled bolts.

Today I tore into the front part of the engine to inspect and see what was going on exactly. I was really hoping to just tear the front cover off and see the oil pump chain hanging off, but of course that wasn't the case. Please note that I don't have the Honda oil pressure tool, so to check oil pressure before I tore the engine down I pulled off the oil lines going to the front tank, started the atv and let it idle and had no oil flow coming in or out of those lines at all. Kinda figured that meant no oil pressure and was sure that I was going to see a chain failure. Not the case.

I am now waiting on the owner to bring me the service manual tonight, also waiting on the puller to get the clutch pack off, and I ordered a new oil pump chain since im already in there. Upon inspection I took these pictures. It appears the clutch basket or outer ring has seen some heat, any thoughts? Clutch that worn to where atvs won't move? Also, there is some writing on the hondamatic...has it been replaced already?? My friend had bought this quad in 2016, and has ridden it this long without any issues.

Any input would be appreciated guys, what should I be checking? Anything I missed?

 

[NB_Small Engines]

Cmon, nobody has any input on this?

 

[spock]

I went through something similar with a 2001 Rubicon, it also had barely enough power to turn the wheels when they were jacked up off the ground. After doing similar research and trying various diagnostics I ended up with replacing the Hondamatic. The first attempt with a used one ended badly, but that's another story. My only suggestion is to verify that the gear is turning freely that the shift motor controls. If it's stuck, try to get it turning again and attempt to reset the ecm. Also, verify that the angle sensor is properly installed and preloaded. Those clutches also show signs of heat but usually work fine as is. Once all the electrical codes are cleared & reset you may end up with nothing much to go on and have to accept that the Hondamatic may have failed. Hope it isn't the case but I was in that boat and invested in a new $2000 part to get this one fixed.

 

[NB_Small Engines]

I went through something similar with a 2001 Rubicon, it also had barely enough power to turn the wheels when they were jacked up off the ground. After doing similar research and trying various diagnostics I ended up with replacing the Hondamatic. The first attempt with a used one ended badly, but that's another story. My only suggestion is to verify that the gear is turning freely that the shift motor controls. If it's stuck, try to get it turning again and attempt to reset the ecm. Also, verify that the angle sensor is properly installed and preloaded. Those clutches also show signs of heat but usually work fine as is. Once all the electrical codes are cleared & reset you may end up with nothing much to go on and have to accept that the Hondamatic may have failed. Hope it isn't the case but I was in that boat and invested in a new $2000 part to get this one fixed.

oh my buddys gonna love to hear that LOL!
thanks for your input man!

 

[jack13803]

You might be sure the axles are not pulled loose from the differential,may be if one is popped out the other will not work, axle itself could be broke inside. Just a guess, hope it's a easy repair.

 

[Dwill]

You can rebuild the Hondamatic, it’s really pretty easy! I rebuilt mind 4 years ago and works perfectly. Plowed my driveway with it today.

 

[andyjcule]

Did you have any trouble finding parts to rebuild your hondamatic? My husband is a quality mechanic, but he doesn't think he should tackle this sealed unit.

 

[Dwill]

Did you have any trouble finding parts to rebuild your hondamatic? My husband is a quality mechanic, but he doesn't think he should tackle this sealed unit.

The bearing is easy to find. You’ll have to have the swash plate machined and if it needs any parts you’ll need a parts transmission. No individual parts are available. I ended up buying two parts ones to rebuild mine and was able to rebuild one of those for a spare if I ever need it.

 

[lk2lrn]

would like to see an answer on why no oil psi since he said chain was still on. Seems I got the same thing on my grandsons 2003 500 rubicon, took the plug out where I think you check the oil psi and nothing coming out. Engine starts and runs good and shows its shifting thru gears when in that mode.. Also reset the angle sensor and can hear the shift motor running. Also when you turn the engine off you can hear somehing still turning or coasting in the bottom of engine. Where should I pull cover to check for oil pump chain. Any guess what I can hear when turning engine off?