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Discussion Starter · #1 ·
My 06 500 has a viberation. At idle, in neutral, the handle bars shake so bad that I cant even read the cluster.
Also, the foot shifter viberates when you rev it up bad. With a small chatter with it.
I just got the bike back. It broke memorial day, come to find out it blew 1st gear apart.
The whole motor was rebuilt about 3 months ago. The tech that fixed it last time said that the previous tech did not shim the gears correctly, and that is why it blew 1st.
But the viberation in the handle bars has been there since the first rebuild.
I am dropping the bike off this week at honda, but I do not think these guys know what they are doing.
Please Help!!!!!!!
 

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Discussion Starter · #3 ·
Unfortunately, because it has to do with the warranty repair done originaly, it has to go back to the same dealer. If I take it somewhere else, honda will tell them it has to go back to the original place. Not to mention, the only other place is really isnt worht a f***.
 

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What was done to the motor 3 months ago ..? .. And what was done Memorial weekend..?.. There are a few things that could the viberation , balancer not timed right , something wrong with the centrifugal clutch , a new rod installed and 1 of the crank weights turned on the crank pin , wrong airgap (bike could be out of time) loose or worn flywheel key etc ..

As for the transmission there is only a couple of thrust washers in the whole transmission and there is no shimming to be done ..
 

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Discussion Starter · #5 ·
originally, the rear out put shaft broke, and filled the motor with mud and water. My fault I didnt stop, but was no where that I could be towed from. They torn the motor down(without my auth.) and let it sit for 4 1/2 months. everthing locked up. They ended up rebuilding the entire motor(so they say). It only cost me about $1000.00. They ate a lot of the parts due to the fact that they tore it down without my ok.

When I got the bike back, the handle bars started to shack bad, and the foot shifter was jumping real bad. Memorial day it broke, the bike would bounce in and out of gear in 1st. They tore the bike down and said that 1st gear was broken, how bad, I dont know. The tech that worked on it was not the same as the first. He said that the first tech dint properly shim the first gear, maybe he meant the thrust washer, but he said the thickness was wrong.

Here is the list from the second repair. The first repair has 4 1/2 pages of parts.
1st gear (55th)
washer 17mm
washer c 25mm
bolt hex 6x25
nut lock 18mm
nut lock 20mm
plate, clutch cam
spring
retainer, ball
washer 10x21-5
washer 12mm x 2
screen oil
filter, oil
roller 4x13-8
oil seal 25x61x8-5
oil seal 22x31x7
tighten bolts for secondary clutch
front & rear output shaft seals
thats about it.

I just dropped the bike of, so lets see what they say. Good news is that they are going to give me a Rincon as a loaner bike until mine is fixed.
 

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Discussion Starter · #6 ·
I just really want to know if they know what they are doing, or if they are incompendant.
 

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Discussion Starter · #7 ·
Anyone got any other ideas?
 

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Why was countershaft 1st gear (55t) replaced and not the mainshaft which has 1st gear machined into the shaft ..

Why was the oil screen replaced it is a metal screen with rubber moulded around the outside , it is cleanable ..


If that shop can't re-build your engine then they are in the wrong business .. The TRX500 Foreman engine is very easy to work on .. All that is needed is a couple of special tools (pullers) ..

With mud/dirty water in the engine how did they clean the 2 oil coolers on the bike ..? ..
 

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Discussion Starter · #9 ·
I do not know how they cleaned the oil coolers. In fact, the first time they didnt, I had to give it back to them because they must not, the oil still had water in it.

I was looking in the Honda manual, the 55t gear is not part of the counter shaft.

Is it possible that the 55t gear is 5th gear?
 

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Discussion Starter · #10 ·
The main shaft has a 28 tooth(c5) gear machined on it.
 

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No 1st gear on the countershaft is just a 55 tooth gear (replaceable gear) but it meshes with the 13 tooth gear that is machined into the mainshaft .. I was wondering what was wrong with the C1 gear that it was replaced , if mud/dirt was in between the meshing gears (1st gear) it would/could mark/wear the C1 gear but it would also do the same to the mainshaft gear .. I also see at least 1 thrust washer was changed ..

Also there are somewhere around 10 bearings in the crankcase it seems odd they were all ok when the same dirt is going thru them ...
 

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Discussion Starter · #12 ·
On the first rebuild, the bearings were replaced, but nut on the second service with first gear.

I see what you say about 1st gear siding onto the 13t shaft.

Also, I picked the bike up, a week and a half later, I returned the bike, and it was put to the back of the list. When I worked at Chevy, if we had a recheck, as soon as we were done with the job we were on, it went right to you, not put on hold.
 

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QUOTE ("Honda Mechanic":37q8gl3f)
No 1st gear on the countershaft is just a 55 tooth gear (replaceable gear) but it meshes with the 13 tooth gear that is machined into the mainshaft .. I was wondering what was wrong with the C1 gear that it was replaced , if mud/dirt was in between the meshing gears (1st gear) it would/could mark/wear the C1 gear but it would also do the same to the mainshaft gear .. I also see at least 1 thrust washer was changed ..

Also there are somewhere around 10 bearings in the crankcase it seems odd they were all ok when the same dirt is going thru them ...

Almost sounds like someone did a half-ass job of rebuilding it... Sort of fishy how they didn't replace the bearings being it was mud/water damage.
 

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Discussion Starter · #15 ·
The first repair the did replace the bearings. I have 4 1/2 pages of parts on the first repair. That is why I didnt post all of the parts from the first repair.
 
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