Hey, I just registered, this forum looks to be a great help with working on the bike. I just got a foreman 500 this past weekend, I already have a Kawasaki 400 4x4 but I have been wanting a honda. Anyways the bike I got had been wrecked before and kinda neglected. I fixed the float on the carberator it was overflowing and the left axle wasn't in the diff. all the way and I got that fixed. My question is I jacked the bike up in the front and back and locked it in 4x4 and the front tires didn't move. The light on the display turned green showing the 4x4 on but nothing moved. Do you think this could be electrical or something in the diff. I am not familiar with how it is suppose to lock in. Any help would be greatly appreciated. I want to fix it before I order tires and snorkle it out.
Whiteboy77
Joined
·
2 Posts
Hi all, I have a '07 Foreman 500 manual shift (not an ES model).
I have a similar issue to what has been discussed in this thread, except, get this:
My 4wd works perfect in reverse only. If I put the bike in neutral and turn the front output shaft by hand (with the engine running) all 4 wheels turn in the reverse direction, but if I rotate the shaft in the forward direction, only the back wheels turn. I have gone through my speed sensors and, obviously, the electronic clutch "FFC" (Front Final Clutch) is working in reverse and neutral. When I have all 4 wheels off the ground, put the transmission in reverse, again, all 4 wheels spin and I can stop all 4 wheels with the front brakes. As soon as I put it in first or any forward gear, the front wheels stop turning while the rears are turning. At 15km/hr, the 4x4 light starts flashing, indicating the speed sensors are detecting a difference between front and rear speed sensors.
Has anyone had one of these FFC units apart? Is it possible to have turned itself into a 1-way ratchet type mechanism or could my shift angle sensor be only working in reverse?
I have a similar issue to what has been discussed in this thread, except, get this:
My 4wd works perfect in reverse only. If I put the bike in neutral and turn the front output shaft by hand (with the engine running) all 4 wheels turn in the reverse direction, but if I rotate the shaft in the forward direction, only the back wheels turn. I have gone through my speed sensors and, obviously, the electronic clutch "FFC" (Front Final Clutch) is working in reverse and neutral. When I have all 4 wheels off the ground, put the transmission in reverse, again, all 4 wheels spin and I can stop all 4 wheels with the front brakes. As soon as I put it in first or any forward gear, the front wheels stop turning while the rears are turning. At 15km/hr, the 4x4 light starts flashing, indicating the speed sensors are detecting a difference between front and rear speed sensors.
Has anyone had one of these FFC units apart? Is it possible to have turned itself into a 1-way ratchet type mechanism or could my shift angle sensor be only working in reverse?
Joined
·
2 Posts
Thanks for the reply Spock, I have an inspection camera and was able to see inside the front diff through the oil fill hole. The pinion shaft at that end looks ok. I think, like you suggested, the back end splines of the pinion shaft and/or the front final clutch are stripped like when you strip a philips head screw in one direction. You can still tighten it but slips when trying to loosen.
I have ordered a replacement front final clutch because I am certain it is the broken link. When I get the replacement one, and take off the original, I'll do more investigating and post some photos.
I am hoping the pinion shaft is the only part stripped. It would be great if I could get a new pinion shaft and have a backup working FFC. We'll see!
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
