wtnhunt Posted September 14, 2013 Report Share Posted September 14, 2013 Real bad timing for the 4 wheeler to break down. Our 2004 honda foreman 450s transmission won't downshift. Tried everything I know to do with the thing. After I shut it off rocked it back and forth, no luck. Of course no way to get it started now either with it in gear. Wife got the 4 wheeler stuck last week, she failed to remember to flip the switch to get it in 4wd, don't know that has anything to do with the problem. Still seemed fine this morning. Then a little earlier today after running through some thick tall swamp grass going to check a stand with it when I put in reverse things went wrong. Feels like something has come loose when pushing the shifter, but dunno. Anyone have any ideas? Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 15, 2013 Report Share Posted September 15, 2013 any atv mechanics? I consider myself a decent mechanic, I have rebuilt 3 Hondas this year. Recon, rancher and foreman450s. The transmission part of it is the part that gives me headaches. The guys at honda foreman forums helped me out a bunch. On my '01 450 there is an adjustment screw for the shifter. It is on shifter side of engine almost below the front drive shaft. Let me go find my '04 Manuel and see if urs is the same Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 15, 2013 Report Share Posted September 15, 2013 any atv mechanics? Ok my first thoughts with out seeing the atv is the bolt on the shift drum may have loosened some, or the shift plate may be cracked. But it could be a couple other things. I have a few questions does the shift lever move freely? Were you able to up shift or is it just stuck in one particular gear? Ps I have a digital copy of service manual I can email to you, if you need one. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 15, 2013 Author Report Share Posted September 15, 2013 Thanks for the help. I was able to upshift, but not downshift. Had trouble getting it in reverse, had to push a little harder than normal, and after that was when the problem started. In 5th gear now. Lever seems to move maybe a little too free, like it is not engaging. Only adjustment outside the front cover I saw when I looked after it happened was the clutch adjustment, I will have to look again this morning to see if there is an adjustment for the shifter. I do not have a service manual, considered buying the clymer service manual for it. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 15, 2013 Report Share Posted September 15, 2013 any atv mechanics? Sounds like the shifter plate, not the drum screw. Not too hard to change, and only a $7 part. It could be something else but you won't know until the cover comes off. Pm me your email address and I can send you the manual. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 15, 2013 Author Report Share Posted September 15, 2013 Got the file, thank you. Looking at that breakdown, looks likely with what it is doing that the problem could be the drum shifter or the shifter plate, unless the linkage itself is broken, does not seem likely to be the problem since it was still shifting to higher gears. Does the clutch assembly have to come out? Looks like probably at least a couple hour job to tear down. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 15, 2013 Report Share Posted September 15, 2013 any atv mechanics? I don't think linkage will be the problem, the plate is made to fail first. The clutches will not have to come out unless the problem lies else where. If you stand the bike up on the rear rack you won't even loose fluids, although I would change them just because. Also if shift plate is broken you will want to find all pieces, and flush engine to be sure not metal is in there to tear up something else. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 15, 2013 Author Report Share Posted September 15, 2013 I really appreciate your help. Changed the oil and filter less than a month ago, probably go ahead on and drain it and change it again to be on the safe side. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 18, 2013 Report Share Posted September 18, 2013 any atv mechanics? How's it coming ? Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 18, 2013 Author Report Share Posted September 18, 2013 Have not gotten into it yet. Going to plan on probably dragging it to the garage either tomorrow afternoon or Friday. Quote Link to comment Share on other sites More sharing options...
dbHunterNY Posted September 21, 2013 Report Share Posted September 21, 2013 kind of missed this ... sounds like you're definitely on the right path. we have other problems with my parent's foreman 450. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 21, 2013 Report Share Posted September 21, 2013 any atv mechanics? I put my 450 thru the test, it's a very strong bike IMO, I've wrenched on my fair share of machines and the 450s is the one I own. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 21, 2013 Author Report Share Posted September 21, 2013 Got it apart, not sure at this point where exactly the problem is, I cannot see real well to see inside the gearshift assembly. Linkage is fine. The assembly did seem to work after I got it opened up, I pulled the sub gearshift arm to try to get at the guide plate but have not pulled that yet. No chunks or broken parts inside so far, oil was clean. The clutch lifter cam assembly jumped out when I pulled the cover and some of those parts were laying inside the bottom of the cover. I had intended on asking if I should be concerned about anything jumping out at me when I opened it up and wish I had. Not sure exactly how/where the parts came out from, may be overlooking it but think I am going to need a better exploded view to figure out how it goes back together. I have the mudflaps off and the inner wheel wells removed, but have not pulled the front rack or fender off, do they need to come off? I did not have the bike standing up when I opened the front cover, thought I would leave it down so the oil could drain out in case there was any debris. Yeah, the 450s has been a pretty good bike. Only issues I have really had with it aside from this was the carb issues from that freaking ethanol gas. Once I started running ethanol free gas, no more problems there. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 21, 2013 Author Report Share Posted September 21, 2013 Sounds like the shifter plate, not the drum screw. You got it right shift plate is broken. Still going to have to figure out how to put it back together when the new part comes in. Guessing it is not supposed to look like this. I did manage to fish out the other half and it was broken clean. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 22, 2013 Author Report Share Posted September 22, 2013 Part should be here Thursday. Is there a trick to get the new shift plate in without removing the clutches? The gearshift arm(# 12 in the pic) and spring will not come out, seem to be in the way. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 24, 2013 Report Share Posted September 24, 2013 I'm pretty sure you can get the new shifter plate to slide in behind the arm with out removing the arm. Something tells me it slides in I haven't messed with shift linkage in a good while. I can make a phone call if need be to find out but I'm 98% sure it will slide in with some finagling. For a blow up for the springs got to motosport.com, go to OEM parts and they have blow ups that I reference time to time that sometimes repair books don't show clearly. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 24, 2013 Author Report Share Posted September 24, 2013 Hope you are right on the plate fitting in. I looked at those at motosport when I ordered the plate, it just came in this morning so hoping I can work on it this afternoon. I will try to print those off and take them out in the garage with me when I am putting it all back together, might be easier to figure out while looking at the pics in front of the actual parts. That motosport place was great too, no local shops had the part in stock would have been the end of the week, I ordered Saturday and ups just dropped off the box. Quote Link to comment Share on other sites More sharing options...
wtnhunt Posted September 24, 2013 Author Report Share Posted September 24, 2013 So glad you were right once again. Cannot say thanks enough for all your help. Got the shift plate in much easier than getting out the broken piece. Only issue I had was getting that round guide plate lined up where the notch was also lined up but finally got it after fighting with it a while. I got the bolt started but had to quit for the night to come in and help the wife with the kids at supper. Thought I read the bolt needed locktite on it, and glad I stopped because I see it does. Hopefully finish it up and have it back running tomorrow afternoon. Quote Link to comment Share on other sites More sharing options...
smha6784 Posted September 25, 2013 Report Share Posted September 25, 2013 Good deal, that's awesome !!!!! glad I could help!!! Quote Link to comment Share on other sites More sharing options...
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