Hot!420 bottom end swap on foreman 500

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2016/06/13 18:45:58 (permalink)

420 bottom end swap on foreman 500

If you haven't been following my rebuild you should look over my past threads:
http://forum.highlifter.com/m/tm.aspx?m=4990758
http://forum.highlifter.com/m/tm.aspx?m=4993596

So, I got the motor in and I went to hookup the front driveshaft slip yoke and I believe the spline count on the 420 front output shaft is different. Yoke will not go on, I need to count the threads tho. Can anyone confirm if the thread count on front output shaft is different than a 420 from the 500?

Here's some pics:


Pictured with 500 shaft (slips right on)




The big question is, if I got a 420 yoke the spline count will be the same on the output shaft, but what about the driveshaft

Coastal chaos
HONDA FOREMAN 2013 
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#1

75 Replies Related Threads

    00_NUTT
    Super Swamper
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    Re: 420 bottom end swap on foreman 500 2016/06/13 19:23:30 (permalink)
    Oh SNAP wish I could help but I do want to see the answer so hopefully someone will know.

    00_NUTT
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    SON'S BIKE
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    #2
    I shoot rooster tails
    Mud Master
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    Re: 420 bottom end swap on foreman 500 2016/06/13 22:13:03 (permalink)
    Yea I know one plot twist after another, when it's sold I'm gonna look at getting a can am

    Coastal chaos
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    #3
    BridelessRacing
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    Re: 420 bottom end swap on foreman 500 2016/06/14 08:09:09 (permalink)
    if it wont work
    I could marry the 2 ends to make a correct length shaft
     


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    #4
    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/06/14 17:48:49 (permalink)
    According to this the coupler that goes on the front of the final shaft and that the front driveshaft slides into (#7) is the same on the 420 and the 500, which means the spline counts would have to be the same.

    http://www.partzilla.com/...+FINAL+GEAR/parts.html

    The end of the final shaft maybe mushroomed from someone banging on it?
    #5
    00_NUTT
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    Re: 420 bottom end swap on foreman 500 2016/06/14 21:14:48 (permalink)
    Could be but I guess you won't know till you try.

    00_NUTT
    1997 Honda 300 4x4
    Head Ported and Polished
    317 Kit
    Big Red Cam
    Clutch Kit
    SuperTrapp IDS2 Exhaust
    K&N Filter
    Carb Kit
    32" Interco Interforce II's
    16" MSA M30 Trottles
    Snorkled 
    54% gear reduction
    Honda 350 rear axle assm.

    6" BPC CUSTOM LIFT WITH 8" STRETCH AND 3" BODY LIFT OLD 300 LOOKING GOOD AS EVER THANKS TO WHITNEY!!!!!

    SON'S BIKE
    1998 Honda 300 2x4
    6" BPC LIft with some sick a-arms
    420 spindles and disk brakes
    29.5" OL2'S
    14" MSA M26 Vibes
     
    Upcoming
    4x4 Frame and Motor that's here now just got to get to work on the swap over!!!
    54% Gear Reduction
     
    #6
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/06/15 19:00:55 (permalink)
    If it was mushroomed how could I fix it

    Coastal chaos
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/06/16 13:02:17 (permalink)
    Dremel or needle file top open up the grooves and smooth out the ends of the splines on the end is the only thing I can think of.
     
    It it flattened out/ schroomed on the end?
    #8
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/06/16 15:32:41 (permalink)
    Not I can see with my naked eye

    Coastal chaos
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/06/17 10:48:26 (permalink)
    Weird.  Has to be some reason it's not going on.
    #10
    00_NUTT
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    Re: 420 bottom end swap on foreman 500 2016/06/17 13:53:34 (permalink)
    Find you a set of digital calipers and that will tell you what's up.

    00_NUTT
    1997 Honda 300 4x4
    Head Ported and Polished
    317 Kit
    Big Red Cam
    Clutch Kit
    SuperTrapp IDS2 Exhaust
    K&N Filter
    Carb Kit
    32" Interco Interforce II's
    16" MSA M30 Trottles
    Snorkled 
    54% gear reduction
    Honda 350 rear axle assm.

    6" BPC CUSTOM LIFT WITH 8" STRETCH AND 3" BODY LIFT OLD 300 LOOKING GOOD AS EVER THANKS TO WHITNEY!!!!!

    SON'S BIKE
    1998 Honda 300 2x4
    6" BPC LIft with some sick a-arms
    420 spindles and disk brakes
    29.5" OL2'S
    14" MSA M26 Vibes
     
    Upcoming
    4x4 Frame and Motor that's here now just got to get to work on the swap over!!!
    54% Gear Reduction
     
    #11
    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/06/20 10:03:37 (permalink)
    Any progress?  You count the splines and make sure they were the same?
    #12
    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/19 12:41:21 (permalink)
    Buller?......Bueller?......
    #13
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/19 12:57:16 (permalink)
    Got it on there got everything all put together, and now I have no fuel or spark.

    Coastal chaos
    HONDA FOREMAN 2013 
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    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/19 12:58:49 (permalink)
    Turns over fine with good compression

    Coastal chaos
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    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/19 14:03:18 (permalink)
    Been doing pin out tests for awhile, I think it's the wiring harness or pgm-fi unit

    Coastal chaos
    HONDA FOREMAN 2013 
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    00_NUTT
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    Re: 420 bottom end swap on foreman 500 2016/08/19 20:58:42 (permalink)
    Yea it's wiring for sure. 

    00_NUTT
    1997 Honda 300 4x4
    Head Ported and Polished
    317 Kit
    Big Red Cam
    Clutch Kit
    SuperTrapp IDS2 Exhaust
    K&N Filter
    Carb Kit
    32" Interco Interforce II's
    16" MSA M30 Trottles
    Snorkled 
    54% gear reduction
    Honda 350 rear axle assm.

    6" BPC CUSTOM LIFT WITH 8" STRETCH AND 3" BODY LIFT OLD 300 LOOKING GOOD AS EVER THANKS TO WHITNEY!!!!!

    SON'S BIKE
    1998 Honda 300 2x4
    6" BPC LIft with some sick a-arms
    420 spindles and disk brakes
    29.5" OL2'S
    14" MSA M26 Vibes
     
    Upcoming
    4x4 Frame and Motor that's here now just got to get to work on the swap over!!!
    54% Gear Reduction
     
    #17
    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/20 10:57:53 (permalink)
    You shouldn't have much. Gear position switch? Temp sensor?
    #18
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/22 08:55:18 (permalink)
    Actually finally ran the right tests one wires for coil was 12v the other was around 6 so I ordered a new coil and that should fix this problem, turns out I'm going to have to make new upper motor mounts on the frame, air box mounts and I'm gonna have to delete the rear air box, for some reason the whole top end is 1/2 inch further back then the old motor good thing I'm a certified welder

    Coastal chaos
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/22 09:42:44 (permalink)
    Really?  That doesn't make sense.  If the crankcases are ths same the lower motor mounts and thus the motor should be in the exact same spot.  The top ends are interchangeable (I have a 500 top end on the wife's 420).
     
    You can't just rotate, pull the top of the motor forward?
     
    Just about every time I've pulled a motor I've had to leave the bottom motor mount bolts loose and pull forward on the top end to get the top motor mount on the back of the top end. 
     
    Had to have the wife flip the upper motor mount for me last week on a 350 Rancher.  It took quite a bit of tugging to pull it far enough forward for the motor mount to slide in.
    #20
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/22 13:38:58 (permalink)
    I'll post pictures later

    Coastal chaos
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    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/22 22:37:35 (permalink)
    That is the lower mounts and the upper motor mount is to far foward by 1/2 inch so is air box

    Coastal chaos
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/23 10:39:35 (permalink)
    Yeah I get that.  Loosen the bolts on the lower motor mounts and pull forward on the top end.  It will move.  There is play in all of that.  1/2" should be easy to move.  The 350 I'm working on was closer to an inch.  I pulled the top end foward and held it while swinging the top motor mount into place.
    #23
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/23 10:58:10 (permalink)
    Didn't think about that, thanks. On a side note do you think a 2013 Honda rancher programmer will work on this?

    Coastal chaos
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/23 14:01:36 (permalink)
    #25
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/26 13:06:56 (permalink)
    Coil goes in today boys

    Coastal chaos
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    00_NUTT
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    Re: 420 bottom end swap on foreman 500 2016/08/26 22:27:19 (permalink)
    Ok it's been 9 hrs since your last post so what happened when you put the coil on???

    00_NUTT
    1997 Honda 300 4x4
    Head Ported and Polished
    317 Kit
    Big Red Cam
    Clutch Kit
    SuperTrapp IDS2 Exhaust
    K&N Filter
    Carb Kit
    32" Interco Interforce II's
    16" MSA M30 Trottles
    Snorkled 
    54% gear reduction
    Honda 350 rear axle assm.

    6" BPC CUSTOM LIFT WITH 8" STRETCH AND 3" BODY LIFT OLD 300 LOOKING GOOD AS EVER THANKS TO WHITNEY!!!!!

    SON'S BIKE
    1998 Honda 300 2x4
    6" BPC LIft with some sick a-arms
    420 spindles and disk brakes
    29.5" OL2'S
    14" MSA M26 Vibes
     
    Upcoming
    4x4 Frame and Motor that's here now just got to get to work on the swap over!!!
    54% Gear Reduction
     
    #27
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/27 00:10:50 (permalink)
    Put coil in, still no spark. I bought it used so hopefully I can return and order new one

    Coastal chaos
    HONDA FOREMAN 2013 
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    14" STI HD3s
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    Jeepwm69
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    Re: 420 bottom end swap on foreman 500 2016/08/29 11:33:41 (permalink)
    You sure it's the coil?  Might be fuel injection relay, bank angle sensor, or a number of other things.
     
    Run a jumper wire from + on the battery to the black/red wire terminal on the coil and see if it will start.
    #29
    I shoot rooster tails
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    Re: 420 bottom end swap on foreman 500 2016/08/29 20:07:18 (permalink)
    Ran power from battery to red black wire on coil pack. Still doesn't bust off

    Coastal chaos
    HONDA FOREMAN 2013 
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    #30
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