Thanks Mac' , I need to find a set of front and rear
fish, BEFORE YOU GO SPENDING ANY MONEY !!!!..lol, start the atv up while all 4 wheels are off the ground, put it in gear, then see if the front drive is turning ?. I had this problem with my '03 trx450fm I just restored, could not figure out why the 2wd & 4wd light on the dash wasn't going from 2wd to 4wd ?. well, come find out, the motor has to be running, and the tranny in gear before my light went from 2wd to 4wd. if that is not your problem ?, then odd are, it's either the speed sensors ?, or, then control unit for the front dfferential ?. this is under the front fender. I replaced mine with a brand new one from Honda, about 142 bucks ?. but my old control unit was good !..lol. I learned this the hard way about the tranny has to be in gear, and motor running !..lol.Thanks for the help with the rims sizes , I was able to trade and barter for 4 nice clean stock rims , I got Dirt Devil 26x12x12 in the rear that had 3 rides on them for $50 and 2 brand new 26x10x12 in the front for $83 a piece so I have $210 in 4 tires and rims , Dirt Devil might not be my first choice but they will do , I Hope
I have the head ready to go , lapped the valves and new stem seals still have to install the .025 over bored jug , new piston and head ------- so yesterday my buddy was over and he pushed me to do some work on the bike , and we found the problem with the wiring , the P.O. had run a toggle to the fan , the fan bearing is bad and barely turns , and it seems the wiringat the fuse box melted , cut the wires off the fuse box and installed a in line fuse holder , got the dash to light up , lights working , neutral , reverse lights but now I need a fan , Partzilla is $199 , wow think I will be buying used----Manny you copy that ????
4 boots for the front cv shaft are $80 from Partzilla , I see there is an after market axle set on e-bay , both axles complete for $ 106 , I can only imagine how cheap these must be , any try those cheap after market axles
Here is the real kicker , the part called the clutch which is on the front drive shaft , which kicks it out of 4x4 into 2x4 , I am not sure it is working , as I have all 4 wheels off the ground , when I spin the rear axle hub the front drive shaft turns but not the axles , when I shift the 2 to 4 button on the handle bars the front axles still don't spin , have not yet got to check if voltage is making it to the clutch , I see that the clutch is listed on Partzilla for $419 , hope that is not the problem , wondering if Open country ( Warn424) is available for the 450 I think I would rather swop to it then buy a clutch
keep me posted when you get far enough for it to run, and find out what condition the front differential is in ?.Shade , the front end needs alot of work , going to do 4 new ball joints , 4 new cv boots minimum , plan on doing bearings and seals in the knuckle even though they don't show slack while I have it apart , the front differential I was planning on the minimum of new seals and flushing it out , the tie rods ends are new already and the only thing I plan on not doing
lol, thank's fish !!. looks like your making great progress !!.Thanks to Shade for giving me a nudge by asking about how this build was going , yesterday mourning I got something done , installed a .025 over piston and jug from G+H , installed the head which I had already lapped the valves and installed new stem seals , then people started coming over and tops were popped and it was over , hope to get it torqued down , adjusted and maybe started today