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2003 Honda foreman 500 slippage???

3179 Views 25 Replies 6 Participants Last post by  Twistedwrist
Hey guys and gals,
Just a question about my 2003 Honda foreman 500
Yesterday I had the trailer hooked up and loaded a bunch of firewood into it( nothing more than I normally do)
And started to drive in low gear , the rear tire of the trailer was up against a rock, I tried to give it more has to see if it wouldn't roll over the rock like I normally do...all of a sudden as I'm accelerating, I hear what sounds like a winch being pulled on free something was slipping....never heard anything like this before and have no clue what it is...I unhooked the trailer and went to get my other bike and as soon as I took the trailer off the bike road first thought was the gears in the front diff were screwed...any ideas?
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So I pulled the oil filter and tore it open.
Didn't have a lot of metal, but had some, so tells me it's probably the bearing in the Hondamatic
Here is a pic


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Yeah thats my guess... thats a lot of metal there in just 3 folds of paper. They look like chromium steel chunks from a grade 10 or better, ball or roller bearing. Can you find any whitish-yellow/browned/burnt plastic (likely will appear as darkened filaments sort of uneven & chunky looking along their lengths) in there?

Whatever it is shedding those bright flakes is getting real close to coming apart. Next time you open a filter those chunks will be a lot bigger I imagine. Of course, there may not be a next time...

Do you know an old-school craftsman machinist? If so, he can fix it for you.

Well, sounds like you've met a monkey alright. He wasn't very intelligent or you wouldn't have pegged him right away.... so hes probably a pool monkey. The dumbest monkeys are never allowed to free-lance, they get added to tiered pools of monkeys who get simple assignments handed to them and usually get paid per post + word count typed. They number about 2/3 of the total employed generally, they work part time on & off throughout the day/night whenever they wish to log on. The free-lancers are the most effective (destructive) trolls cause they are highly skilled... AND intelligent enough to work unsupervised, or be spoon fed.
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I still have to learn how to use this forum...I kept checking in all day and didn't see your reply until now.
You are exactly right though, that's a lot of metal in the filter. I didn't see anything like you described regarding plastic.
At this point I don't think I want to waste a new oil filter and 5 litres of fresh oil in it if it's just going to blow in the near future.
I've messaged harig, but no response as of yet.
I don't know any machinists, and I'd feel a lot more confident if a guy like harig or someone else that has experience with these Hondamatics
So unless I get a response from him it seems like I'm just going to park it and throw a tarp over it.
I know I only got it for a parts bike for my good one, but I've spent about $500 on parts to get it usable as my work bike and was hoping to keep my mint one for hunting and trail riding.
What would you do if you were in my situation?
Well, I would tear it down and fix it myself but I'm not you... and I already know an exceptional machinist. I'd estimate my costs to be about $150-$200 or so total in parts & labor & supplies, not counting the big box of adult beverage I'd have for my old friend when I pulled into his driveway. :)

I'd guess that if you can tear it down, thoroughly clean it out, replace the oil pump if necessary and reassemble it competently, you'll find a machinist equipped to lathe on hardened steel, not faraway.

Its your call...
This guy in my region has been doing these rebuilds for years, $450 net cost to you, would just need to ship your old one to him:
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That's not a bad deal for $450, I'm in Canada so it will be about $585-600 in Canadian
Everything I've read says to replace oil pump too, cost up here is $360
So I'd be looking at over a grand with gaskets, oil, and I'd want to put a new piston and rings in too, so not sure I will do this.
I had cancer and been off work for a long time and doubt I'll ever be able to go money is tight and I've got two dogs that are going to cost money very soon at the vet.
So may just eat the $1200 I have into this bike and keep it as a parts bike. Or with all the reading I'm doing sell it And my mint Hondamatic as a package and get a foot shift
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