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1997 Honda Foreman TRX400FM
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Discussion Starter · #1 ·
Hey ATV Brothers and Sisters,
Mrs. Bounty Hunter and I have been kinda looking around for a project Honda ATV to fix up for when our son, who is a Sergeant in the ARMY, can ride when he comes home on leave. We were hoping to find a decent ATV for a low price that needed basic repairs, not a total basket case. We may have succeeded, but only time will tell.

We found a 2003 Honda Rincon 650 at orchard just north of us, and went to go see it. The trip was fun, dirt backroads and beautiful central California coastal mountains. When we finally found the place, we were shown to the poor old Rincon...which had been stripped of its plastics and sat there unashamedly naked. The orchard maintenance guy had had a go at fixing it, but gave up. A bunch of parts were removed, and mostly collected up in sandwich baggies. The tires are badly worn out, bald and cracking. Someone replaced the rear wheels with wheels from a straight axel ATV with deep offset, resulting in the back of the rig being absurdly wide...like 6 inches wider than normal. Looks funny, but probably was pretty stable in the turns.

It was pretty clear that this stout old ATV had had a relatively easy life, there didn't appear to be the usual signs of long abuse and neglect...instead it seemed it had been pretty well cared for by the orchard staff. Oil looked clean and recently changed, air filter well maintained, the battery was fairly new. There is a little surface rust on the frame but very minor. All the electrics work, including lights and dash panel.

But here's the bad...the engine had locked up one day just putting around in the tree rows. Transmission seemed fine, it shifts and can be rolled around in neutral. The engine can be rocked a little bit in gear, but will not turn with starter or pull rope.

They had already bought a new Honda Foreman, so they were just wanting to get rid of the Rincon. We offered 600 bucks, and they gladly shook hands. We used a cable come-along to load it in the truck, and piled the various bits and pieces around it. Everyone was happy.

We have not started to get into the Rincon yet, but will soon. I have read that with certain Rincons there have been problems with flywheel bolts backing out and hitting the stator...which could cause the sort of symptoms we are seeing. The stator is probably toast, but the engine may not be cooked otherwise. Hopefully we will see next weekend.

Thanks for reading, if ya have any experience with this model and problems like this, please throw a shout our way!
Have a Blessed and Peaceful day, and Ride Safe
Bounty Hunter
 
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Rincons can be a PITA to work on, but they're very smooth riding and have a lot of power.

Main thing I would be worried about is one that's been sunk. Sounds like this one likely has not been, so should make a good project!

Post lots of pics as you go, and make sure to download the FSM before you dig into it.
 

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1997 Honda Foreman TRX400FM
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Discussion Starter · #3 ·
Hey Guys,
We got some time to take a look at the Rincon, and sure enough...the flywheel bolts (5 out of 6 of them!) had backed out and badly chewed up the stator. Man, that poor stator is completely toast...the copper windings are torn up and even the plates are racked and bent. The flywheel is damaged on the inside too...there seems to be a thin metal strip that was ripped up and mangled by the bolts. Does anyone know if that can be repaired? Can a new piece of metal be fabricated and glued inside the flywheel (i'm trying to save the cost of a new flywheel...not cheap...and like to fix things when ever possible).
The engine turns smoothly now, we have high hopes that the Rinny can be repaired and restored without too much drama. We just sent off for new exterior body plastics from Partzilla, as almost all of them were missing or broken. On the plus side the Rinny came with a Warn winch that works...i figure that alone is a part of the 600 bones we paid for the sad little ATV. It has very little wear and tear also, no dented or damaged frame members, A-arms look good, wheel bearings, brakes, and steering components all seem to be in good shape.
I'm going to try to post a few pics of the Rincon and the stator, not sure how well (or if) it will work...I'm new to the forum and have never tried to post a picture before.
Thanks for reading, have a great day and Ride Safe Brothers and Sisters,
Bounty Hunter
 

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1997 Honda Foreman TRX400FM
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Discussion Starter · #5 ·
Hey thanks for the link jeepwn69, hooked us up with a good used stator for less than 1/2 price of a new part. Plus, we found a big "grab bag" of all the fasteners off a 650 Rincon...perfect for all the ones that get lost, break or need to be drilled out to keep the rebuild going. Cool site...
 
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Hey thanks for the link jeepwn69, hooked us up with a good used stator for less than 1/2 price of a new part. Plus, we found a big "grab bag" of all the fasteners off a 650 Rincon...perfect for all the ones that get lost, break or need to be drilled out to keep the rebuild going. Cool site...
I've been a big fan of PSN. Perhaps I shouldn't have been such a vocal supporter because here lately when I've needed a part they haven't had what I needed. People have been keeping them cleaned out!
 

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1997 Honda Foreman TRX400FM
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Discussion Starter · #7 ·
Rincon update: had a minor issue with PSN, they didn't send out the stator until I called and found out they hadn't...they said it was a hiccup with their shipping department. We just got the part, which looks great, is exactly what we needed, and it was certified as tested. We had to locate some wheels for the Rinny too, as the ones that came with it were obviously wrong as the offset was waaaaay off. A little investigation learned that stock Rincon wheels were anodized aluminum, not the typical steel wheels our other utility quads have. Partzilla wanted a fortune for 'em...couldn't justify that...but did want to retain the original look. A lengthy search on FleaBay turned up a set of original aluminum Rinny wheels at a great price. Man, those wheels are nice! (our other quads are jealous now...). We needed tires too. The ones that came on the Rinny were wore out and a weird highway tread, they weren't even off-road tires. We have Kenda BearClaws on our 2002 Rancher, and I like them...they seem to have fantastic traction in our rocky, sandy, rough mountain terrain. So we got new ones and mounted them up. Dismounting old tires can be challenging without a professional tire machine...atv wheels have an inner roll bead on the rims to keep the tire on in low pressures...so it takes ingenuity. Or, at least ******* engineering. We cut a 2x6 about 30 inches long and trimmed one end with a radius like the wheel, set the tire on the ground, put the 2x6 with the round edge next to the rim on the tire, and drove a chevy truck up onto the 2x6. Presto! bead unseated. Getting new tires mounted is no piece-of-cake either, sometimes. One of the rear tires, a 25x12.5.x12 was especially "tweaked" from being compressed for shipping, and it didn't want to seat on the new wheels bead to allow air to inflate it. That turned into a wrestling match, and it eventually took 2 ratcheting tie-downs to squeeze the tire into a shape that allowed it to air up.
Just for fun, we temporarily mounted the wheels and tires on the now-naked Rincon chassis to see how they looked...Wow, we like it! Sometimes ya gotta do stuff like that to inspire you to keep on with your build...to know what all the effort is for and what the finished product will be like. It's part of the fun.
So, back to the next step which will be removing all of the rear driveline components to be able to get the case section off to pull the old flywheel. The Rinny is on a Harbor Freight hydraulic lift table, which is cool because everything is at bench height working level, not on the ground. We strapped a wood 4x4 perpendicularly under the lift table as insurance it wont fall over (that would be way more excitement than what we need). We have the new gaskets ready, the Hondabond, and some red Locktite for the flywheel bolts once we get that far.
I will post some pics of the project as it proceeds, so far its been a lot of fun and family time which is part of the whole reason to do it. Our son is an ARMY helicopter mechanic, and hes gonna help too. He likes the idea of working on something that doesn't have to fly the next day!
Thanks for reading ATV Brothers and Sisters, have a Blessed and Peaceful day
Bounty Hunter
 

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1997 Honda Foreman TRX400FM
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Discussion Starter · #8 ·
New tire and wheel...Like the anodized aluminum...hope they hold up as well as the steel ones. New BearClaws!
 

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