[Phil Danes]

hi guys, im Phil and im located in the UK.
I have a foreman 450 ES, (2003) I have owned it for about 5 years now.
the machine has been good and reliable up until now, hence me joining the group, looking for a bit of support

 

[SamUK]

Hi Phil, I'm also in the UK..! What issues are you experiencing?

 

[Phil Danes]

Hi am, thanks for the reply, im based in Peterborough, midlands / east of England.
I was getting issues with 2/4 wd selection and then I couldn't select any gears. I have traced that back to a voltage issue. the battery seems ok, although only holding 12.54 volts. with the high beam on its still only charging at around 12.8 volts. I have ordered a new voltage regulator to see if that will cure the problem, im hoping that its not the alternator.
do you have any thoughts/recommendations?

 

[SamUK]

ES, electric shift almost always play up, usually it's the shift motor gears sticking due to the old grease becoming hard and dirty.
It's a relatively simple process to remove the motor and overhaul it, clean out the old grease and use a silicone based grease when refitting.
It's also worth cleaning every electrical connection (plug) with contact cleaner and reconnecting using either WD40 or dielectric grease. DO NOT use silicone grease, it conducts electricity, regardless of 'common knowledge' it IS different and not the same as dielectric grease

The 2/4wd, again clean the connections, especially the plug done by the front diff. These diffs use an electro magnetic to engage and disengage. If it turns out to be the magnetic side of things that is the issue then parts I should imagine are available from HondaUK or the USA only.
I've never seen parts available here on any aftermarket website unfortunately.

 

[Phil Danes]

ES, electric shift almost always play up, usually it's the shift motor gears sticking due to the old grease becoming hard and dirty.
It's a relatively simple process to remove the motor and overhaul it, clean out the old grease and use a silicone based grease when refitting.
It's also worth cleaning every electrical connection (plug) with contact cleaner and reconnecting using either WD40 or dielectric grease. DO NOT use silicone grease, it conducts electricity, regardless of 'common knowledge' it IS different and not the same as dielectric grease

The 2/4wd, again clean the connections, especially the plug done by the front diff. These diffs use an electro magnetic to engage and disengage. If it turns out to be the magnetic side of things that is the issue then parts I should imagine are available from HondaUK or the USA only.
I've never seen parts available here on any aftermarket website unfortunately.

Hi Sam, I have done all of the electrical checks and everything seems to be ok. the plugs have all been cleaned and reassembled with WD40. I hope to get the rectifier this week so I will fit that and hopefully resolve the issue.
as for the gear cleaning, I will start that tonight. I assume cleaning down with paraffin is ok? how much silicone grease should go back over the gears?
Phil

 

[SamUK]

Ok that's a great start. Can I ask where you bought the rectifier from? I ask because Amazon and eBay are mostly Chinese and fail regularly.

Yes, parrafin or diesel will be fine to clean the gears with. When rebuilding it won't need a lot, just enough to keep things running smoothly.

Let me know how you get on buddy

 

[Phil Danes]

Hi Sam, I did buy the rectifier from Ebay, (Link below) it stated from a UK supplier in Leicester, however; the on payment it showed being paid to a Chinese supplier :-(
Where do you recommend buying spares from?
The gears are cleaned up now waiting for the grease to be delivered today, I hope to get it all rebuilt tonight. There wasn't much grease on the gears at all, what was on there was a little bit sticky but not solid. I will see what improvements I get after the rebuild.
Thanks for your support mate.

(https://www.ebay.co.uk/itm/For-Hond...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649)

 

[SamUK]

For good quality parts options are limited really here in the UK.
Obviously, Honda are one option but usually very costly. I always look for parts in the USA.

Powersportsnation.com is a well respected company that sells used parts, definitely worth a try. All parts are used OEM (genuine Honda).

You may also try, Rick's Motorsport electrics.com

He specialises in CDI units, rectifiers etc. Again, a well respected company and the go to company over in the USA.

If your struggling I may be able to assist you with sourcing used parts from the USA.

PM me for further assistance buddy, I'll do my best.

Sam

 

[Phil Danes]

Hi Sam.
All put back together, the voltage is now at 14.6 volts with the engine at circa 5000RPM with the lights on full beam. The gears are all working smoothly.
thanks for your advice on this, very much appreciated.
Phil

 

[SamUK]

Hi Sam.
All put back together, the voltage is now at 14.6 volts with the engine at circa 5000RPM with the lights on full beam. The gears are all working smoothly.
thanks for your advice on this, very much appreciated.
Phil

That's a good voltage reading Phil, I see nothing wrong with the charging system.. Let us know how you get on with the other issues once parts arrive