[Hondawasaki]

Hi everyone im from eastern NC ,well raised and live here ..was born in New Orleans.. I recently rebuilt a 99 Foreman 450, completely disassembling the bottom end to replace the crank bearings . I got it all back together , and running and shifting , but apparently mucked up a ring when putting the top end back together .. ran perfect friday afternoon then would not hit a lick on monday morning ? il start a thread on this .. i had started one earlier but mislabeled it Rubicon ...

 

[mrbb]

welcome to the site
it could be a nicked rings
BUT also, have to ask was this atv sunk< and if so, if NOT properly cleaned out, any dirt or?? in there could also have eaten things up on you
its rather common deal, for folks to sink things, flush a few times, do a top end and BOOM, a few hours or less later being back to square one with smoking or low power/compression

 

[Hondawasaki]

it may have been sunk, but not since i went through it .. i split the cases and replaced all the case bearings with OEM parts installed a fresh timing chain and converted the worn tensioner to a manual one .. ive tore the top end back down and am sure it is a ring problem there were metal shavings in the jug .. .. just my luck .. Im courious if i can install a 92.5mm foreman 500 piston ?? because it currently has a 92mm piston which is the largest available for a 450 foreman and i can have the jug machine work done locally by a professional .. the sleeve looks to have plenty of room for the .5 mm but needs re bored and honed as it is loose in the center and snug at the top and bottom . ( makes me think it is a 500 jug from a 2valve model ) im doing the work for my boss man and he wishes to sell the quad .. if this is a bad idea i may have him purchase a oem jug and piston going
back to the stock 90mm

 

[retro]

You'll need to buy an OEM 450 cylinder, piston and rings. The 500 piston (and/or jug) won't work. You'll need to put the OEM chain tensioner back in it too, unless you are an expert setting up the manual one... and you are willing check & readjust the chain tension precisely, every few hours.

 

[Hondawasaki]

the oem spring was shot .. i can get a replacement tensioner .. manual works great on my 400ex but is also a lot easier to access .. the biggest pain in adjusting it is the motor needs to be at TDC .. thanks for your response