[Jeepwm69]

Hey man! Now you're getting into what I know!

White was a 2008 color. 05-09 and 2011 (no 2010 model) are pretty much the same. The 05-06 had two tail lights and the 07-up had a single in the cargo box lid.

05-08 had a weak first gear. 09-11 they improved the design and if you're splitting cases it's easy to replace while you're in there. New gearset is about $50.

I got a parts bike a couple of years ago that was yellow. Couldn't give those plastics away (they weren't in great shape, but still).

Red, yellow, green, black, white, and camo are all available for that bike. Dark Blue too (only on the 05-06 2wd machines though, so no blue pod light cover is available as the 2wd didn't come with the top light).

You got a great deal on that if it's complete. Disc brakes, selectable 4wd, and the last of the air cooled Honda designs.

 

[Jeepwm69]

I'll be sitting here waiting on pics......

 

[Jeepwm69]

lol, will be headed out here shortly, and get her unloaded, it's cold out side !!..lol.

congrats on the new project. just looked up the temp in your area. must be rough living where 39F is considered cold.

LOl

Of course, down here the skeeters are big enough to screw a turkey standing flat footed.

That will clean up nice Shade. It will be nice to see you tear into something that I'll be familiar with.

 

[Jeepwm69]

We have Asian Tiger Mosquitoes down here now. Supposedly came into the port in Houston. They fly and bite in full sunlight, unlike the native skeeters that were only active at dusk and nighttime.

 

[Jeepwm69]

At least it will be done right.

Crank feel ok?

 

[Jeepwm69]

I think Shadetree will like this one so much he'll end up keeping it......

 

[Jeepwm69]

Wow.

I mean wow.

I bought my 06 that had been ridden for 2500 miles with, from looking at it, no oil change. Crank, top end, and balancer were trashed. knuckles were ruined from riding with wheels at / \ angles for so long.....but just wow.

Can you imagine what it took to get to that point?

But, if the crank is good; a new crank would cost more than all the other stuff combined.

 

[Jeepwm69]

Crank is $400+ from Honda East. Retail is $600+

Hot rods finally made a rod kit for them, so at least you can have them rebuilt now.

Used cases are pretty cheap. New? Yeah that's gonna be $$$.

Sent you a guy's number that I biught a crank from a couple of weeks ago. Maybe he has the rest of the motor

 

[Jeepwm69]

Awesome deal, I was afraid this project was going to get scrapped ..

Get er done!!


Sent from my iPhone using Tapatalk

well, I won't scrap this project.....yet !, but it's starting to cost me a ton of my time for little work !...lmfao. the second crank I got with those parts ?, well, the top of the connecting rod is too worn, this old wrist pin has wayyyyy to much slop in the pin to connecting rod clearance !!. this sucks, so now I've got to buy a new crank, NO GONNA RISK ANOTHER USED CRANK BEING BAD !..screw that crap. I should have taken the old wrist pin with me ?, but at first I wasn't even thinking of buying a crank ?, sooo..damnit!!!..lol. oh, and nooo, I can't locate just a connecting rod for this crank ?, it seems to be the only damn year/model/make that no one makes an after market single connecting rod for it ?..wth !!..lol.

Hot Rods 8699 is a rod kit. Get your dealership buddy to install it.

 

[Jeepwm69]

Hot Rods 8699 Replacement Connecting Rod https://www.amazon.com/dp/B00JHJVC1Q/ref=cm_sw_r_cp_api_7Y0Lyb16CXYEX

Here you go.

Sucks about the drain plug bung.

 

[Jeepwm69]

Here's what I did on the 420 Rancher the wife rides when I found a stripped drain plug.

Oil drain plug size - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

 

[Jeepwm69]

guy is going to give me some of my money back, that's cool of him, so I still can use his oil pump, idle gear, and cam, that still saves me a few bucks !.

Good deal. The guy I referred you to is honest, so I figured anyone he deals with would be too.

 

[Jeepwm69]

:icon_cool:

 

[Jeepwm69]

I didn't know you could go over 1.00 oversize (4 sizes over).

Was the ring gear bad in the rear diff, or is replacing that just a precautionary measure since you're replacing the pinion gear?

 

[Jeepwm69]

I wouldn't could standard as an oversize, what is that like 0 over lol 0.25 is 1 size over, 0.50 is 2 sizes over, 0.75 is 3 sizes over, 1.00 is 4 sizes over. After that is buy a new cylinder sizes over....although I know you can do 3mm overbore without a sleeve because that's what the old HL 506.5cc big bore kits were.

Hmmm..

OEM Honda has .25, .50, .75, 1.00

Stock is 92MM, so this one would actually be 6 sizes over, right?

Honda TRX 500 Foreman FE FM TM FPE 93.50 mm .060 Bore Namura Piston Gasket Seals | eBay

I've got an old cylinder that had a circlip pop out, gouged the crap out of the cylinder wall.

New cylinders are about $230. Sleeving was more than that so I figured it was scrap. Now I might need to get it measured.

Mac, didn't those 506 motors have a lot of overheating issues due to thin cylinder walls and being air cooled?

 

[Jeepwm69]

I wouldn't could standard as an oversize, what is that like 0 over lol 0.25 is 1 size over, 0.50 is 2 sizes over, 0.75 is 3 sizes over, 1.00 is 4 sizes over. After that is buy a new cylinder sizes over....although I know you can do 3mm overbore without a sleeve because that's what the old HL 506.5cc big bore kits were.

no, no, i'm just counting std as a size, it's not over bored until you hit 0.25, which is the first size over. i'm just starting at std, and going to 1.00, that's 5 sizes, right ?.

If you want to look at it that way, sure.

BUT, 92mm is standard.

Honda OEM kits are 92.25, 92.5, 92.75, 93

The namura kit I posted is a 93.5, and it doesn't look like they make a 93.25 so I guess the 93.5 is what you're getting.

Looking at is with std as a size, that makes 6 available piston sizes.

That would make it 5 steps up over standard since they don't make a 93.25

 

[Jeepwm69]

Looking good. I wouldn't paint that motor. It's clean enough and when you paint it were I a potential buyer I would think you were covering something up. (of course, with old Jeeps, anytime you see new paint it's covering up something).

I actually drilled my upper a-arms and added grease zerks so I could grease them periodically.

Also, when you go to order fenders and plastics, keep in mind that sometimes the same part costs more for some slight difference.

For example, I just put red plastics on a friend's Rubicon. The red pull start cover for a Rubicon is $51. The pull start cover for a Foreman is $18. Exact same part, except the Rubicon cover has a Rubicon sticker on it. Point is, nose around and check prices on different years/ models as 05-11 Foremans and 05-14 Rubicon plastics are all the same except for the left tank cover.

Funny thing is, my buddy bought this Rubicon a few weeks ago, and his wife freaked, so he told her that he bought it for her, and she calmed down a bit, and then said she didn't like the camo plastics. I casually mentioned that I happened to have some red fenders (had everything but the rear fender that I bought a while back for future builds). She said she'd trade the camo fenders for the red ones I had, so I got camo plastics. My buddy wanted the camo, but since he "bought it for her" he couldn't say anything.

That reminds me, if you haven't already ordered plastics, I have a Foreman left tank cover, red, in perfect shape. I had to buy a Rubicon left tank cover for "her" Rubicon. If interested maybe we can work out a trade/ partial trade for other parts.

 

[Jeepwm69]

don't plan on selling it bro !..lol. she's a keeper. yeah, i'd love to have that red side cover, let me know ?, we'll work out something on trade/cost ?.

Good deal!

Question....since you've already got your bottom end back together, but motor isn't installed yet...and I know you tend to keep things LONG term like I do.....

Did you replace 1st gear in the transmission, or at least inspect it? The 05-08 had weak dogs on first gear in the FM's. 09-11 they changed the design after so many reported problems.

Before you reinstall it, you might want to pull the front crankcase 1/2 off and check it. It's the gear right on top of the transmission if you lay the cases on the rear end. The new updated style gear is about $50. Honda doesn't sell the old style gear anymore.

 

[Jeepwm69]

Lol. Ok

Yeah I knew you were waiting on a timing chain so the front cover and clutches are still off.

If it looked ok I'm sure it will hold up fine to the way you ride.

 

[Jeepwm69]

Tractor Supply has implement paint for $2.99/can.

Better than Rustoleum Professonal, and cheaper right now.