[Mjp83]

Hi,
My new to me 2007 Electric shift Rancher is smoking like crazy, and it also grinds as it tries to go into fourth gear. Bike has 7000! Miles......I know.....
I had the piston checked at a local bike machine shop, and the head needs to be bored over .30, it will get a new piston and gasket kit and the valves cleaned, ground and re-installed.

Pulled the rest of the motor apart, and now I am looking to replace wear parts.
Would you guys recommend I check all bushings, clutches etc with my micrometer per Honda manual specs?
Also a timing chain would be a good idea to swap at this time?
Anything else? Water pump?
I know I need at least one shift fork, and the 3 rd and 4 th gear kit, #04104-HP5-505 to address the grinding 4 th gear.

Thanks!

 

[shadetree]

seems your on top of the 4th gear issue these models had !. I hope you inspected the cranks connecting rod for any play at bottom ?, and at the wrist pin on top ?. if not ?, you need too !. if the rod is bad ?, your wasting your time and cash. ever been sunk that you know of ?, if so ?, you will need to tear the motor all the way down, and clean it all out. this is the time to inspect all parts, replace cam chain, all new gaskets ( where they call for ) DO NOT USE RTV SEALANT ANYWHERE ON THIS ENGINE !. yamabond or hondabond where there is no gaskets !. replace all oil seals while your at it.

 

[Mjp83]

Thanks for the reply. Engine is apart following 4 part video you all have suggested in other threads. Only thing is there is no explanation of what parts to look out for and replace. Crank moves only side to side, no up and down. I will make sure to check specs.
I know the manual lists min specs so I will mic parts today. Pretty sure shift forks are toast too.
And no RTV! I will order a seal kit as well. Time to clean and inspect. Thanks

 

[shadetree]

Thanks for the reply. Engine is apart following 4 part video you all have suggested in other threads. Only thing is there is no explanation of what parts to look out for and replace. Crank moves only side to side, no up and down. I will make sure to check specs.
I know the manual lists min specs so I will mic parts today. Pretty sure shift forks are toast too.
And no RTV! I will order a seal kit as well. Time to clean and inspect. Thanks

simple test at top of rod, take the old wrist pin, slide it into the top of rod, just so the very end of the wrist pin is flush with the other side, then lift up, push down on the long end sticking out, if any play by doing this ?, your connecting rod is bad.

 

[Mjp83]

Thanks, will do!

 

[Jeepwm69]

If you're tearing it all the way down (which is good) fix the 4th gear in the transmission.

Make sure you check the wrist pin hole on the crank like Shade said. You don't want to get it back together and find that while the crank has no up/down play, the wrist pin end of the rod is worn (just had that happen on a 350 Rancher)

Replace the timing chain while you're in there. It's cheap, so do it while you're in there.

Replace reverse seal, shifter seal, crank seal, front and rear output seals, and the seals in the front cover under the shift motor (and of course, the shift motor seal).

Seals are pretty cheap, and MUCH easier to install with the motor on the bench than with the motor in the bike.

 

[Mjp83]

Thanks, I pulled motor, took it apart and took head and cranck to a local bike machine shop.
Upon disassembly and you alls advice, I ordered lower seal kit, timing chain, 3 rd and 4 th gears and the shift drum (came together in a kit, makes me wonder if Honda is on to something on the 07 & 08 models), two shift forks, along with my local machine shop boring the cylinder over .30 and ordering a top end kit w piston and gaskets.

I was able to download the manual and took my time and mic’ed clutch and other wear parts and hope I am in good shape to clean and put it back together.

 

[shadetree]

Thanks, I pulled motor, took it apart and took head and cranck to a local bike machine shop.
Upon disassembly and you alls advice, I ordered lower seal kit, timing chain, 3 rd and 4 th gears and the shift drum (came together in a kit, makes me wonder if Honda is on to something on the 07 & 08 models), two shift forks, along with my local machine shop boring the cylinder over .30 and ordering a top end kit w piston and gaskets.

I was able to download the manual and took my time and mic’ed clutch and other wear parts and hope I am in good shape to clean and put it back together.

thanks for the update, keep us posted !.

 

[Mjp83]

Well, here are some pics of the faulty parts! I have a feeling lack of oil and a gummed up shift motor were the culprits. Also, Honda’s seal kit B does NOT contain any oil seals, as in final shaft seals, shift seal, etc. only o rings for the interior of the case.