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Discussion Starter · #1 ·
hey guys, new here, fairly new to atvs, but not new to repairing vehicles. A little back story here.

At my wifes grandparents for a few more days. Hes got a pair of older (2009 and 2008 iirc)Honda atvs. the 2009 is a Foreman es 450 or 500, cant remember. No clue what the 2008 is, havent started on it yet. Neither one of them have ran for about 3 years. They ran fine when parked after they got replaced.

Here is what I have done so far.
1) Drained all the old fuel out
2) Replaced the spark plug and tested for spark, spark is good
3) Cleaned the gas tank, and refilled with fresh gas
4) Completely disassembled the carb, sprayed everything with carb cleaner, and confirmed there are no blocked or clogged passages or needle jets.
5) Checked and reset valve clearance

Now, it will fire up after a couple cranks, but wont stay running unless i keep giving it gas. Each time it dies, it takes a little bit longer to start up again.

Im at a stand still, and leaving for home in a few days, would like to get at least the Foreman running properly so the Grandpa can sell it, as its one of six 4 wheelers, and he has 3 side by sides that he uses now.

Any help is appreciated. TIA
 

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You didn't specify the model of your carbed TRX500 Foreman so I'll drop some general info here until you tell me I'm working on the wrong bike. :)

First thing to check might be the choke. Verify that the choke enrichment valve is not stuck open and that it operates easily and opens/closes completely.

Next up, check the pilot screw adjustment and the idle speed (throttle stop) screw.



You may have to replace the fuel filter as well. If there is a petcock & strainer in the bottom of the fuel tank those will both need cleaning if you haven't already. You can check for fuel delivery by disconnecting the hose and allowing fuel to drain into a small container. Fuel flow should be steady, not slow or stop after a few seconds...

You can find copies of the service manuals for those two Hondas HERE if you still need them. If you have any questions just ask, its cheaper than buying parts you don't need. :)

Welcome to the forums!
 

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Added a couple more pages from the manual:
An exploded view of the carb and the air cutoff and choke valve. Notice the strainer in the fuel hose barb...

Enjoy your works!
 

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Discussion Starter · #4 ·
not sure exactly which model it is. Pics in your second post look just like the carb im working on. Ill defintly try your tips, and ill let you know if they work or not. I forgot to clean the petcock, but i did remove and spray out the filter screen.
 

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Yup definitely dirty carb idle jets put some seafoam in the tank that might help
and that ES won’t start unless it’s in N on the display. Put it in N before you shut it off. There should be a bent 8 inch handle with a socket head in the rear box that’s to help you shift into neutral if the ES fails,
Sound like some nice machines you should be a nice son in law and help him out by buying em. :D
 

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I would invest in a $25 gallon can of carb cleaner , totally disassemble the carb and soak all the metal parts for a few hours , blow every passage with compressed air , reassemble , install , try running it again , if it is still messing up , repeat the previous procedures again ---- also clean the petcock and the inner tank screen
 

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Discussion Starter · #7 ·
Yup definitely dirty carb idle jets put some seafoam in the tank that might help
and that ES won’t start unless it’s in N on the display. Put it in N before you shut it off. There should be a bent 8 inch handle with a socket head in the rear box that’s to help you shift into neutral if the ES fails,
Sound like some nice machines you should be a nice son in law and help him out by buying em. :D
trans is in neutral, i made sure of that before ever trying to start it. im hoping he gives me one, but then i gotta figure out how to get it from texas to indiana, when i drove a car down here.
 

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I agree regarding the clogged petcock. I suggest disconnecting the fuel line from the carburetor and observe fuel flow in to a container. You should have good flow. If not, the petcock is the most likely culprit, but check everything from the carburetor back to the tank.
 

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Yup definitely dirty carb idle jets put some seafoam in the tank that might help
and that ES won’t start unless it’s in N on the display. Put it in N before you shut it off. There should be a bent 8 inch handle with a socket head in the rear box that’s to help you shift into neutral if the ES fails,
Sound like some nice machines you should be a nice son in law and help him out by buying em. :D
trans is in neutral, i made sure of that before ever trying to start it. im hoping he gives me one, but then i gotta figure out how to get it from texas to indiana, when i drove a car down here.
rent a U-Haul trailer to get it back home. or buy a trailer from harbor freight, add a hitch to your car.
 
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Discussion Starter · #10 ·
I agree regarding the clogged petcock. I suggest disconnecting the fuel line from the carburetor and observe fuel flow in to a container. You should have good flow. If not, the petcock is the most likely culprit, but check everything from the carburetor back to the tank.
petcock is clear, fuel flows great through the hose when in on and res.

it seems the problem is that fuel is getting into the carb, but not through the carb. Every once in a while, the motor will kick over for a second, but thats it. Im about out of time to work on it during this trip, if i cant get it running, then its going to a dealership to get fixed :(
 
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