Howdy, new guy here.
I have a 2001 trx500fa that is in the middle of a noise issue. I was dragging some cut down trees with no problem. I took it for a spin to cool down after I pulled the last tree section, went for a mile or so ride. Got back and going slow I noticed a squeal squeal squeal like something rotating. It worked in rev, I shut it down. Later I started it and when in fwd or rev it runs like its missing and kind of surges fwd in little bits like something is slipping plus it makes that squeal. It idles fine in neutral though.

Figured might be the clutch due to the tree dragging....so I pulled it today and there isn't any metal fragments or abnormal wear....I'm going to do a dimensional inspection tomorrow on the clutch but I don't think thats it.
Hoping it isn't the trans.....any ideas?

I wondered if anyone ever tried to get the bearing numbers and go to Motion Industries or some bearing vendor. Unless they're proprietary you might be able to get them. That Hondamatic is really only a hydraulic pump with a wobble plate.....I used to work in commercial aviation in a hydraulic shop and we did them all the time...anyone look into that?

I notice the driven gear off the clutch unit seems to have some slop in it but also see it is supported inside the front case which makes me wonder if this slop is ok.
My clutch hub measures about half a mm from the limit, flyweights at or below min.
Springs measure ok.
Looks like some of its rutch.

The assy that holds the driven gear on the trans shaft....I spin it both ways.....something makes a little clicking noise.....that normal? What is in there?

Plus it has axial play about a fat 1/16th inch fwd/bkwd. That normal?
If I took the driven gear off, then a jaw puller on the flange that held the gear to get the assy off? Does it need heat to get off?

Found a pic/cutaway - http://world.honda.com/motorcycle-te...ic/image5.html

From this cutaway, I'm guessing if you take off the driven gear bolts...the front assy comes off then?
I just want to be safe....thanks

 

Now wait a minute. You worked as an A&P mechanic in hydraulics and you're asking US ? You sound like we should be asking YOU questions. I'm willing to bet that the next post from you will be: "Well, I found the problem and fixed it. It was easy" And then explain to us what you did. And it will be as clear as mud to us.

 

LOL.....the Honda manual is a little light on info on the trans.
I got a pretty good idea I got a busted race in the assy that holds the driven gear.
I was wondering how much effort it takes in removing the assy like will it pull or do I need to heat it up before pulling......looking for a been there done that guy, that's all.

Remember in the airlines, they got all the geewhiz gizmo's and tooling. Here at home its the standard variety tooling.
We had a hydro pump test stand about 12' x 30' that you could do all sorts of things with, including a Hondamatic probably if you had some data.

 

Well that guy is not me but I'm sure there's a few on here that can help. But being the backyard mechanic that I am, it seems to me that if it doesn't come out, then a press would be better than heat. Can you get a wheel puller to work?

 

I got an electric heat gun....lot of times they want you to heat the bearing race to expand a few thousandths for install/removal and you don't have to heat it that much. I didn't mean a torch.
I got a jaw puller.....I'll give it a shot in the AM.

My concern is what lives behind the hub....where you can't see.

Thanks for your input.

 

Got it off with some metric all thread and a borrowed steering wheel puller. Front bearing is moving about 1/16th to 3/32nds fore and aft. Think its affecting the pump stroke from the wobble plate plus the clutch hub ID is about 149.95mm with a limit of 150.4 mm . Move it fwd and backwards in gear with driven gear hub on, makes lots of wobble and clicks......take it off and trans seems smooth. Going to get some bearings and a clutch hub....seals......lots of meat on the flyweights, springs within spec.

 

I knew you'd figure it out. Now I have to figure out how to do a timing belt on my Volvo which I've never done.

 

Worked in a foreign car garage on my way to becoming an airline mech...

Mr Peabody, set the wayback for 1972.....LOL

 

Well hey, you're the guy that can help me. I've got some liquid refreshments here. Come on over.

 

Timing belts usually aren't the big deal, its all the crap you have to take off thats the pain.