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Foreman Down - Gear reduction/outlaws/maintenance
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Here she is, you can see we like to play dirty. These pics were taken at Highlifter Park in Shreveport, LA.
Attachment 13254 Mods are HL 2" bracket lift, EPI clutch kit, 450 swingarm stretch, 28"zillas. Attachment 13255 Attachment 13256 So the idea for the winter months was make the bike more mud/Highlifter Park friendly. First thing was getting my hands on some more aggressive tires. These are 29.5 OG Outlaws, all skinnies. Attachment 13257 Attachment 13258 Attachment 13259 Attachment 13260 ---------------------------------------------- |
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I found out real quick how kickass these tires are, and that this Honda doesn't like turning them in thick mud.....more on that later.
In the meantime we needed more light for our nighttime neighborhood rides so I picked this up off ebay. Attachment 13247 Much better: Attachment 13248 I really don't even know how this all started. This bike had the big aluminum skids on it when I bought it. They hold a lot of clay mud. I think I was just wanting to do a good winter cleaning. Then it started spiraling out of control. Attachment 13249 Attachment 13250 Attachment 13251 Took all the aluminum off the bike, and its not going back on. I think I can make some custom frame sliders that will work as good but be easier to clean. Attachment 13252 Some holes fall off on you quick, so just for insurance I decided it would be a great time to snorkel, so I swung by Home depot and got some various pipe, having no clue what I actually needed. Attachment 13253 --------------------------------------------------- |
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So I thought this bike was fairly clean when I started, then I started looking closer. What I found in the oil cooler I knew I had sprayed with the hose didn't make me very happy.
Attachment 13241 This is an air cooled only bike (meaning no radiator) so it's important the oil coolers stay clean......and obviously I don't wanna dig this thing out every time I ride to clean it so I gave Summit Racing a call and ordered this......Honda gave this bike two small coolers, I'm gonna replace both with one big one. The plan is to leave the engine fan in place and working and mount this to the rack. Attachment 13242 Attachment 13243 Kind of a general idea of where I want it. Attachment 13244 Made some real simple flat bar brackets and welded them to the rack. Attachment 13245 Attachment 13246 ----------------------------------------------------- |
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It keeps haunting me how I can't turn these tires I bought and I realized this was as good a time as any to do a gear reduction. I selected a 35% primary reduction from Don aka BridelessRacing. Would not hesitate to buy from him again.
Attachment 13233 Here you can see the stock fan in place and the front cover of the engine which needs to be removed. Attachment 13234 This is your centrifigal clutch, and behind it is where the small gear will be exchanged for the new one. Attachment 13235 Need to remove the staked nut. This is easily done with an impact however I found out its better to have new nuts on hand because it tends to mess up the bent section on the used nut. Attachment 13236 It just slides right off Attachment 13237 Stock on the right, 35% on the left. This is the drive gear Attachment 13238 Stock on the right, 35% on the left. This is the driven gear. Attachment 13239 Don't forget to move this bushing to the new clutch basket. Attachment 13240 ---------------------------------------------------------- |
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Loosen the 4 bolts and remove the clutch pack.
Attachment 13223 Attachment 13224 Move them to your new housing. Attachment 13225 Attachment 13226 Before you reassemble you need to grind the engine case just above the right side shaft to make room for the larger gear. I did this with an air cutoff tool and took a little then installed and checked for drag. It took a couple of times removing a tad bit of material each time. Also you need to grind the head of the timing tensioner damn near off, again check for clearance periodically as you grind. Attachment 13227 All clear and starting to go back together. Attachment 13228 This is the ES shift mechanism. WHile its given me no issues since owning the bike I dont ever want it to so I'm deleting it and making this bike foot shift. One less thing for me to worry about. You can remove the internal gears but leave the ES motor on or delete it completely. If you want to delete it completely cut the splines off the small sshaft sticking out so we can make a cover plate. Attachment 13229 Here's the engine cover, shift motor, gasket, and gears. These are the gears you want to get rid of. Attachment 13230 Figured the easiest way to make a cover plate was to trace something: Metal is from Home Depot. Attachment 13231 Attachment 13232 -------------------------------------------------------------------------- |
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Loosen the 4 bolts and remove the clutch pack.
Attachment 13213 Attachment 13214 Move them to your new housing. Attachment 13215 Attachment 13216 Before you reassemble you need to grind the engine case just above the right side shaft to make room for the larger gear. I did this with an air cutoff tool and took a little then installed and checked for drag. It took a couple of times removing a tad bit of material each time. Also you need to grind the head of the timing tensioner damn near off, again check for clearance periodically as you grind. Attachment 13217 All clear and starting to go back together. Attachment 13218 This is the ES shift mechanism. WHile its given me no issues since owning the bike I dont ever want it to so I'm deleting it and making this bike foot shift. One less thing for me to worry about. You can remove the internal gears but leave the ES motor on or delete it completely. If you want to delete it completely cut the splines off the small sshaft sticking out so we can make a cover plate. Attachment 13219 Here's the engine cover, shift motor, gasket, and gears. These are the gears you want to get rid of. Attachment 13220 Figured the easiest way to make a cover plate was to trace something: Metal is from Home Depot. Attachment 13221 Attachment 13222 -------------------------------------------------------------------------- |
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Rough shape.
Attachment 13207 This is all I used to make the cover plate, took ten minutes or less. Attachment 13208 Completed. Attachment 13209 Stock bolts wont work for this cover so you'll need to source some....pretty short ones will work fine. Attachment 13210 Cover is all cleaned up and ready to be reinstalled. Attachment 13211 Reassembled and waiting for the cover. Attachment 13212 -------------------------------------------------------------------------------- |
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While the bike was apart I noticed all 4 ball joints had rips in the boots. Figured well now was as good a time as any so 4 new ball joints got installed.
Attachment 13200 Brake pads and wheel bearings had seen better days too so I ordered the stuff. Attachment 13201 Visitor came to see me. Attachment 13202 I've always hated how the front bumper on these bikes was silver while the racks were black, plus mine had some rust from the aluminum front cover holding mud against it so I decided to have it powder coated black while it was off. Attachment 13203 Speaking of things I hate.....that pile of PVC on my table. I said F it and decided to order one from snorkel your atv dot com. Attachment 13204 Did a quick mock up to see how it would look. Attachment 13205 Plumbed the cooler with 1/2 cooler line spliced into the stock braided lines and cut the hole for the snorkel. Attachment 13206 To come: custom frame sliders, snorkel completion, custom foot shift lever, and final reassembly! Stay tuned. |
Lot's of hard work going on there...Good Job! I will check back in and see how much difference the gear reduction made in regards to turning over those giant tires. :D
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Looks good so far.
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