ChinaRiders Forums - View Single Post - Foreman Down

01SSRedA4 · 01-31-2016, 02:38 PM

Loosen the 4 bolts and remove the clutch pack.

Move them to your new housing.

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.

All clear and starting to go back together.

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.

Here's the engine cover, shift motor, gasket, and gears. These are the gears you want to get rid of.

Figured the easiest way to make a cover plate was to trace something: Metal is from Home Depot.

--------------------------------------------------------------------------

01-31-2016, 02:38 PM	#5
01SSRedA4 Join Date: Jun 2012 Posts: 220	Loosen the 4 bolts and remove the clutch pack. Move them to your new housing. 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. All clear and starting to go back together. 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. Here's the engine cover, shift motor, gasket, and gears. These are the gears you want to get rid of. Figured the easiest way to make a cover plate was to trace something: Metal is from Home Depot. -------------------------------------------------------------------------- __________________ 06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF 95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2" 04 XR80 - Stock 07 CRF50 - Stock
	1