reverse leaver

[jstalnaker]

can anyone tell me where i can find a reverse leaver?
the one thats down on the side case...i stopped at honda today and they cant find it on any parts list and ive searched all over the internet trying to find it but no luck..
part number would be nice too if you have it..
thanks everyone

[CJM]

The reverse lever? There isnt one on these quads. Its a knob you turn on the plastics on the 2005 and later quads that have reverse. If yours is older it doesnt have reverse.

Im not following with what your talking about. Can you provide a picture?

[jstalnaker]

yes it a 05 it the leaver that the cable hooks to down on ste side case for the gear.
or should i say its a arm?

[crownandmonster]

number 24?

http://www.motosport.com/atv/oem-parts/HONDA/2006/TRX400EX%20FOURTRAX/?modelyearid=180&typeid=2&groupId=8692

[jstalnaker]

i dont think its number 24 i think thats the cable stay...
it the arm that the cable attaches to and turns the gear for reverse

[CJM]

Not much else is down there, Id agree #24 is probably it.

[jstalnaker]

number 24 ataches to the side case for a cable holder...
the end of the cable attaches to a arm...
the honda shop couldnt find it either
im trying to find a pic to show what i mean

[jstalnaker]

http://i124.photobucket.com/albums/p13/jstalnaker70/15.jpg

its the piece that the cable attaches to

[CJM]

Searched 3 different parts fiches, I cant find it either.

IDK man, maybe you can buy a case cover on ebay and it might come with it?

[hocman123]

looked for a little bit and found it

http://www.motosport.com/atv/oem-parts/HONDA/2006/TRX400EX%20FOURTRAX/?modelyearid=180&typeid=2&groupId=8705

it is # 14 sometimes u got to look in odd places to find parts u need they like to hide things on u :)

[jstalnaker]

Originally posted by hocman123
looked for a little bit and found it

http://www.motosport.com/atv/oem-parts/HONDA/2006/TRX400EX%20FOURTRAX/?modelyearid=180&typeid=2&groupId=8705

it is # 14 sometimes u got to look in odd places to find parts u need they like to hide things on u :)
thats what the parts guy at honda said too but he couldnt find it...lol

[jstalnaker]

thank you very much

[CJM]

Really odd spot for it to be in, nice find man!

[hocman123]

np just glad to help out. i have had to search over those pics tons of times to find little parts in odd places

[jstalnaker]

looks like i need the shaft too...
i bought the bike used and thought there was a bolt broke off in it but now it looks like the end of the shaft is suposed to have threads...:(

might try to drill and tape it first though

[NMills]

That part is a pain to find... when i put reverse on mine i needed that lever... called my local dealership... explained to them what i need... and he ordered it... come to find out he ordered my the cable stay plate... and then i spent the next 40 minutes with the guy going thru diagrams... what a pain..

Are you talking about drilling and tapping the shaft that the lever connects to?? i'm pretty sure a nuts spins onto it... so i don't think drilling will help you at all...

[jstalnaker]

yea because it looks like part of the threads are broke off..
idk if there is enough to get a nut on it after putting that arm on..
but if not ill cut the rest of the threads off and try to drill and tap it before having to order a new shaft..

[duroc825]

Originally posted by jstalnaker
yea because it looks like part of the threads are broke off..
idk if there is enough to get a nut on it after putting that arm on..
but if not ill cut the rest of the threads off and try to drill and tap it before having to order a new shaft..
OOH, replacing that shaft will require case splitting. I'd be tempted to try and drill and tap it before going through all that. Either that or learn to do without reverse! :D

[jstalnaker]

Originally posted by duroc825
OOH, replacing that shaft will require case splitting. I'd be tempted to try and drill and tap it before going through all that. Either that or learn to do without reverse! :D
ive never have had reverse before...lol so i guess i wont miss it but if it is on there id like for it to worl..;) ...i get pretty picky about my bikes and the way some people take care of these machines dont deserve to own one....lol
not saying anything bad about anyone on here just from what i have personaly seen

[CJM]

If I were you-call up places that weld and ask if they can tig weld a threaded end on for you. Takes no more than 15 mins and well worth it not having to tap and drill it.

Really all they would have to do is tack on a piece of a threaded bolt then you can put it back on easy.

[NMills]

I'd like to see pics of the shaft... are there any threads left??? you really don't need many... and to weld it could be a huge pain..... Can you post pics of it???

[jstalnaker]

yea i can go get a pic now

[jstalnaker]

http://i124.photobucket.com/albums/p13/jstalnaker70/2011-03-30_21-15-21_133.jpg

[NMills]

That's a bummer.... really is... too bad there aren't just a couple threads.... i guess if needed... put the lever on and then have it kinda tack welded on .... I'm not sure if you have enough to do use a die on...

[jstalnaker]

do you know if the shaft is solid or hollow

[NMills]

I'm not sure... What are you thinkin? drill it??? by lookin at the diagram it looks like it has a hole so it might be hollow... but it's soo thin that it can very easily screwed up... so it might be a bit easier to just split the case and put the right working parts in...

[jstalnaker]

if its hollow and i tap it ill have to be able to seal the threads so it wont leak oil..
i do have a TIG machine so maybe ill just tack it on so that if i need to split cases later i can grind the weld off..but cant use to much heat with a seal right there

[CJM]

appears to be solid, but no telling for sure. I would first grind it flat, then see about welding it.

If you really want to try, drill it out with a decent size-say 1/4" or maybe something in the mm sizes since 8mm would probably fit well on there. Buy a tap, tap it out and see what happens. Worst thing is you need a new shaft and your back to square one.

Id personally try for 8mm or 7mm and get an allen socket cap screw since its low profile.

[jstalnaker]

glad i bought this bike realy cheap...lol
it also need a hole new top end
and swing arm bearings
and most of the nuts and bolts were missing from the plastic
i gave 1200 for it

[NMills]

I would not go with those sizes if you are drilling... the threaded rod is only a 6mm ... so to drill and tap you'd have to go smaller... and keep it perfectly straight...

[NMills]

Originally posted by jstalnaker
glad i bought this bike realy cheap...lol
it also need a hole new top end
and swing arm bearings
and most of the nuts and bolts were missing from the plastic
i gave 1200 for it

Wow... that's a bit of work... if you are gonna do all that anyways... mine as well split the case... i've heard it's not hard to do... atleast that's the route i'd go....

[CJM]

Was just a guess b/c I dont have one sitting next to me to compare it too.

If its indeed 6mm thats gonna be super tough to make work imho. Are you sure the head isnt just 6mm but the shafts larger???

[hocman123]

thats sounds like a lot of money for a bike with so many problems i proberly would only have given 600 -700 maybe.

but i think u would be better off replaceing it if u are going to have most of it apart now and u should replace the timing chain when u redo the top end anyway so u need to take the clutch cover off and ur allmost there

[NMills]

The threaded part is a 6mm according to the nut... the thicker part is much thicker... but it turns back and forth... it's kinda like the clutch lever on the engine case... i think trying to drill it and then tap would be a HUGE pain.. I like to skip things too and try to make it quick... but somethings should just be done the right way...

[jstalnaker]

yea i would try to go the same size as what is sticking out..

and what is the differance in the 04 and 05 handle bars switch

[CJM]

cant really tap the same size bud, thats not how drilling a hole and tapping a new one works in such a case as yours.

You drill smaller hole and use smaller nut/bolt.

[NMills]

Originally posted by jstalnaker
yea i would try to go the same size as what is sticking out..

and what is the differance in the 04 and 05 handle bars switch

04 and 05 handle bars switch??? which switch are we talking about?? headlight/kill switch?

[jstalnaker]

yea the head light /run/stop switch

[NMills]

i believe they are the same... but just double check... use servicehond.com and look up your machine get the part number and look up the donor machine and compare... probably the best way to go...

[jstalnaker]

cool thanks

ill let you know how it turns out and what i decide to do...lol