The CV boot installation was fairly easily. I had to remove the axle and completely disassemble the joint to clean out all foreign debris, then installed the new boot with new factory style clamps. This time I covered the clamps with electrical tape to keep the short tag end in place, hopefully this will stop them from breaking, which has plagued this bike since new. The cables for the rear drum brake were fairly easy to install. I had to take off the gas tank cover to replace the one to the handle bar, the one to the foot brake was easy to install. I also greased the pivot point for the foot brake and it's now as smooth as it was when new. The front wheel bearing was replaced following the usual steps, I coincided this repair with my new front brake installation.

First ride on the new brakes April 25, 2009 in Southern Harbour went great!

On my last ATV ride (May 8, 2009) I had my first major mechanical break down in 11 years of ownership where I had to be towed out of the country. I lost drive to the rear wheels and developed a major engine oil leak.

As it turnd out, the U-Joint in the rear drive shaft failed causing the broken parts to bind up inside the rear drive shaft tube.

The binding in a such a closed space severely bent the main output shaft of the motor, which tore out the rear engine oil seal and cracked the rear most segment of the 4 piece engine case. This caused a huge oil leak, hence having to be towed to the next community on the trail.

I completely disassembled the rear of the bike to remove the rear swing arm and engine. All plastics except for the front fenders were removed for easier access. To remove the engine I also had to unbolt and pull the front differential forward (CV axels & front suspension stayed together) to disengage the front driveshaft, the entire exhaust had to be removed as well as the carb, air box and snorkel. With the engine removed I was quite startled by the cost for some of the replacement parts needed.  Luckily Reid's Used Motorcycle Parts had a good used bottom end in stock which had all of the parts I needed at a much lower cost then buying new.

After researching what was necessary to perform this repair I opted to drop my engine and the parts engine to Honda One to have it professionally taken apart and re-assembled. I didn't want to tackle all the gears and shims of the transmission as the engine had to come completely apart and the cases split. The Service Department at Honda One supplied and installed necessary engine seals/gaskets and used the output shaft and rear most case from the donor engine. I purchased a new rear U-Joint & driveshaft assembly, dust boot and exhaust manifold seals & studs for reinstalling the repaired engine back at Area51.

When I received my repaired motor from Honda One I noticed how old and dirty it looked. Since many motorcycles have painted engines I decided to treat mine to a fresh coat of high heat black paint, and I'm happy with how it turned out. The paint I used was Duplicolour Brake Calliper Paint which actually has a higher heat rating than engine enamel.

I also took the opportunity to touch up paint on the frame that I couldn't reach last year with the motor and rear plastics in place.

After a few nights in Area51 I now have the bike reassembled and it everything is working well. It was a PITA repair, unexpected and without warning. It doesn't happen to all Foreman's, but this is not the first one its happened to. I suspect that the hole in the new swing arm to engine boot that I replaced last year had over time let enough muddy water inside to destroy the U-joint. Unfortunately the location of the hole was impossible to see while installed on the bike.

Before all the trouble with the engine output shaft I had already ordered a full camo wrap kit for project Foreman to update the tired, faded yellow plastics. The kit arrived soon after getting the engine and rear end back together so I quickly set about installing it. Check the Camowrap Installation for the full story and pics.

Spoiler alert, it came out awesome!

First run on repaired Project Foreman August 22, 2009, now sporting black accents & Natural Gear Camouflage Wrap!

Labour Day weekend in Southern Harbour, Project Foreman continues to run & look great!

March 11, 2010, found out how thick the ice was at the later than normal Annual Winter Trip to the Sooley cabin near Whitbourne.

November 2010 Southern Shore small game hunting trip to Maffer's cabin.

April 22,2011 Goulds Solo Ride

Southern Shore Moose hunting October 2011. On this trip Moose won and Maffer didn't fill his tags. Unfortunately for Project Foreman, the common problem of the rear differential ring gear failure finally reared its ugly head on my bike. Fortunately the bike was still rideable in 4wd which operated only the front wheels so the trip wasn't a complete write off.

Cheers, MIKE