BN: "I'm Bryan Nylander and welcome to this episode of ATV Rider's 'This Old Quad.' Today we're with Jimmy Lewis, who found this 2000 Honda Foreman, or TRX450S 4x4, and we're going to see what he can do with it. It's quite a roach, but Jimmy has spent some time fixing up motorcycles. Let's see if that experience will help him accomplish his goals on this four-wheeled pile of neglected mechanization. Jimmy, you've been a professional motorcycle racer, how's that going to help with this four-wheeler?"
JL: "Easy, Flat Lander, we're here to get this quad shipshape, and for not too much dough. So let's not compare my race bikes with this beater and get right to the build part, OK?"
BN: "Yeah, sure, um, it's No-Hander, and hey, why don't you tell us how you found this quad."
JL: "Well, I grew up on a ranch. If there was one thing I learned, it's that farmers can grow trees and plants, but when it comes to mechanical stuff, they run it till it breaks, then leave it where it stopped and go buy a new one. Like this yellow Honda right here. I've had my eye on it for a while, watching weeds grow around it."
BN: "Is that because it was your dad's?"
JL: "Look, we won't get into specifics here, but what I'm trying to say is that I'm going in to rescue this quad from a slow oxidation process intermingled with a rodent and insect habitation program. I know on the open market I could haggle a good price on this pile of junk and have a really sano ride in a few days' time. Dude, I have a plan."
Day 1With that, Jimmy took the neglected quad back to his home shop, where the first order of business was to assess the damage and plot out his plan.
JL: "First things first. I took a quick look at the visible damage and made a list. The seat is sun-dried rat food; the plastic, it needs a serious scrubbing. The tires are dried and have a few leaks, plus the bogus rims are steel ranch material-wouldn't be caught out on the trail with those deals if my image depended on it."
BN: "Does it even run?"
JL: "Look, Tank Slapper, I'm a solid mechanic, too. Just stand back and learn. This battery isn't worth the lead inside of it, so I'm going to jump-start this pig."
BN: "Yeah, that's No-Hander, and it's cranking, but there isn't much life in there."
JL: "That is usually the result of just one thing, a gummed-up carb. With the horrible gas these days, you let a bike or quad sit with it in the carb and it turns to jelly. I'm going in!"
BN: "So it helps that you have a really killer set of tools, then?"
JL: "My dad was a farmer, not a TV repairman. We grew up on hammers and crescent wrenches; now I have a full set of those and a few metrics and screwdrivers. I get by. Look at this sludge-good thing I have a new can of carb cleaner and a small piece of wire to clean it all up."
BN: "So will this get it running?"
JL: "More than likely, this and a new Yuasa battery. This air filter is suspect, too; it looks like urban housing for a family of mice. I'll slide in a K&N. The only other known problem with these particular models is the valves sometimes gum up and stick open when the machine sits for a while, but this fixer-upper isn't blowing back through the intake and it seems to have good compression. I'll have this carb cleaned out in a few minutes and then I'm calling it a night. I have to go running!"
Day 2BN: "We're here on the second day of 'This Old Quad.' Jimmy has diagnosed the running issues of the Honda and is deep in the catalogs looking for the fixes and customization to make this project come to life."
JL: "Like I said about the wheels, they were shot, mostly from rotting, so I'm sliding on these Kenda Bounty Hunter tires set up on Douglas wheels. Not only am I getting traction, but I'm procuring nearly a 2-inch lift out of the added profile. Plus, it is going to look dope! What hop-up doesn't get a killer set of wheels?"
BN: "Yes, I think every one does."
JL: "But I'm not stopping there 'cause I'm a man with a plan. I'm going to get this ride away from hoppity-hopville and plush out the suspension with a set of Works Performance A-T Steeler shocks all the way around. Then the dead grease-pumping spring carriers can go in the garbage where they belong, and every bump I hit will remind me how good of an investment these babies were."
BN: "This sounds like it is going to get crazy. We have a budget, you know."
JL: "You know, Big Jumper, crazy would be running this muffler, all rusted out like it is. And it's a boat anchor, too. FMF has a really neat line of utility mufflers called the PowerLine. They use mechanical sound damping, are made from stainless steel and are usually lighter than the standard unit. They look smooth and sound good, giving the quad a good tone without being loud."
BN: "That makes sense, but the mods are making this Foreman into a trail hound, and you said you were going to keep it functional in the work environment. And it's No-Hander, they call me No-Hander!"
JL: "OK, keep your hands on the wheel, because all work and no play makes Jimmy a dull boy. So I'm keeping it real and putting this thing to work like it never worked before. That's why I'm sliding in this Ramsey remote-controlled front winch. It is a tight fit, but the mounting kit has everything you need to make it a perfect fit. It will take me from tugging a load to getting super-unstuck with the push of a button. And the finishing touch is a trip to my Honda dealer, where I'm getting a new seat, an oil filter and a few quarts of Honda HP4 to give the motor something to thank me for."