Foreman 500 Output Shaft Replacement How To

[01SSRedA4]

I'm gonna tag this thread with Foreman 500 secondary gear reduction. Im doing that because on the 500s the secondary gear reduction is accomplished by changing the gear on the output shaft and the smaller gear directly above it. So this could be very useful for someone doing that procedure as well.

So let's start from the beginning. It was a great day to ride at Highlifter, and we set out into the woods. Not long after a heard a huge clunk and the bike lurched forward when giving it gas. I was able to engage 4wd and the front tires pulled me back to the trailer. There was some awful noises along the way however so I knew something was torn up pretty good. I cut the driveshaft boot off and found this:



So I went ahead and took the swingarm off and this curious little guy fell out:



When I dumped the swingarm out, this was in the driveshaft tunnel:



I also noticed the output shaft was bugared up, and the rear case was cracked a little, so I ordered up some parts.

Output shaft 23611-HP0-A00 $43
Rear crankcase cover 11340-HP0-A10 $136 (comes with 91201-965-000 o'ring pre-installed)
Kickstart cover gasket 11396-HP0-A00 $11
Rear cover gasket 11395-HP0-A00 $13
Output shaft seal 91205-HM7-003 $10

Optional but I did not order:
Kickstart oil seal 91202-HP0-A01 $8

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