Comprehensive Guide to Installing a Honda 450 Cylinder on a 400 Foreman
When considering modifications to enhance the performance of your Honda Foreman, one of the most popular swaps is installing a 450 cylinder on a 400 model. This guide aims to provide an in-depth look at the process, the benefits and potential pitfalls, and to help you make an informed decision about this upgrade. Drawing insights from various forums and expert opinions, we will dissect the components, applications, and specifications to ensure you have all the information needed for a successful upgrade.
Comparison of Cylinder Options for Honda Foreman
| Cylinder Type | Displacement | Compatibility | Performance Gains | Common Issues |
|---|---|---|---|---|
| Honda 400 Cylinder | 400cc | Foreman 400 | Base performance | Less power |
| Honda 450 Cylinder | 450cc | Foreman 400 | Increased torque/power | Potential overheating |
| Honda 420 Cylinder | 420cc | Foreman 400 | Moderate gains | Fitment issues |
| Honda 500 Cylinder | 500cc | Foreman 450 | Significant increase | Heavy modifications required |
Understanding the Basics of the Cylinder Swap
What is a Cylinder Swap?
A cylinder swap involves replacing the original cylinder of an ATV with a different model to enhance performance. In the case of the Honda Foreman 400, many enthusiasts opt for a 450 cylinder to benefit from its larger displacement and improved horsepower. This swap can lead to better acceleration, torque, and overall riding experience.
Why Consider a 450 Cylinder?
The 450 cylinder is often sought after due to its ability to provide a noticeable performance boost. Riders looking for more power for off-road adventures or heavy-duty tasks may find this upgrade particularly appealing. Additionally, it can lead to improved towing capacity and better handling in challenging terrains.
Step-by-Step Guide to the Cylinder Swap
Preparation
Before embarking on the cylinder swap, ensure you have all necessary tools and parts. You will need:
- A compatible Honda 450 cylinder
- Gasket set
- Torque wrench
- Basic hand tools (sockets, wrenches, screwdrivers)
- Clean workspace
Disassembling the Engine
- Remove the Seat and Plastics: Start by taking off the seat and any plastic covers to access the engine.
- Drain Fluids: Drain the oil and coolant to prevent spills during the process.
- Remove the Intake and Exhaust: Detach the intake manifold and exhaust pipe to clear the way for the cylinder removal.
Cylinder Removal
- Unbolt the Cylinder Head: Carefully remove the bolts securing the cylinder head using a torque wrench to prevent stripping.
- Lift Off the Cylinder: Once the head is detached, gently lift the cylinder off the crankcase. Inspect for any wear or damage.
Installing the 450 Cylinder
- Prepare the New Cylinder: Clean the surfaces of the new 450 cylinder and ensure it is free from debris.
- Install New Gaskets: Place new gaskets on the crankcase to ensure a proper seal.
- Bolt Down the Cylinder: Position the new cylinder over the crankcase and secure it with the appropriate torque settings.
Reassembly
- Reattach the Cylinder Head: Secure the cylinder head with the correct torque specifications to prevent leaks.
- Reinstall Intake and Exhaust: Reattach the intake manifold and exhaust pipe.
- Refill Fluids: Add fresh oil and coolant before reassembling any plastic covers and the seat.
Key Considerations and Common Issues
Performance vs. Reliability
When upgrading to a 450 cylinder, it’s essential to balance performance gains with reliability. While the increased power can enhance your riding experience, it may also put additional stress on other engine components, potentially leading to premature wear.
Overheating Concerns
One common issue with installing a 450 cylinder on a 400 Foreman is overheating. The larger displacement can generate more heat, so it’s crucial to ensure your cooling system is functioning optimally. Consider upgrading the radiator or using a higher performance coolant.
Fitment Issues
Ensure that the 450 cylinder is compatible with your specific model year of the Foreman 400, as there may be slight variations in fitment. It’s advisable to consult forums like www.hondaforeman.com and www.hondaatvforums.net for insights from other users who have completed the swap.
Technical Features Comparison
| Feature | Honda 400 Cylinder | Honda 450 Cylinder |
|---|---|---|
| Displacement | 400cc | 450cc |
| Bore Size | 85mm | 88mm |
| Stroke | 70mm | 70mm |
| Compression Ratio | 9.0:1 | 9.5:1 |
| Weight | 12 lbs | 14 lbs |
| Power Output | ~25 HP | ~32 HP |
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Conclusion
Upgrading from a Honda 400 cylinder to a 450 cylinder can significantly enhance your ATV’s performance, offering greater torque and power for various riding conditions. However, it is essential to carefully consider the potential issues of overheating and fitment challenges. By following the outlined steps and understanding the implications of this swap, you can enjoy the benefits of improved performance while maintaining reliability.
FAQ
What is a cylinder swap?
A cylinder swap involves replacing the engine cylinder of an ATV with a different model to enhance performance, such as swapping a 400cc cylinder for a 450cc cylinder on a Honda Foreman.
Why upgrade to a 450 cylinder?
Upgrading to a 450 cylinder can provide increased horsepower and torque, improving acceleration, towing capacity, and overall performance in challenging terrains.
What tools do I need for the swap?
You will need a compatible Honda 450 cylinder, a gasket set, a torque wrench, basic hand tools (sockets, wrenches, screwdrivers), and a clean workspace.
Are there any common issues with this swap?
Yes, common issues include overheating due to increased engine stress and potential fitment problems, especially if the cylinder is not compatible with the specific model year.
How can I prevent overheating after the swap?
To prevent overheating, ensure your cooling system is in good condition, consider upgrading the radiator, and use a higher performance coolant.
Do I need to modify anything else on my ATV?
In some cases, upgrading the exhaust system or tuning the engine management may be necessary to optimize performance with the larger cylinder.
Is it worth the investment?
For many enthusiasts, the performance gains from installing a 450 cylinder on a 400 Foreman make it a worthwhile investment, especially for off-road use.
Where can I find more information on this?
Forums like www.hondaforeman.com and www.hondaatvforums.net are excellent resources for tips, experiences, and advice from other riders who have completed similar swaps.
Can I revert back to the original cylinder?
Yes, if you encounter significant issues or prefer the original performance, you can revert to the stock cylinder, provided you keep the original parts.
What is the expected power gain from the swap?
Typically, a 450 cylinder can provide an increase from around 25 HP to approximately 32 HP, depending on other modifications and tuning.