need help with my first quad

[ktm300ex]

Ok I have been searching around and need a little more help. So here it goes. I just bought a 95 300ex and is ALL STOCK. so far I put on a hmf slip on, and jet kit. because im sure it is worn down I plan on a 40 over 11:1 comp. piston, new clutch, and a stage 1 hot cam. It doesnt have to be the fastest but I want more..

so my questions:
does this sound like a decent setup?
will I feel the difference?
what gearing/ tire size should I go with? (all kinds of riding but NO MX)
and lastly......what is the final engine size with 40 over?


thanks a lot for the help!!

and just a few pics..
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00111.jpg
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00109.jpg

[SET THE STAGE]

you'll be happy with the upgrade. that high comp. piston and cam will make a big difference

i wouldn't worry too much about the gearing if you're not going to really be racing or anything. as for tires, 18" or 20" rear kenda klaws would suit nicely. (the 18" are really more like 19". they're a little bigger than most)

[dabomb_350x]

Tire choose depends on where you ride. And what else rides there. I ride on 22" do to the trails I ride with deep utility ruts and narrow trails. It help keep for bottoming out my skidplates on rock and hard packed dirt.

[bwamos]

The most popular all around (non MX) setup for tire size on the 300ex is 20" rear.. 21" front.

I run the common.. 20" Razr rear w/ 21" Razr2 front setup.

[dabomb_350x]

If I rode on 20" I spend a lot of time picking up back end and to get off rocks and center hump. I know it only difference of 1" but if not careful have to lift the back for the 22" too.

[honda300EXtreme]

i had almost the same set-up as your planing at one point, except i had a 400ex carb,and a WB header.

and it was a real strong running machine. and ran alot better than stock

i would run 14/38 gearing with 20'' rear tires


.40 over gives ya 289 cc's

[ktm300ex]

will a WB header fit my hmf slip on?
where do I get one?

and

would a 400ex carb help even compared to a properly jetted stock one?

thanks for all the help guys. Im looking forward to tearing into pretty soon...

[honda300EXtreme]

yes a white brothers header will match up with a hmf slip on, its a pretty common combo,

you can get them straight from whitebrothers there around $125

and yes a 400ex carb will make a durastic improvment compared to a stock carb.

[bwamos]

Originally posted by honda300EXtreme
you can get them straight from whitebrothers there around $125

They got bought out by Vance & Hines.

[ktm300ex]

ok I have a few stupid questions I need some help with.

1. How the hell do you get the carb off???? I cant get the throttle cable thing loose.

2. My quad used to have and hmf pipe on it and the owner took it off before I bought. Well then I bought the same pipe from him and put it back on the quad. It seems like it runs good but it gets so hot. If it were to lean would it cause it to run hot???

3. To jet I have to take off the 4bolts on the bottom. well mine are seized in there real good, any good ideas on how to get them out with out damage? and is there a gasket in there?

4. you guys have any good links to oil coolers? It just runs so dam hot I think it would help a lot.


thanks for all the help....
kyle

[SET THE STAGE]

1. the throttle cable off the carb itself?

2. if you're lean, it would run hotter.

3. just try your hardest i guess? haha if you screw them up but happen to get them out, just get new bolts from a hardware store? just take your old ones and compare to new ones

4. fourstroketech.net has a good oil cooler for 85

[dabomb_350x]

To remove throttle cable first losen the jam nut on the throttle cable tube. Then remove the screws from the black cover and remove the cover. Then rotate the the part the cable attached to until you can get cable to the slot in it to slide and remove cable out.

I used a hand impact to get those stubborn screws out. But if you are just doing the main jet you can remove the bowl drain plug and change it that way.

[ktm300ex]

thanks for the help. but Those dam screws just wont come out no matter what I tried.........so I just bought a 400ex carb and hot cam and 40 over high comp. piston so it looks like I am going to start tear down a little sooner then I thought.


any tips or ticks, "what not do to" when rebuilding the top end?

[ktm300ex]

Im looking for a jet kit for the 400ex carb....
Is there anyone that is better then another?


thanks for all the help

[honda300EXtreme]

most jet kits boil down to two styles.

factory keihin jets and those such as dyno jet

personally i always stick with the factory style jets, just for the simplicity factor, and id much rather pay a few bucks for the jets i need rather than 60 bucks for jets i will never use

[ktm300ex]

ok I have a few more questions.

does this look ok for oil cooler placement?
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00110.jpg
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00111.jpg
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00112.jpg

and this is the oil line I cut and run one side to the cooler and the other back to the head.
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00113.jpg

and one more realy stupid question but >>>>..... I ordered the hot cam and do I need new bearings? I know stupid question but I would rather know now then have to wait for more parts.



thanks agian for all the help

[dabomb_350x]

That is where I have seen several of that style oil cooler installed. Only issue is you need to install some type of guard to prevent damage from flying object: rocks, sticks, etc.

And that is the correct oil line to install it on.

[honda300EXtreme]

everything looks good. just get a piece of wire mesh or something along those lines and install it in front of the oil cooler.

and if you are buying the cam brand new, it should already have new bearings installed, at least my hot cams always have

[bwamos]

Originally posted by ktm300ex
and this is the oil line I cut and run one side to the cooler and the other back to the head.
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00113.jpg

That is the one you cut.. and that is the return line to the head.

The line going from the engine to the cooler is the bottom end of that same tube.

Basically you are rerouting that tube to go through the cooler.

[ktm300ex]

are these the right jets to get???
and which "kit" should I get?
.40 over high comp piston, hot cam, valve job, 400ex carb.
I was thinking the one second from the bottom??

thanks again for the help, this site rocks!

http://www.bikebandit.com/aftermarket-parts-list?d=1151496+1153788+1230796+1230913

[honda300EXtreme]

with those mods, you will probably be in the 148 range. (148 is stock 400ex jet size)

also get a 42 pilot jet, it really helps these carbs with cold starting problems,

that should get you in the ball park and you will need to fine tune from there

[ktm300ex]

Ok I have more stupid questions.......
I just got my 400ex carb and have no clue what im looking at.... so HELP!

here is what im looking at:
http://i120.photobucket.com/albums/o182/kylemm1002/DSC00115a.jpg

now I THINK that the yellow is main jet???....it says 132
red is air/fuel mix
blue is pilot......it says 38

Is that right???
so 132 is stock main?
and 38 is stock pilot?

and do 300ex and 400ex carbs take the same jets??

thanks for all the help!!!! REALLY!!! THANKS

[honda300EXtreme]

yes yellow is the main jet
blue is your pilot jet,
and red would be your fuel mixture screw

a 148 keihin jet is stock for the 400ex
and yes 38 is the stock pilot jet for a 400

i do believe the jets are interchangeable actually,

heres a another good site to buy individual jets
www.jetsrus.com

[ktm300ex]

is there any way to I.D. a 400 carb from a 300???
cuz my main jet is 132, so mabey I got screwd???

I know a stock carb is 32mm? right
mine measured to 36mm, inside

[honda300EXtreme]

i just checked service honda and they list 3 different parts numbers for a 400ex carb

QB10AA
QB10AB
QB11AA

this would be the most simple way for you to ID the carb,, its late so i cant think of any other positive id marks for the carb

[ktm300ex]

mine is QB01BA

[honda300EXtreme]

man im so tired i cant even think

ill check my carb tomorrow for the number and let ya know,

or somebody else might chime in, in the mean time

[dabomb_350x]

You got sold a 250X carb.

QB01BA is a 250X carb, and also noticed in the picture the choke lever is black all 300EX and 400EX are yellow that I have ever seen.

[dabomb_350x]

A 250X and 300EX carb look the same from the outside but the 250X has a black chock lever and the 300EX has a yellow. See first pic of 250X Carb. Second pic is of a 400EX carb. the thottle action cover is different between the 300EX and 400EX carbs. Also the 250X carb has a straight idle adjust screw where the 300EX and 400EX has the flex able idle screw. And the 400EX have more vent tubes. Also the carbs have serial number down close to the bowl that is for each bike. The 250X is QB01BA for a 91-92, the 300EX has two different ones either , QB02A or QB04A depending on the year of the bike and honda300EXtreme listed the option of the 400EX

[dabomb_350x]

400EX CARB

[honda300EXtreme]

that sucks man, hopefully you get it straitened out,

yea ive never seen a black choke lever on a 300 or 400 carb either

[ktm300ex]

well I got screwed........ Im in the process now of returning the carb and getting my money back. and just so you guys know, I bought it off "xcbob" on ebay. so watch out for him selling the wrong stuff.

anyone got a 400ex carb for sale???
thanks

[SET THE STAGE]

just keep an eye on the classifieds here on the forums. a lot of people get rid of stock 400 parts prettyyyy cheap

[ktm300ex]

so I tried to rejet my stock 300 carb for my exhaust to try and cure the runing to hot problem, and I went from a 122 to 125 and it feels good except for when its at idle and you punch it wide open it sputers and bogs. all this is while in out of gear. So now I put a 130 in it and feels great once you are moving but the first 1/4 when you punch it bogs
what should I do?


when I adjust the fuel screw out about 2 turns it runs like crap and dies if you punch it.


WHAT DO I DO???
I need to have this thing runing good by saturday for my last ride before tear down!!

THANKS

[ktm300ex]

mabey I need to adjust the needle???? What the hell is that?? Ive searched and searched and looked at my carb and I dont see a needle with a clip that you adjust. can someone post a pics to help my dump ***?

thanks
kyle

[SET THE STAGE]

you have to access the needle from the top of the carb. it's inside of the slide

[honda300EXtreme]

theres really no good how to on adjusting the needle on here that im aware of.

i think its time to invest in a repair manual.
it will walk you through step by step with pics

[ktm300ex]

Originally posted by honda300EXtreme
theres really no good how to on adjusting the needle on here that im aware of.

i think its time to invest in a repair manual.
it will walk you through step by step with pics

funny you say that, im buying one now.
thanks for all the help guys I got it running like a bat outa hell now!!

but check back to this thread because when rebuild time gets here im gona have some more questions for sure.

THANKS A LOT, you have realy helped me

[honda300EXtreme]

glad to hear it man.

yea when rebuild time comes dont be shy. myself and other will be happy to help ya out.

ill keep an eye on this thread ;)

[ktm300ex]

ok so Ive searched and cant find it, and my repair manual is lost in shipping somewhere so I have one last question for you guys.

How do you tighten the chain?????????

something like put a allen wrench through the sprocket in the carrier, loosen the tow hex bolts on the back and roll the quad forward to tighten then tighten back down the twohex bolts.

Is that close?
thanks again

[honda300EXtreme]

loosen the 2 pinch bolts on the rear of the swingarm,

place a piece of roundbar or a screwdriver in the carrier (sprocket side) and rotate it back to tighten.

let me see if i can dig a pic up for ya

[ktm300ex]

ok so that was simple, but my chain is stil waaaaaaaaaaaayyyyyyyyyy to loose. it still rides on the bottom skid plate.

so I guess I need to take a link or two out.
and make sure my carrier bearings are still good.
so I just cut a link out and put in a master link?

thanks

[honda300EXtreme]

yea sounds like its time to cut a link out,

take your master link off and decide how many links you need to remove, and then remove them, just make sure your not cutting too short, and that when you remove your link(s) you will have the correct end. to accept the master link

[ktm300ex]

this thing is so worn down from rubbing, Im just going to get a new chain and sprocket set, with stock size sprockets.
what do you think of this set:

http://www.rockymountainatv.com/productDetail.do?navType=type&vehicleId=2973&webTypeId=123&navTitle=Drive&webCatId=9&stockId=115464&prodFamilyId=2218#vehicleSelect

[honda300EXtreme]

yea that looks like a nice chain and sprocket combo, x-ring are good chains,

[honda300EXtreme]

and did everything turn out ok with your whole carb situation, is he sending you the right on or a refund?

[ktm300ex]

Originally posted by honda300EXtreme
and did everything turn out ok with your whole carb situation, is he sending you the right on or a refund?

well he did refund my money, but then paypal refunded that money to bank account that was not there.....so Ive got some money floating around cyber space untill it either automaticaly re-opens the closed account.....or (hopfully) just gets credited to my pay pal......

I just got new chain and sprockets today......and wow the front sprocket didnt have a good tooth on it lol. but everything seems fine but if the quad is off and you push is in a hard circle the chain kinda pops just once or so. Not sure if it is just cuz its new or what but ive got about 1-1/2 of play.

[honda300EXtreme]

thats good, did you find a 400 carb yet?


make sure your swingarm bearings are good, and if they are dont worry about the popping, our Z does that in reverse

make sure you keep that new chain lubed up

[ktm300ex]

there is only about 1/4" of play in the bearings, they still feel good and tight and roll fine.

and ya a member on here sold me one, should be here next week.

[honda300EXtreme]

there should be no play in the needle bearings in your swingarm,


thats the popping your hearing, your chain is binding