Kfx 400 wont crank over

[kfx400110238]

I have an 03 KFX 400. I just replaced the timing chain a few weeks ago. Today I started to reassemble everything. Once that was in the clear, I tried to hand crank it. It only cranks so far and then stops, in both directions. I triple checked the timing, I did exactly like the manual says to do. Both cams have a 1,2,3 on them. The Intakes number 3 is pointing up and the exhausts number 1 is pointing toward the front of the block. Counted the pins on the timing chain. The 15th pin is on 3 and the 1st pin is on number 2. Doubled checked, everything is in check, still at TDC. When the intake cam is about to push the valves down, it stops, tried both ways. Any ideas?

Thanks a lot.

[airmobile101]

Isnt the cam lobes suppose to point to the 11 and 2 oclock position?

[airmobile101]

Originally posted by airmobile101
Isnt the cam lobes suppose to point to the 11 and 2 oclock position?

I mean 10 oclock on the intake and 2 oclock for the exhaust.

[kfx400110238]

Im not sure. This is what my manual is telling me how to do the timing. I can give that a shot.

Thanks

[knoxville9]

Okay, I think I know your problem I've done it a hundread times when your timing it theres slack in the cam chain and you need to pull the slack to the left while your timing it because once the tensioner is in its going to pull the chain in that direction and it can put both cams off 2 or 3 teetch which would make your valve touch the piston. If this isn't let me know and I'm sure I can think of something else to try

[kfx400110238]

Well I replaced the cam chain tensionor with a manual one. So once everythings assembled, Do I put tension on the cam chain , or before? I'm assuming after everythings assembled.

Thanks

[knoxville9]

After but when you set your cams roll them left on the chain so the slack is on the left and the right is tight

[350ex]

Are you sure youre not just feeling decompression on your exhaust cam? Theres a little tab that gives some resistance. But yeah cam lobes should be at 10 and 2. You did align the timing mark on the flywheel, correct?

[kfx400110238]

****, no i didn't mark the flywheel. I'm sure it's not decompression because even the starter won't crank it. Later tonight I'll try timing it with 10 and 2o'clock. Why does the manual say otherwise? It says 9 and 3o'clock.

Thanks

[350ex]

I dont know what manual you have but its more like 10 and 2. I just set my timing a couple weeks ago. Check z400central theyve got a good right up on there, its pinned in the performance parts section. You have to have the motor at tdc. Pull out that plug on the topside of the flywheel cover





heres what the cams should look like from the left.
http://i170.photobucket.com/albums/u246/kdale117/DSCF1124.jpg

Here's the timing mark through the hole on the flywheel cover. Line up the line with the center of the opening, the T will be to the right.
http://i170.photobucket.com/albums/u246/kdale117/DSCF1128.jpg


These are hotcams but its the same concept. The hotcams only have 14 1/2 pins between timing marks stock has 15.
http://i170.photobucket.com/albums/u246/kdale117/DSCF1122.jpg

[350ex]

Oh and by the way Tim everythings in and runnin good. Jumped up to a 165 mj. Still have some tweaking to do.

[kfx400110238]

Wow I feel like an idiot. Minds is a hundred different places. Yes I did have it at TDC. Mine doesn't have a T but it has a little groove to notify if it's at TDC. The manuals for a ltz400, but it's all the same ****. Thanks for all the input. Hopfully everything goes good tomorrow.

[jonboy]

There should be a T, there are 2 marks on mine but the one with the T is TDC

[350ex]

Yeah you should have a t. Turn that crank some more. Just dont drop that timing chain...:rolleyes:

[350ex]

If for some odd reason you don't have a T, put something in the spark plug hole to make sure the piston is at tdc when you set the timing on the cams.

[kfx400110238]

Well, I took the cam chain off and tried to crank it. Does same thing. But for some reason every once in awhile it will rotate a good amount, then stop again. Thanks for everyones help.

[350ex]

Sorry to be the bearer of bad news but you have problems. Theres no simple reason that it wouldnt turn over. Somethings getting stuck in the bottom end. Which probably means something is broken down there. Did you take apart the bottom end? Its not the cam chain getting jammed up is it? Last time I had a motor do that there were chunks of metal in the bottom end...

[miles Machine]

pm sent

[kfx400110238]

Yea, figured so. I checked to make sure the chain wasn't getting caught up. I'll take the motor out and start a tear down. Thanks again for everyones input.

[350ex]

Did you drop a valve? Take your head off first and check that.

[kfx400110238]

That's what I'm kinda thinking it may be. I'll take a look.

[kfx400110238]

Took the head off today and found the end of the exhaust valve laying ontop of the piston. Thanks again for everyones help.

Travis

[350ex]

Bummer. Did it ruin your cylinder and piston?

[kfx400110238]

Surprizing no. The last time the quad ran was when i tried bump starting it. So it really didn't have the chance to mess anything up, due to the fact that it didn't start. The piston's got a little tiny nick in it thought. Nothing to be worried about.

Thanks

[350ex]

Wow, thats nice.