Engine tear down- what am I seeing?

[flyboy1294]

To make a long story short, stripped the quad to the frame for a total rebuild over the passed week. Now I'm working on the engine.

I took everything apart the way the service manual tells me to, and I have a few questions:

First, my piston has about 25 hours on it. Is it suppose to have the black in the middle like it does? (Also, if anyone sees any wear that looks abnormal please let me know)

Second, the intake boot has 3 bolts holding it on, I cannot get the the bottom one with a socket, and my little 8mm wrench keeps slipping, any advise?

Third, I'm having a hard time getting the bottom of the jug off. The bolts are REALLY hard to turn. I am only using a 12" ratchet. Does anyone have any tips? Maybe heating them would help? (I'm talking about where the ratchet is in the pictures)

Fourth and finally, the quad has a Hotcam in it. I was told it was a Stage 1, however I have not had a chance to confirm this until now. It says"
HCEF
WW-
NO:07
"
Can anyone tell me what this means or what stage it is? Also, a friend of mine wants to buy the cam for his Ex build. He is new to 400exs and I wouldn't want to give him anything that was defective at all. So can anyone tell by the pictures if they cam is in good condition or not?

Thanks for the help.

http://i82.photobucket.com/albums/j245/jerry42633/101_0472.jpg
http://i82.photobucket.com/albums/j245/jerry42633/101_0473.jpg
http://i82.photobucket.com/albums/j245/jerry42633/101_0474.jpg
http://i82.photobucket.com/albums/j245/jerry42633/101_0476.jpg

[flyboy1294]

Well I kept at it and here is what I accomplished:

The piston now sets at TDC (I had it at tdc before, but when I rotated the cam to get the other bolt out of the sprocket, it changed.)

I was able to loosen those 4 12mm bolts at the bottom of the jug. Just took a lot of torque.

And I figure I need a circle wrench to get those other bolts out. I'll try to get that Monday or tomorrow depending on if I can find one or not.

[sc400ex_rider]

piston looks fine. valve color is normal. the 07 on the cam is the HC stg 1. the old stg 2 now stg 3 was 08 and the new stg 2 is 32 or 34.

[flyboy1294]

Originally posted by sc400ex_rider
piston looks fine. valve color is normal. the 07 on the cam is the HC stg 1. the old stg 2 now stg 3 was 08 and the new stg 2 is 32 or 34.

Thank you, Exactly the answers I was looking for.

I have Kibblewhite valves on the way. I think those are the OEM ones in it which means they are 11 years old. Probably well over do for a replacement.

[flyboy1294]

Alright I tried the circle wrench. It just rounded off the bolt heads. I am TOTALLY at a loss here.

Does anyone have any idea how to get these bolts out? I need to get that jug off.

[Buscg1]

Ive had good luck on stuff like those using a set of "needle nose" type locking pliers, as long as they have good teeth and you set them to clamp real good.

[flyboy1294]

Originally posted by Buscg1
Ive had good luck on stuff like those using a set of "needle nose" type locking pliers, as long as they have good teeth and you set them to clamp real good.

You mean like needle-nosed vise grips or something?

[68Firebird]

Flyboy, use a 6-point wrench or socket. Do not use a 12-point. Try to tap the socket all the way to the bottom of the head to get the most contact. It should be able to be removed this way.

[flyboy1294]

Originally posted by 68Firebird
Flyboy, use a 6-point wrench or socket. Do not use a 12-point. Try to tap the socket all the way to the bottom of the head to get the most contact. It should be able to be removed this way.

That sounds like a good plan. I can't get it to with a socket though because of the lip above it.

BUT I think that if I use my little 6" ratchet with a micro universal joint I might be able to get it. I'll try to pick up those parts tomorrow and get the 6 point wrench as you suggested.

[CJM]

Extension, 12 inch maybe and a universal joint socket should do the trick. Since you rounded them now it might be hard to get off.

[xcracer416]

sears sell a 8mm 6 point wobble socket that i 1/4 inch drive. that is what you need, trust me its worth its weight in gold.



http://www.sears.com/shc/s/p_10153_12605_00943194000P?vName=Tools&sName=Sockets&cName=Wrenches%2C+Ratchets+%26+Sockets

[flyboy1294]

Originally posted by xcracer416
sears sell a 8mm 6 point wobble socket that i 1/4 inch drive. that is what you need, trust me its worth its weight in gold.



http://www.sears.com/shc/s/p_10153_12605_00943194000P?vName=Tools&sName=Sockets&cName=Wrenches%2C+Ratchets+%26+Sockets

I just got it using the 6 point socket like some suggested. Thanks to all that helped. Rebuild will be coming up soon