First quad, first breakage, first post

[Hubjeep]

Hello all,
Earlier this year I bought a 2003 TRX400EX from a friend who rarely used it and maintained it well.

I use it a couple times a week to drive around the neighborhood, occasionally take it on the beach, and once to an ATV trail.

Last Sunday it stopped driving and "N" felt like it was still in gear. We look at the engine sprocket and see a chunk of bearing race fall out and shaft misaligned. :eek2:

We pulled the engine, which is on the bench, I have the factory service manual (followed it to take engine out), has anyone else had this happen? Any tips/suggestions would be great. I have yet to read about taking it apart.

http://img.photobucket.com/albums/v222/Hubjeep/400EX/shaft1.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/shaft2.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9151142.jpg

Thanks,
John

[Chuck75]

just my opinion, being that you are new to quads, I would definatly take it to a certified mechanic or dealer. thats a big job witch takes splitting the case I believe. that get to be real hard if you dont know whats in there.

[dalejiw25]

Whoa, That's an ugly picture. That chain looks pretty dry and rusty as well, Hell there's even rust on the chain guard. That might have contributed to your problem. It could have also been on too tight, Which put undo stress on that bearing. That's too bad. That amounts to a complete tear down there. Sorry bout your luck.

[Hubjeep]

Originally posted by dalejiw25
Whoa, That's an ugly picture. That chain looks pretty dry and rusty as well, Hell there's even rust on the chain guard. That might have contributed to your problem. It could have also been on too tight, Which put undo stress on that bearing. That's too bad. That amounts to a complete tear down there. Sorry bout your luck.

It looks rusty in the pic, that is actually red dirt from PEI (Prince Edward Island), they even have red "dirt shirts" there.

I don't think chain was too tight, a few quad riding friends said it was fine.

[Hubjeep]

Took it apart last night. Was less complex inside than I expected.

Looks like only damage was that bearing.

Where do you suggest I buy the bearing and gasket kit?

Thanks,
John

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171150.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171143.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171138.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171161.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171159.jpg

http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171151.jpg

LOL
http://img.photobucket.com/albums/v222/Hubjeep/400EX/P9171154.jpg

[jcs003]

get the gaskets from a honda dealer. also since you have it apart check everything you can and replace valve seals, cam chain and it would be wise to have it bored a size up and put a new piston and rings in it.

[dalejiw25]

Judging by that last picture, It appears as though it was a 4 Beer tear down. Not bad for a First-Timer. I'd pick up at least a 6-Pack for the assembly and you should be good to go. Keep up the good work and Good Luck !!!!
Whoa, Just noticed The Penis box hangin on the wall.... Hmmmm.... Care to explain ???? Looks pretty scary to me. I mean, I've seen a lot of "Keep out" signs But that's brief and to the point.

[sc400ex_rider]

no i never seen this before. i too think the chain was to tight just because everyone does it and wipes out the rear carrier bearings. its better to be a little lose than tight. i also applaud your getter dun attitude. get a honda bearing and get back to riding.

[togup]

Try Service Honda, it will be about 20 bucks for the bearing and shaft seal ,hope the seal will stay in, the case looks wallowed out

[Hubjeep]

Thanks for the replies, will check Honda for the bearing. Are gasket kits available, or just individual ones?

I figure a 24 pack over a few days assembly, looking at many exploded diagrams and torque specs.

HAHA at the box. It used to say "PENS" until a friend added the "I". :D

[MtnEX]

Chain too tight!!!!!

When you put it back together, line up all 3 centers straight it a line.... front sprocket, rear sprocket and swing arm pivot...

This usually the point in the wheel travel where chain tension is it's tightest.

[Hubjeep]

Thanks for all the replies.

I ordered the bearing, seal, and complete engine gasket set with oil seals from bikebandit.com, shipped today from CA, prob friday or monday to NY.

Will keep y'all updated.
-John

[Hubjeep]

After nearly 3 months I finally put it all back together last weekend.

The assembly went surprisingly well, no leftover or lost parts. The moose racing gasket kit had every gasket I needed. I found no other damage besides the bearing. Used a bit of retaining compound on the new bearing outer race, adjusted valves and CHAIN.

Thanks for the help, all is back to normal!

I lost count of beer consumption, had a couple friends over too, haha.

http://img.photobucket.com/albums/v222/Hubjeep/JU/DSCN1245.jpg

[MtnEX]

Nice... I always say there is nothing like a little drunken determination for getting things done!

[jensenracing77]

now for the tree decorations. :D

[MtnEX]

Oh.... that's golden right there... lol...

Beer tree...
It is a wonder mine didn't turn out like that this year.
The lights almost drove me nuts this time around.

[CJM]

I didnt decorate mine my mom did, I went riding haha.

[jensenracing77]

don't get me wrong, that's not my tree. i don't drink. :)

[Hubjeep]

Nice tree!

I will re check the service manual, but a friend said something about the chain is to be adjusted with a rider on it? Or no load on the suspension? :confused:

[CJM]

Rider on rider off imho its basically like this:

Take a take measure and go to the middle of the chain and make sure its all settled down and has some slack. Then pick up the chain by the tape and set it to have between 1.25 to 1.5 inches of slack or so. When you sit on the quad the slack gets taken up.

Mine I measure from my skid and make sure the chain has slack then adjust it for 1.25 inches and it never has failed me.

Thats the way i do it at least. A loose chain is better than a tight chain!