Where does this go???

[o1440ex]

I was replacing my head gasket tonight, and where i set down my head i found a little tube (oil passsage???) and spring this can someone tell me where it goes?? Somone please help

[CJM]

picture? sounds possibly like the decompressor

[o1440ex]

http://i25.photobucket.com/albums/c57/IQkid/IMG_0074.jpg

[honda400ex2003]

that would be the decomp. Way to go CJM. steve

[rubbersdown]

thats the compression release spring and plunger thing. it goes in the tiny hole in your head. If you look at your head from the cam chain side. look at valve closest to you on your left hand side. close to the bottom right hand corner of that valve you will see a little hole. Spring first than the plunger. It gets hit by the loose compression release lobe on the stock cam

[CJM]

Thanks Steve.

Rubbers right, goes in the head just like that. Its needed if you have a stock cam, a non stock cam it is not used usually.

[o1440ex]

Its got a stage 2 cam in it so i dont neeed to put it back it??

[hocman123]

yea ur good no need to put it back

[honda400ex2003]

Did you tear it down again? I thought you were riding the hundy out in harrison not too long ago. lol steve

[o1440ex]

Thx for the quick replies guys!

[o1440ex]

What does the head have to be torqued down to"?

[honda400ex2003]

check out the manual that was just posted for all of the specs. Why did you tear it down again? steve

[honda400ex2003]

http://www.sendspace.com/file/wcy9is


steve

[hocman123]

the head it's self with the 4 nuts is 33 ft lb. But the valve cover bolts are 8 ft lbs

[honda400ex2003]

cool! Now i know too for next time. I couldnt remember off the top of my head what they were. steve

[o1440ex]

The head gasket was leaking steve

[hocman123]

yea i have had my head off about 7-8 times this year so it is stuck in my head.

[honda400ex2003]

400EX Engine Torque Specifications
from the '99-'05 TRX400EX service manual
Maintenance
spark plug -- 13 lbf-ft
valve adjusting hole cap -- 11 lbf-ft
valve adjusting lock nut -- 17 lbf-ft
crankshaft hole cap -- 5.8 lbf-ft
timing hole cap -- 7 lbf-ft
engine oil drain bolt (crankcase) -- 18 lbf-ft
engine oil drain bolt (oil tank) -- 14 lbf-ft
engine oil strainer screen (at oil tank) -- 40 lbf-ft
oil pipe joint flare nut -- 14lbf-ft


Cylinder Head/Valve
cylinder head cover bolt -- 8 lbf-ft
rocker arm shaft -- 20 lbf-ft
intake sub-rocker arm shaft -- 20 lbf-ft
exhaust sub-rocker arm shaft -- 20 lbf-ft
cam sprocket bolt -- 14 lbf-ft
cam tensioner plug -- 2.9 lbf-ft
cylinder head nut -- 33 lbf-ft


Cylinder/Piston
cylinder bolt -- 33 lbf-ft
cylinder stud bolt -- 33 lbf-ft


Clutch/Gearshift Linkage
clutch center lock nut -- 80 lbf-ft
primary drive gear nut -- 65 lbf-ft
gearshift drum stopper arm pivot bolt -- 9 lbf-ft
gearshift spindle return spring -- 17 lbf-ft


Altenator/Starter Clutch
flywheel bolt -- 94 lbf-ft
starter clutch bolt -- 22 lbf-ft
left crankcase cover stud bolt -- 7 lbf-ft
gearshift pedal pinch bolt -- 14 lbf-ft


Crankcase/Transmission/Crankshaft
mainshaft bearing setting plate bolt -- 9 lbf-ft


Lights/Switches
neutral switch -- 9 lbf-ft


bummer on the gasket. steve

[CJM]

Originally posted by hocman123
yea i have had my head off about 7-8 times this year so it is stuck in my head.

haha indeed...

[honda400ex2003]

you guys are nuts lol. i havent had mine off since i rebuilt 2 years ago. lol steve

[trailrider894]

Originally posted by honda400ex2003
you guys are nuts lol. i havent had mine off since i rebuilt 2 years ago. lol steve

i have had my quad for 5 years and mine has never been off??? :confused:


lol. ITS GONNA GET TAKEN OFF THIS WINTER THOUGH!!! IT WILL GET PUT BACK ON A DIFFERENT BEAST!!!

[hocman123]

well when i got my o6 over the winter it was one used and abused atv. the engine broke down 2 times. all most all the bolts were heilcoiled and they all started failling so i retapped them. they held good for about 15 min, then oil was everywere. so i tapped bigger again and compremised the gasket and it leaked like crazy so then i replaced the head and all is happy. :)

o and me and cjm did his sweet 416 so yea i might have done it more then 8 times

[CJM]

Nah your leaving it out lol:
1. hocmans quad we find all the bolts on the valve cover helicoiled and loose so we tap to 7mm.
2. all was well till the auto tensioner failed, in our quest to find out wtf it was we took it all apart again
2a. replaced it, tore it down and even honed the cyl.
3. Had it apart yet again cause auto tensioner failed again. Decided this time to replace guides, chain and tensioner yet again.
4. All was well but head decided to leak, so again it comes apart. After a much frustrating night and using some allen bolts it leaks oil everywhere.
5. F it! We agree its time for a new for a new head. Finds one, goes back together and all is well..for now!

Me:
1. Opened it up after it began to smoke like the piston was worn. Did the whole bore job and its been fine since.

I probably left out a time or two... But yea I can now take apart the entire thing and have it back together in about 2-3 hours max. this is stopping for breaks too lol..


Hocmans quad sucks tho, it like never ends. Seemed ok when we went and looked at it but it was truly beat. bad head, bad rear bearings, clutch cable, odd springs TAPED together for the rear brake, messed up skids, etc. But really, cant look at much or ride it much to check it out when its like 20F outside and its late at night was the only time you could go see it. hey we learned how to repair it to the hilt lol.

About the only thing I havent done is split the cases, which by now Im sure I could.

[honda400ex2003]

bummer sounds like a new motor would be in order if it was mine. I would not helicoil all of those bolts thats for sure. lol steve

[bherriman]

Originally posted by trailrider894
i have had my quad for 5 years and mine has never been off??? :confused:


lol. ITS GONNA GET TAKEN OFF THIS WINTER THOUGH!!! IT WILL GET PUT BACK ON A DIFFERENT BEAST!!!


PLEASE tell me you are not talking about re-using a head gasket!

[trailrider894]

Originally posted by bherriman
PLEASE tell me you are not talking about re-using a head gasket!

Why? Is that a bad idea? :eek2:

lol ha ha I plan on doing it right. But i'll probably have these guys luck.

[bherriman]

Everyone is talking about head gasket problems and you said you are gonna take yours off this winter and put it on a different beast. Just making sure you were talking about the head and not the gasket...you might think its funny or common sense, but people try it more often than you think.

[CJM]

Originally posted by honda400ex2003
bummer sounds like a new motor would be in order if it was mine. I would not helicoil all of those bolts thats for sure. lol steve

Honestly it just needed a new head and alls well. It was fine before we tore it apart to replace the cam chain again, course we also over torqued the bolts everytime till then, somehow we did 33ft-lbs instead of 8 for the cover. I said to use RTV instead of the gasket but was voted down.