timming chain/cam chain?

[01boneless]

hi i have a 400ex i need to know what all i need to replace the cam chain other than chain and tentioner and around how much thanks

[hocman123]

u will need both chain guides they are around 70 a piece and a new side case gaskit.

[CJM]

make sure you buy an 02 CRF 450 chain. Not only is it cheaper then the 400ex one-its much stronger and better.

[01boneless]

why will i need the guides ? and does that gasket come in the top end gasket kits?

[CJM]

B/c the guides are usually quite worn. It is also a very good idea to replace them since you will have everything else apart.

The gasket for the tensioner should come in the topend kit, you wil need to buy the side cover gasket from honda. Also will want to invest in a clutch holding tool since you will have to remove the clutch and basket to replace the chain and guide.

[hocman123]

well sometimes just like ur chain they get old and worn and need to be replaced. it really sucks to open it up then find out u need new ones then u need to order them and a 4-6 hour job becomes a week and a half job when u wait for parts.

no the side case gaskit will not come with a top end kit b/c it is not in the top end it is on the bottom. u shouldn't need any gaskits for the top anyway unless u have a leak now b/c they are all metal and are reusable for many times. the side case gaskit is paper and needs to be replaced everytime

[01boneless]

thanks for the help buddy does 400 bucks sound hight for the shop to supply all the parts and fix it?

[CJM]

Yea, but really you can do it yourself for WAY cheaper, like half of that easy.

Trust me, its that simple.

[01boneless]

belive me i dont think i could do it

[hocman123]

not really sure b/c i allways do my own work but most will charge 80-100 bucks a hour for labor. and u are looking at 140 for both guides 70 for the new tensioner 50 for the chain 12 for the gaskit with tax u will be about 300 just for the parts. and for a good shop i would think it would take 1.5 -2.5 hours depending how many times they have done it and how fast they are.

[CJM]

Originally posted by 01boneless
belive me i dont think i could do it

Aw have some confidence...

But if ya dont think you can 400 isnt bad. Parts alone are at least 200 if they replace the guides, chain and auto-tensioner.

[01boneless]

lol im good at every thing but motor work ha ps do you have any pics of your 416?

[01boneless]

there a certified honda at 50 an hour

[hocman123]

wow that is real low for a dealler i have never seen it so low before

[01boneless]

ya there they only shop for like 100 miles thats why when he said 400 bucks i bout dumped my pants

[CJM]

Very cheap, most charge 75-125/hr.

Sorry no pics, I never really got around to it lol. I can tell you the plastics look like crap-but with the engine mods it moves quite well.

[2001400exrida]

what is the clutch holding tool? is it really needed or is there a way to change the chain and guide out without using one?

[hocman123]

it is a tool that holds the clutch baskit still so u can take off the baskit which u need to do inorder to gert the chain off the bottom end. but if the dealer is doing it then u don't need to worry about it they will have one

http://www.rockymountainatvmc.com/productDetail.do?navType=type&webTypeId=140&navTitle=Tools%2FShop&webCatId=22&keyword=clutch+holding+tool&prodFamilyId=18289

[2001400exrida]

looks like a fancy pair of vise grips.

are there any other methods to doing this so id on't have to buy the dang clutch holding tool.....it looks like a total waste of money.

i may stop in to my local guy here and see what he suggests, or maybe he has one i can borrow.

[hocman123]

o i didn't relise who was posting. but it is extreamly helpfull tool. i tryed jaming the baskit up with wood and rages and a few other things and couldn't hold it still to take the baskit even with a inpact gun. got this and it poped off like nothing

[CJM]

Yea for what it is, it works well. Believe me I tried jamming the basket with all kinds of stuff and even holding it with regular vise grips. The tool made it so much easier for the 15 bucks it cost on rocky mtn.

[2001400exrida]

i'm a little clueless with this motor since i've never been into the case before.

so when i take the side cover off to change out the cam chain and the cam chain guide, i have to somehow hold the clutch? does the clutch want to fall out when i take off the cover? i wouldn't think so.

or do i have to press the clutch in to get to the cam chain sprocket and guide?

is there anyway to change the cam chain without taking the side cover off? i have to change the guide no matter what but i was just wondering out of curiousity if you have to take off the side cover just to change out the cam chain?

[CJM]

Cant change the one guide without taking off the aside cover nor can you change the chain.

Reason you need the holding tool will be apparent once you take the cover off and see theres no way to hold the basket really.

Step by step, forgive me if I miss anything this is all from memory:
Note-you will also have to remove at least the valve cover to get the cam out and off the chain.

Also almost forgot-DRAIN THE OIL, otherwise it will go everywhere. you will also have to fill the oil more b/c you removed more than 2 qts.

1. Remove all the bolts for the side cover and oil lines
2. Remove the clutch cable from the linkage on the case.
3. Try to separate cases, be gentle the aluminum can crack and break if you beat on it.
4. Swing the clutch linkage towards back of atv, disengaging it from the throwout bearing (not sure if thats the proper name)
5. Pull case off
6. Remove clutch pressure plate (thing with 6 or little bolts in it. When you put it back together its VERY important you use a 1/4 drive ratchet and snug these little bolts up in a star pattern, you dont not want to overtorque them and the only torque spec is to make them snug. I usually choke up on the ratchet to make sure Im not applying to much force.
7. Remove clutch discs and fibers-note how the last disc goes into the fingers of the basket when you reassemble it thats the way it goes in. Now is the time to check the specs and see if they are within service limits, you need a dial caliper for this.
8. Undo staked nut on basket. Need chisel/punch to unstake it.
9. This is where you need the holder tool: put holder tool on basket and hold, take off staked nut-an impact would be a really good idea as it makes it easy.
10. Now that the baskets off you can gain access to some of the gears in there blocking the chain. Take them off, pop new chain on, pop guide on.
11. Reverse of everything you just did. You really need to torque down the basket, I used an impact and then checked with a torque wrench.
12. Once everything is back together

Sorry if I missed anything, manual covers it pretty well and its rather easy once you get into it.

[CJM]

Just so were not confusing each post, there is another way if your only replacing the chain and not the one guide that gets bolted in:

Drill out the rivets on the old chain, drill out rivets on new chain. Weld chains together and thread thru case, then drill apart and weld back together. But thats above most skill levels round here Id say.

[hocman123]

i would also note that in order to replace the guide that doesn't bolt down inside the case u most remove the head off the bike b/c that is what hold the guide in

[2001400exrida]

ok so in order to change the cam chain i have to split the cases? damm that's another gasket i gotta get now haha.

[CJM]

No, sorry if you misunderstood-you just gotta remove the clutch side (right side) cover. Once thats done you can get to everything.

[2001400exrida]

ok good, whew i was worried there for a min. i'm already balls deep in this thing haha, splitting cases would go way beyond my abilities i'm pretty sure.

[2001400exrida]

is there any other way to get the basket out without having to have the special tool?

[Scro]

Sticking a penny between the gears will hold the basket still.

[400exmxrider15]

I used an impact gun, came off in about 5 secs....

[2001400exrida]

did you not hold the basket in place while you were using the impact? the basket spins freely in there and the nut spins with it. I'm not able to get mine off with just an impact, so i broke down and ordered the tool.