400EX Cylinder / Piston Issue

[pontiacgtp97]

I had a problem with a clutch that I had installed and caused some shavings in the engine. When it did, the piston and cylinder became gouged. There wasn't any oil on the piston skirt, so assumed that the strainer was clogged. I cleaned everything could but I didn't split the cases. I reassembled the engine it ran for approximately 30 mintues then the same problem. I removed the plug above the lines going into the engine and oil was shooting out when I cranked. Is there something that I'm missing? The bike was full of oil and the filter is installed correctly. Any suggestions?

http://i135.photobucket.com/albums/q130/sdarnaby/0315112157.jpg
http://i135.photobucket.com/albums/q130/sdarnaby/0315112158.jpg

[DragonGunner]

I'm failing to understand..." after running for 30 min. the same problem.." what is the problem?

[IMSROLL450R]

Have you always had this bike? Whats the cylinder to piston clearance??? Something else isnt right here it shouldnt do that without some tolerances being way off....

[2001400exrida]

yeah metal shavings wont' do that. you should see the shavings i just pulled out of mjy motor after break-in.

that looks like it wasn't getting oil or the piston/cylinder didn't match up.

[CJM]

You need a new cylinder and piston and check the rod for play.

[pontiacgtp97]

Originally posted by DragonGunner
I'm failing to understand..." after running for 30 min. the same problem.." what is the problem?
This is the second piston and cylinder this has happened to.

Originally posted by IMSROLL450R
Have you always had this bike? Whats the cylinder to piston clearance??? Something else isnt right here it shouldnt do that without some tolerances being way off....
I've had this bike six years, so there isn't any suprises. The last cylinder I put in measured 85mm with a bore gauge and I had a new JE 85mm piston. I didn't check the piston clearance.

Originally posted by 2001400exrida
yeah metal shavings wont' do that. you should see the shavings i just pulled out of mjy motor after break-in. that looks like it wasn't getting oil or the piston/cylinder didn't match up.
Is there any oil passages to the cylinder that would clog up. I pulled the oil strainer and it was full of trash.

[IMSROLL450R]

If you get a new piston and cylinder, usually they need to be mated as in a slight bore if necessary to gain the correct piston clearance....

[killer454]

when putting a new piston in my 400ex i allways bore the cylinder to match the piston.i just dont feel like its worth it to buy the same size piston,and run it in a used cylinder bore.

in my opinion you should allways buy a bigger piston and have the cylinder bored to match.

if you invest 150.00 on a new wisco piston kit,you should invest another 65.00 at honda dealership and have the cylinder bored out to fit a bigger piston.i feel this saves time and headaches from what your going through.

the 400ex has 2 oil strainer screens in the engine you need to check both of them:
the 1st one is in the clutch cover side of the engine
the 2nd one is in a line at the bottom of the oil resavour

my piston was just like yours when i bought my 400ex blowedup,both screens where plugedup i checked them before starting new engine.

check it out on youtube under (400ex first startup)i show the piston.

[pontiacgtp97]

I didn't put a new piston in a used cylinder. The first time it was a 88mm bore so instead of going to 440kit, I decided to go with a new stock bore cylinder and piston.

[2001400exrida]

how do you get to the clutch cover side oil screen?

[pontiacgtp97]

Originally posted by 2001400exrida
how do you get to the clutch cover side oil screen? Remove the clutch cover, its under there.

[pontiacgtp97]

Any further ideas?

[hocman123]

do what cjm said and check the rod for up and down movement. a little side to side is ok but u shouldn't have any up or down play