sorry guys.

[dxcody]

Well i wasnt going to bother you guys anymore with my problems that never seem to go away, but boneless kinda inspired me to do this... SO BLAME HIM! lol jk! :D

Alright so most of you know that i just replaced my rings, GTT head studs, stage 2 hotcam, new timing chain..

My quad was hard as He** to start up the first time, but when it finally fired up and i got my idle set right, it ran amazing. Power in all the gears, 100% accurate throttle response.. everything.. But it was still hard to start at the begining of the day, it probably took about 5 mins of cranking to get it to fire.

I killed it in the back yard one day and it was making a grinding sound when i tried to start it, well my CAM sprocket fell off the camshaft, no damage done to the cam, but the cam sprocket was twisted and somehow my valve adjustment lock nut on the left intake valve fell off and landed on top of my head.

So i replaced the cam sprocket, replaced the lock nut for the valve adjuster, and now it wont start.. Jetting with the E-series was 155 main, 38 pilot, 3rd clip on needle, 2 turns out on a/f. I thought maybe me having a stock pilot was the culprit to it not starting and so i threw the stock muffler back on, threw in the 148 main, went to 1 1/2 turns on the a/f, just left the needle as it was. Still wont start..

drained the oil, i figured from all the cranking it may have gotten contaminated, and IT DID!

Getting good spark, getting fuel. took the carb off and the gas tank and hooked the fuel line up to the carb and turned the gas on and its not flooding.

Checked the timing at least 10 times and its always dead on, advanced it a couple teeth and still nothing, retarded it a couple teeth and still wont run..

I adjusted the valves and it doesnt seem to have any effect on it, loosened them to .12 and tried every feeler guage i had down to .07.

I have no clue, any ideas? I even tried putting the stock cam/ spring and plunger back in and still nothing.. :mad:

sorry for the long post guys but this is making me mad, with how much time and effort i have put into this thing.

[CJM]

Can you get it to push start?

Id say its a valve issue, there is a possibility they are worn out and need replacing.

[dxcody]

nope tried and the motor turns over really good but it just wont run on its own.

[dxcody]

i was thinking maybe the valves being how as thats the only thing thats old.

[01boneless]

hmm sounds valve related for sure if the valve adjustment nut came off check all rockers and make sure it dident hurt any of them :confused: i not just buy some valves a set with springs can be picked up for like 150-200 bucks and have new seats cut in the head and it may fix you up if not then its a mystery lol also like mark said try pull starting it first to see what happends addjust the valves to intake 004 and exhaust 005 :D also when it came off the sproket the chain could have been sretched or maybe broke teeth on the bottom sproket :confused: HIGHLY unlikely but its something to check

[dxcody]

i was kinda leaning twards maybe when the sprocket came off and that valve adjustment nut came off it bent a valve or something... idk looks like im pullin her apart...

What does a valve shim kit do? Not that i am going to use one, just always wondered that..

[01boneless]

dont even think 400exs can use shim kits i know when you adjust the valves in a 450r you always have to reshim them whitch belive me is a pain in the a**

[dxcody]

haha :D good thing i dont have to use one then!

[01boneless]

yup just pop your valves out and see what they look like hopefully if there bent it dident ruin the valve guids cuase those gotta be pressed out and 3 machine shops have my head and couldent get them out lol

[dxcody]

i got new seals, guess it dont matter if i cant get them out tho huh? lol..

And also your post about paint... Sparked a wicked idea in my head.. :D

Something new and totally awesome!

[01boneless]

haha do it!!!! pm me your facebook and we will plan a beast lol

[05DodgeDakota]

You mentioned you only went down to .07 on the valves. Hot Cams recommends .05 and .06. The .04 and .05 boneless recommended is for the stock cam. It's worth a shot.

BTW, to make it much easier to do your valves, buy the motion pro feeler gagues from rocky mountain atv

[01boneless]

^^^ X2 good call!!

[dxcody]

Originally posted by 05DodgeDakota
You mentioned you only went down to .07 on the valves. Hot Cams recommends .05 and .06. The .04 and .05 boneless recommended is for the stock cam. It's worth a shot.

BTW, to make it much easier to do your valves, buy the motion pro feeler gagues from rocky mountain atv

Yea i was actually looking at the motion pro feeler guages because its kinda a pain lol, and alrighty thanks. The reason why i didnt do them to hotcam, or stock cam specs is because i broke the .06 trying to bend it to fit in there.. lol

[dxcody]

Ok, adjusted the valves AGAIN, tried to push start it and it actually rumbled for a min, but didnt run very good.. Will it not run if the valves are adjusted too tight now? They are pretty tight..

Im not worth a pis* at adjusting the darn things..

Should i try to loosen them just a hair and try it again?

[CJM]

To tight of valves since these are non hydraulic valves is a bad thing, loosen them up a bit.

I still say you have a timing problem.

[dxcody]

Well this is how i did the timing,

set the cam in the head, lobes down,

Set flywheel to "T"

Put cam sprocket on, horizontal marks even with head, Well actually i put them like +1 tooth fwd so when i put the tensioner on, the marks were lined up perfect.

Checked it 3 times, and its always dead on..

[CJM]

When your adjusting the valves they have play in them, you can grab the rockers a bit and they move?

[dxcody]

Yea they will lift up a little bit not alot but some play

[CJM]

Ok that ensures your at TDC.

Next id check to make sure you have good compression and perform a leakdown test.

[dxcody]

Ok, i will have a compression tester Thursday..

Where should i buy a leak down tester? I saw a few on the harbor frieght site, but i wasnt sure, some things from harbor frieght are built worse than McDonalds happy meal toys

[CJM]

I made one using some gauges and pipes from home depot. See if you can borrow one form autozone or something.

Heres an interesting idea you should do before anything. Set the engine to TDC-where do your cam marks line up? The bunch you wrote about putting it forward a bit is making me think its out.

[01boneless]

also there are several marks on the fly wheel make sure it is indeed the T mark just a thought

[dxcody]

my neighbor came over tonight and i was tellin him about what was going on, we checked the timing and he said it was good, and he adjusted the valves for me.

He told me to pull the plug and check the fire. I did and once again it was getting fire. He said he still doesnt think its firing properly, he put his finger about a 1/16th of an inch in front of the plug and pushed the start button (i was like WTF!) and he didnt even flinch. He said that you could barely feel any spark at all and so he said to replace the plug to see if anything changes before i go any farther.

The last few times i pulled the plug before he adjusted the valves it was soaked in gas so maybe the plug is the problem... guess i will find out tomorrow. Worth a shot right?

[01boneless]

definitly worth a shot!

[CJM]

Whats your jetting?

[dxcody]

CJM, i had a white brothers slip on w/ 165 main, 40 pilot, and 2 1/4 turns out on the A/F but then i threw my stocker pipe back on and put the 148, 38, 1 3/4 turns << i believe thats stock, thats what i set it back to..

Boneless, It would be truely amazing if a $2 spark plug fixed her up huh! lol

[CJM]

It ran after you put the stock jets back in?

Id look to see a carb/jet problem. Id leave the larger pilot in there, the stocks to lean and the stock jet is to lean also, I suggest a 150-152.

[dxcody]

HOLY &$^%!!!!

Put the new plug in, turned it over like twice, and it fired up. Its 11:13 PM so i didnt get to ride it, but it fired right up and idled good and everything.

We will see tomorrow!

[01boneless]

haha nice if that aint a killer ! :P

[dxcody]

i am so pumped right now, i just wanna go rip the crap out of it...

My buddy on his 300ex has been dieing to race me, and ride it so i am gonna eat a 300 tomorrow!

[01boneless]

haha just think you missed that race becuase of a spark plug :( haha eat em up :D

[dxcody]

I know, I know...

My own stupidity kills me. :devil:

[dxcody]

Welp! Shes goin! Thanks alot guys for everything!

[dxcody]

ARGH!!!!!!

The entire right side of my motor, just shattered... Clutch, crankcase cover, clutch arm, Clutch basket, everything.

[01boneless]

^^ please tell me your joking? :ermm:

[dxcody]

ill have to take some pics... i have no idea how this ever could have happend!

[dxcody]

Where the 5 clutch springs go on the clutch plate, 2 of them broke off and dominated my clutch/ crankcase cover.

[dxcody]

My clutch arm spring got twisted pretty bad.

[dxcody]

And the clutch center, its the culprit.

[dxcody]

and one of the clutch springs!

[dxcody]

Check out the clutch arm!

[01boneless]

dang that sucks well might as well thro a tusk clutch in it while your in thier :D

[dxcody]

Originally posted by 01boneless
dang that sucks well might as well thro a tusk clutch in it while your in thier :D

im gonna get the barnett clutch basket + clutch kit

[HondaRacing83]

Originally posted by dxcody
im gonna get the barnett clutch basket + clutch kit this is way off topic but can you post pics of your quad haha

[CJM]

When you redid the clutch (I recall you did..didnt ya?) did you make sure to torque that sucker on (basket)? I used an impact but made damn sure it was on there.

Something walked itself out and caused this. Id think it was a loose basket or plate.

[dxcody]

Pics will come soon, and CJM i fastened everything, the basket was still tight when i pulled it off, you know the clutch center? Where you bolt the clutch springs on? Two of them broke off with the spring bolts still inside them, im thinking i must have over torqued them.

[dxcody]

Here is one pic let me know if you want more

[dxcody]

This is what the quad looked like when i bought it, then i stripped it down to the frame and did a complete rebuild on it.

[dxcody]

Pic 2

[dxcody]

How tight are the 5 clutch springs supposed to be?

I stole some parts off my buddies 400 and now my quad takes off fine, but when you nail it, the clutch revvs way up and it doesnt have any pep to it.

[CJM]

Basically hand tight.

[dxcody]

I probably have them too tight then, sounds like thats the problem?

I have them like flush with the pressure plate

[CJM]

Yea more than likely too tight.

When i did mine I looked and looked for a torque spec, there is none. I tightened them just like I did the rocker cover-1/4 drive ratchet and make them snug.

[dxcody]

yea i looked in my manual and all it says is
Spring Free play 1.97 inch

I didnt know wtf that meant, made me feel dumb haha

Thanks man.