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Thread: jetting placement

  1. #1
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    jetting placement

    Just for reference for me, i am making a thread with this info on it. It shows where each part of the carb is in effect. now i can just search for my name and find this lol. steve

    My jetting suggestions:


    Jetting placement chart:
    Attached Images Attached Images
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  2. #2
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    I know this is on here already. lol now i know what to search easy when i want to find this stuff. steve

    Width------Keihin # -- DynoJets # -- Mikuni #
    0.0350---- 92.5--------- 92----------- 86.3
    0.0360---- 95----------- 94----------- 88.1
    0.0370---- 97.5--------- 96----------- 90.0
    0.0380---- 100---------- 98----------- 91.9
    0.0390---- 102.5------- 100---------- 93.8
    0.0400---- 105--------- 102---------- 95.6
    0.0410---- 107.5------- 104---------- 97.5
    0.0420---- 110--------- 106---------- 99.4
    0.0430---- 112.5------- 108--------- 101.3
    0.0440---- 115--------- 110--------- 103.1
    0.0450---- 117.5------- 112--------- 105.0
    0.0460---- 120--------- 114--------- 106.9
    0.0470---- 122.5------- 116--------- 108.8
    0.0480---- 125--------- 118--------- 110.6
    0.0490---- 127.5------- 120--------- 112.5
    0.0500---- 130--------- 122--------- 114.4
    0.0510---- 132.5------- 124--------- 116.3
    0.0520---- 135--------- 126--------- 118.1
    0.0530---- 137.5------- 128--------- 120.0
    0.0540---- 140--------- 130--------- 121.9
    0.0550---- 142.5------- 132--------- 123.8
    0.0560---- 145--------- 134--------- 125.6
    0.0570---- 147.5------- 136--------- 127.5
    0.0580---- 150--------- 138--------- 129.4
    0.0590---- 152.5------- 140--------- 131.3
    0.0600---- 155--------- 142--------- 133.1
    0.0610---- 157.5------- 144--------- 135.0
    0.0620---- 160--------- 146--------- 136.9
    0.0630---- 162.5------- 148--------- 138.8
    0.0640---- 165--------- 150--------- 140.6
    0.0650---- 167.5------- 152--------- 142.5
    0.0660---- 170--------- 154--------- 144.4
    0.0670---- 172.5------- 156--------- 146.3
    0.0680---- 175--------- 158--------- 148.1
    0.0690---- 177.5------- 160--------- 150.0
    0.0700---- 180--------- 162--------- 151.9
    0.0710---- 182.5------- 164--------- 153.8
    0.0720---- 185--------- 166--------- 155.6
    0.0730---- 187.5------- 168--------- 157.5
    0.0740---- 190--------- 170--------- 159.4
    0.0750---- 192.5------- 172--------- 161.3
    0.0760---- 195--------- 174--------- 163.1
    0.0770---- 197.5------- 176--------- 165.0
    0.0780---- 200--------- 178--------- 166.9
    0.0790---- 202.5------- 180--------- 168.8
    0.0800---- 205--------- 182--------- 170.6
    0.0810---- 207.5------- 184--------- 172.5
    0.0820---- 210--------- 186--------- 174.4
    0.0830---- 212.5------- 188--------- 176.3
    0.0840---- 215--------- 190--------- 178.1
    0.0850---- 217.5------- 192--------- 180.0
    0.0860---- 220--------- 194--------- 181.9
    0.0870---- 222.5------- 196--------- 183.7
    0.0880---- 225--------- 198--------- 185.6
    0.0890---- 227.5------- 200--------- 187.5
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  3. #3
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    pilot adjustment procedure

    http://s759.photobucket.com/albums/x...adjustment.jpg

    same with the picture.

    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  4. #4
    Join Date
    Nov 2009
    Posts
    238
    mods put this in faq!!
    2002 416ex
    ported head

    wiseco 10:1

    hot cam stage 1

    u.m. performance Nerfs with pro pegs

    houser +2 anti vibe stem

    protaper countor reed bend

    new holeshots all the way around
    SOON TO COME:
    450r shocks, and carb and 2 inch wheel spacers

  5. #5
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    most of it is hidden in there or other places. I just get tired of trying to search for it all the time. so i made my own so i know what to search for with my name to get the correct thread. steve
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  6. #6
    Join Date
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    plug chopping
    the plug chop is an essential step in setting up jetting. not only does it help you get good performance, but more importantly, it helps you make sure yr bike is not running so lean that it will blow up!

    1. wind it out! . warm the bike up well (5-10 min) with a new or fairly clean plug, correctly gapped, then wind the bike out in a gear. generally, i like to do this in 3d, but it depends how fast your bike goes in each gear and where you're doing this test (trying to run a bike out in 4th is not advisable in, say, a school zone). at least get into 2d.

    2. hold it there ... even though you will be nervous, hold it in gear at max rpm for a while... what you are trying to do here is simulate the hardest use the bike will ever conceivably see. if you jet for the most stressful conditions, then yr normal use will be well within safe margins. keep yr hand on the clutch, as you could (doubt it, though) seize if you are jetted too lean to begin with. as always, use yr own judgment!

    3. kill it. simultaneously hit the kill switch and pull in the clutch. hitting the kill stops the plug sparking; pulling the clutch stops the clutch from turning the engine over (bringing in more unburnt fuel). thus, you get a perfect picture of what the sparkplug looks like at the moment you hit the kill switch.

    4. pull over, pull the plug out you will want to have gloves or a set of pliers, cause the plug will be hot!!!

    5. read the plug. if the plug is:

    black and wet: your jetting is too rich

    chocolate brown: your jetting is right on!

    white and burnt smelling: yr jetting is too lean! upjet now . you might also notice a blistered insulator. this is real bad. you are lucky you haven't hurt your bike worse!
    See sheets below for proper plug colors and pictures.

    steve
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  7. #7
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    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  8. #8
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    Old manual:
    http://www.sendspace.com/file/wcy9is

    New manual:

    http://go.redirectingat.com/?id=162...x-400-ex-2.html

    Password is: trx400ex400x

    Pages for specs on top end: 104, 110, 121 for cylinder, head, and head cover specifically

    Torque specs:
    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
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

  9. #9
    Join Date
    Sep 2010
    Posts
    427
    This is a nice post, mod should def. sticky this. Maybe it will cut down on some of the 100 daily jetting question posts lol.

  10. #10
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    450r carb adaptor information
    http://www.exriders.com/vbb/showthre...hlight=adaptor


    I stickied it already in post on the second page. it is doubtful that people will go that far back and read through everything but it is good for me as a base guide for any questions that arise. steve
    2019 Maverick X3 XDS Turbo R
    2003 TRX 400EX
    2016 HONDA RANCHER

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