i am a new member in need of some assistance.
here is the deal..
bought a 2000 ex wiht following mods

440 big bore kit / 13.5:1 compression / oversized valves / port and polished head / hotcams stage 3 cam / stock carb, jetted and choke removed / oversized aluminum oil tank/ white brothers full exhaust / white brothers rev kit / K&N Filter / 450R wheels / sidewinder sprockets / Pro Taper bars / AC front bumper / AC nerf bars /

i run cam2 110 in it.  i have ridden it probably 20 hours or so since buying it.

the motor has slight noise like ticking
it ran solid, but seemed as if the carb wasnt dialed in.. i messed wiht the carb got it dialed in. stock carb, jet kit (180 jet)
anywas.. 3 weeks ago took it out, and on the top end it would sputter kinda sounded like hittin grev limit but it was alot sooner than rev limit should be.  

plug was white.
adjust the a/f fattened it up still white etc. etc.

took it out 2 weeks ago...

noise in the motor is a little louder.  and now missing worse.. changed plugs twice, still a little lean fattened it up.  still a miss.  now not jsut at WOT but at any throttle position if held steady.  like the bike in neutral at about 1/2 throttle.. it missed pretty bad.

the noise im thinking was a timing chain.  i bought a a hd true double roller to put in it.  from a guy in lancaster that everyone raves about.  sells factory honda double roller chians.  the bike is tore most of the way down as of now.

upon inspection.  the left side whatever you cal lit dowel or slide that sits besides the cam to hold it.. and also kind of rubs agains the end of the cam (not the sprocket side) seems a little worn, and the end of the cam has a slight grove in it. enough where i cannot pull the bearing off that end.


so ill have to take care of that.  the bearing still spins free and is in great shape though.

anyways.  im tryin gto figure out why it has a miss.

i dont know if its the timing chain, or if it skipped a tooth on the timing or what.

the tensioner was all the way out, and the chain has some play in it, so i know it was wore and needed changed.  the sprockets look good and show no abnormal wear.

the valleys where the cam rides on show some wear, but feel smooth to the touch.

sorry im going on and on.  but this is my first quad.  

first time tearing one apart as well.  i have alot of mechanical experience, and i have a clymer manual helping me out as well.


so anyone have any suggestions or tips??

i have an 05 400ex sitting right next to this one incase i need to try some parts as in coil or carb or something.  let me know what you think.

thanks in advance

also forgot to mention it has irradic idle.

if the idle is set to were it will stay idleing its high.  adjsut it lower even jsut a tad and it wont idle at all.. just dies

It sounds like a air leak somewhere or maybe a blown base or head gasket. Are you using a hd stud kit?  Was the noise a popping sound that got louder, kind've like kicking the motor over with the plug out? It really sounds like a blown head gasket.  You should try hd studs, and a cometic big bore gasket.  The timing chain could be some of that, but usually when they skip you break stuff(piston hits valves).  Also, the stock carb is probably a little small, even with the high compression.  If using kehin jets, you should probably be around a 200 or better main(I used a 172 or 175 on a 400ex, stock guts, full hmf, k&n with aluminum airbox at 1000' above sea level).  You may want to upgrade to a bigger oil cooler since you already have a oversized oil tank when you get it back together.  You also may want to go with a 11:1 piston unless you race alot as cam 2 gets expensive and aircooled bikes don't handle heat so well.  How does the piston, rings, and cylinder wall look?

i have yet to tear the head off.  but the head gasket was replaced before i got the bike.  my cousin owned the bike bofore me.

the bike does nor smoke one bit.. any other tell tail signs of a blown gasket??

i have no idea if its got HD stud kit or not. how can i tell??

the noise was a slight ticking noise all the time.  was told it was from the oversized valves.  which i checked righ tafter buying it.  all valve clearnces were fine.

the last time i took it out.. the noise was when i was at wot and it was liek a smacking noise for a sec or 2 then went away.  but did it again if i pinned it.

buying cam 2 doenst realyl bother me.  its on the way to our riding spot and its like $5 a gallon.  not a big deal since it only takes 2 gal or so to fill.

im almost positive they are nto kiehn jets.  but dynojet jets.
any idea on the correct jetting for a stock carb with dynojet kit for this application??

The noises you describe sound like the timing chain, but the symptoms sound like a blown head gasket or base gasket, or a air leak somewhere.  Check where the carb intake bolts into the jug-put some soapy water in a spray bottle and spray while it's running to see if it bubbles or spray some carb cleaner around there and see if it revs up or bogs down by itself.  Is your airfilter tight, are the carb boots tight, and is the exhaust tight(sometimes the nuts back themselves off).  Where do you ride at, and are you a member of ohiomafiariders.com?  I ride at elson's st., crow's canyon, and wellsville.  Oh, ditch the dynojets and keep the dynojet needle, it's a lot easier to use regular kehin jets, and the adapter for the dynojets sometimes doesn't seal right.  Also, is the plug white at wot, 1/2 throttle, at idle, or at all 3?  Are you running a 42 or 45 pilot?

i am not a member of that site.  i ride with some friends at a place in huntsville, also wayne national.  havent gotten out a whole lot since i jsut got the bike about a month ago.

i will check to see if there is any leaks in the exhaust, carb boots, airfilter.  once its back together and running.  i am also going to probably get a new battery, or check to see if the one i have is good, if it is ill get it charged fully.

hopefully, the timing chain, clean the carb , new gaskets on the carb.  and check for air leaks will do it.  if not i might swap coils and shti off the other bike to see if any of that shit is the problem.

so heres what i have found out.. called the original owner of the bike..
JE piston 13.5:1 compression
oversized valves with HD Springs and retainers
HD (oversized) stud kit
Keihn jets in the carb

Head Gasket was changed not but 3 months ago.. which it was only ridden a few times before i bought it.

also foun dout a similar problem with cutting out happened to him.  was dirt in the carb.
tore the carb completely down and cleaned it tonight.  its back together now.  now i have to go pick up my timing chain tomorrow, and my gaskets i ordered and get it back together.  then see what happens.

well new timing chain is installed.  got the true double roller, very nice chain alot more heavy duty.. you can tell jsut by lookin gat it.  and the guy was super nice i got it from.  knows a ton about 400s.  gave me some good tips and some good places to get parts from. but anyway...
but i still havent got my right side case cover gasket in yet so im held off from putting it fully together.  also i broke the clutch hub taking the nut off.  so i have to order one.  anyone got a used one lying around they want to sell and ship next day??

i can get one new shipped to my door for $50 but if i can get it cheaper ill go the cheap route

Did You ever find out the problem?

Holy cow, have you checked any other jets besides the main?  Your probably super lean everywhere else and waaaay too fat on the main.  A 200 main someone suggested!! NO WAY!  You shouldn't need anything close to that.  You were too rich to begin with the 180.  

Please list all of the motor mods/exhaust mods/ intake mods.  Also what timing chain did you go with?  CRF hopefully?  A stock cam chain will stretch again in no time, and its about $90 where the 02 CRF cam chain is identical to a DID heavy duty and is only $25

Also forgot to mention... please keep in mind that dynojets numbers are in fact different than kehein's numbers.  A 175 dyno is larger than a 175 kehein.

What was the final jetting?

I have the same problem.

THANX.

the ticking is your valves, and if its loud ticking when you rev it up, then you might need to get them readjusted, but even when they are right, they will tick, because that is just that awsome power makin it tick. i have a 440 kit in mine and everything done right and it will always tick. but your other problem is a blown head gasket, i have blown mine befor and what your saying sounds like its blown.

also i would upgrade your carb to the Edelbrock Doug Eichner signature series. its for a big bore and i got it and love it.

Have you checked the compression?

Hi just join the site to help you out.  I would never go with a 200 main that is cazy.  The biggest I hear was 190 maybe.  i have a 2003 460ex I got it storked, ported and the nine yards about 8000.00 in parts.  I know the sound your taking about, I do know that sould all to while.  I was just like you thanking what the hell is that nocies I have a new motor.  
'
Ok the loud noice your heard was the timng chain hitting the spocket, and you did the right thing.  But when you get it back toghter you will still heard that ticking noice.  See these air cooled motors are a little louder then the water cooled motors.  Hot cams tells me it is the valves hitting the seats, not heard at all and not a problem the cam is just opening the valve a lot more then the stock one.  Trust me this not a bad thing and is every normal.
Just remeber and lession to the motor and just used to the noice and do the same thing you did this time.  If at anytime the noice get louder or you feel it is not the normal tick ( it will tick ) it just matters how hard and loud it is ticking.  
(Your doing the right thing you rather be safe then sorry)

it there is any other question feel free to e-mail me at
Perplex555@cox.net
Just pull 400EX MODS in all caps under the subject.

One more thing go with a NEW card Edlen Brock 440 serice.  TOP OF THE LINE JETTING THE MIAN TAKES NO MORE THEN 5SEC. PERIOND!!

You can get one on E-Bay for 399.99
If you feel I leading you on about the carb YOU MUST READ UP ON IT!  Iam telling you starting and the whole CARB is setup for this 440es Quad.  ITIS A HAVE TO!!!

I would get a keihin FCR, can be had for cheaper than the edelbrock, and ive read good and bad things about the edelbrock, only bad thing about the FCR is the bog, but it can be tuned out.

I've had similar problems on bikes mainly 2-strokes. the taper of the needle is the most important part to how a bike runs most of the time.  I've found it near impossible to find any information relating the numbers on the needle to a chart indicating richer or leaner, but you need a richer (thinner/steeper taper needle) if everything else is good, then you can bring the main jet down.

i just got a 99' 440ex it has a k&n air filter and super trapp slip on exhaust. it's bored 40 over. Thats the only mods that i know of.. it has an keighin fcr 39mm carb on it with a 172 main jet. my problem is when i get to half throttle and past it starts cutting out.. i checked all the jets and they are all clean. any ideas????

Just curious what valve clearances are you running with?