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Spent the weekend at Anthracite Outdoor Adventure area and camped at the Trailhead Campground. This campground is next to the trails so you can just ride over to the trails.
AOAA has about 311 miles of trails on 6,500 acres of land. All kind of terrain depending on what you like.
I've never done this before but after reading a few thread I decided to check my valves for the first time and to my surprise it was much easier than I thought.
My bike is a 2005 Sp 500 HO.
I first pulled the seat and the right side panel off, and that's it! It wasn't too bad to get at.
Next I pulled the spark plug out and removed both the head cover ( 8-8mm bolts)
then the side cam cover (5-8mm bolts).
Also remove the plug in the recoil cover (14mm bolt) to see the timming marks.
Next I turned the engine over with the pull cord untill it was at TDC of the compression stroke.
The best was to tell that your at TDC of the compression stroke is to rotate the engine until the
timing marks are parallel to rocker cover gasket surface.
The cam sprocket locating pin will be facing upward directly in line with the crankshaft to camshaft center line.
Now fine adjust by looking into the timing hole in the recoil cover and line up the upside down "T" on
the flywheel into the center of the hole.
Now using a feeler gauge, slide the .006" (.15mm)blade between the top of the valve and the bottom of the adjuster and adjust accordingly
To adjust, Loosen the locknut (10mm) and check clearance with a feeler guage. Clearance should be .006" (.15mm) for both, intake and exhaust valves. Turn the adjuster with a stubby flat blade screwdriver untill the proper clearance is achieved then tighten the locknut (5.8-7.2 ft. lbs) while holding the adjuster in place with the screwdriver. Re-check the clearance with the feeler guage one last time and re-assemble the covers (72 in.lbs) and plugs.
The only thing that i noticed was that I had to clean and silicone the side cam cover other than that I found the whole process rather simple.
I'd give it a 4 out of 10 on the skill level scale.
I hope this helps!
I have an Outlander 800 XT with 480 hours on it. Very recently the engine power dropped significantly while riding. Soon thereafter the engine created much noise and stopped.
On opening the rear cylinder I found one inlet valve stem bent and the other broken. The valve head caused considerable damage inside the cylinder.
My reading is that the timing chain to the rear cylinder jumped at least one sprocket tooth to reduce the engine power, thereby compromising engine power, and then shortly thereafter jumped one or more teeth to allow the rear piston to contact the intake valves. On disassembly I did not notice that the timing chain was particularly slack, but neither was I looking for such things. The ATV has been serviced by agents according to requirements, in fact it was serviced very recently, by accredited agents.
Coincidently I met another 800 XT owner a couple of days ago who had had a similar incident a few years ago, which makes it likely that there are others out there who have had similar experiences. If there are I'd very much like to hear from you.
I have an old 400ex that needs the top end rebuilt, Does anyone have any real life experience with the cheaper ebay or amazon top end kits. I know most will probably say to stay away from them. I dont have a lot of money into this bike and it isnt worth putting a whole lot into is why i ask. It doesnt get raced or road hard, my son and i just drive around the fields. thanks for any help
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My mother has a 05 John Deere 650 trail buck ext and someone told me that can am made the atv for JD. I was wondering what model can am it would be so I can find a service manual for it.
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