HeWasRidinDirty

I had to adjust the valves on this 500 (and few other things) and I'm trying to get the cam timing right, and something is really out-of-whack here. It seems anyway. When I line up the dots like the service manual describes, the lobes on the 2 cams are in almost in the same position. According to the manual (and a youtube vid or 2) the lobes should be at aproximatley 10 oclock on the int and 2 oclock on the exhaust. These are nowhere near that. There must be a woodruff type key on the sprockets. I wonder if those are sheared off? Thanks for any input!

Might be something in the key switch, no? The ignition would still have to be "on"when jumping the solenoid.

Anyone know where I can get a free download? I had one a month or so ago on my 'puter but one day it flipped out and I lost it. I gotta put the top end of this 450 together (hopefully today) and I need some info. I've searched and searched this morning, but, I can't find one. Thanks!

Great pics Dra O. Sorry you got hosed. I got one of those too a couple of months ago. Mine, however is from the original owner that bought it new in 85. But, it's stuck in R. It's on my project list to take the engine out and fix the trans. I paid $100 for it. with that said, anyone point me to a service manual for a 2005 trx 450r? I had a pdf on my computer when I fixed the kicker on this thing, but, my computer flipped out one day and I lost it. Now the 450 is back and I'm ready to put the top end back together. I've searched and searched trying to find a free download, but, I got nothing. I can usually find em for just about quad/bike pretty easily.

It just stopped. I got it back together and fired it up. I had a dirt bike that did that outta the blue. I fixed it then it did it again in short order. My buddy suggested to put valve grinding compound on the crankshaft and put the flywheel on and spin it, spin it........ so I did that and it's been good ever since. So, I did the same thing on the 400. We'll see how it goes!

Well the 400 crapped out on Saturday. I took a look at it yesterday and this is what I found. Sheared the key right the f*** off!

Ya, the thing fires up with just a touch of the button! I'm nursing a bum leg that I messed up a couple weeks ago. About 5 of my buddies went riding today, but, I gotta pass until the leg is %100. The weather is freaking perfect too! 😧

I got a battery just like the one that was in it. It's charging now. I drained the engine and the plug is clean. And the oil. Very clean

Hey, I think I'm going to pick up a new battery today for the 400. Now, since this thing with the aftermarket cams doesn't have the auto-decompression, should I look for a battery that has a little bit more cranking power? It looks like the stock battery is 8ah. Is that the number that I need to look at? Thanks, dood. 👊

Ya, that would be an interesting thread. This engine sounds really good. Snappy as hell.

That's all been covered. You gotta read the entire thread, noob. LOL. I'm just messin with ya. I think I got it all sorted out thanks to Frank and some others. 👊

You guessed it. I adjusted the float and it's all good. I rode it around a bit yesterday. Runs pretty damn good! I'm gonna drain the oil from the engine into a nice clean container and see if there is any more debris in it. And, it needs a new a battery. damnit! Freakin $90. 😧

Sonuvabitch it fired up! It ran for a few seconds and I shut it off. Started it up and it ran for 30-45 seconds (no water in the radiator) and shut it off. Sounds like it runs like it's supposed to. I got fuel coming out of the carb, so I gotta check that out and the battery craps out very quickly. Progress tho!

Frank, I had a bit of an erratic spark before I took the stator and flywheel off. Do you suppose that all the metal pcs that were flying around in there had anything to do with that? And, I might just put it back on and check the spark. Will not having any oil in it have any effect on the performance of the stator? And I don't think that cranking it over for a few seconds with no oil will hurt anything. IDK. I will put assembly lube on the camshafts and rockers tho.

I found the specs for a 2009 ltz 400. This one is a 2003. IDK if they're the same. I have a tester.

I got the cams back yesterday. But, before I put all this back together I want to check the ignition components" IE stator, coil, pick up coil. Any info on specs for that?

Yes. Toy hauler. I can fit 2 4x4 quads and 2 bikes in it. Barely! And dum-dum. LOL

Whatchoo ride? still a few patches of snow!

No,no,no, I'm riding tomorrow! I prefer 2 wheels, but, I do it on all 4 sometimes!

I had to order a new woodruff key yesterday........so, I'm stuck until tomorrow. Tomorrow is riding day!!!! So, it'll have to wait until saturday.

Welp, it's going back together. I did my best to flush out any remaining debris. I spoke to HotCams yesterday and the cams are on their way. Inspector Woof says my work is a bit ruff, but, he signed it off! Lol

So, the update.... The camshafts are old Stage 2 HotCams. I sent them off to H.C and they are going to put some marks on them so I can time them properly. In the old days. H.C's put paint marks on the camshafts for timing purposes. They wear off over time. They're doing this at no charge. Just shipping. I think it's $15 total. ANyway, the pcs of metal debris that came out of the engine is the starter sprague or starter clutch. Ya.Came out in many many pcs. Not good. However, I have removed the head and the valves look good and piston and cylinder look great. This thing right here is what is broken. https://www.ebay.com/itm/New-LTZ-400-Quadsport-Starter-Clutch-for-Suzuki-LT-Z400-03-14-LTZ-400Z/231436719164?hash=item35e2b4143c:g:gvoAAOSwwTlUnK5g This is what's left!

Most 4 strokes have a compression releif mechanism on the exhaust cam right? This doesn't have anything on the ex cam. Nothing. It looks exactly the same as the IN cam. ANd if there was a spring on the ex cam, how would it get to the stator? IDK. I'm about to light this thing on fire! LOL

Yes, exactly. That round pc was stuck on the drain plug. What kind of seals are in this engine? It doesn't have crank seals like a 2 stroke does it? Water pump seals come to mind, but, there's no water in the oil or oil inthe water. It hasn't leaked any oil either.

Heres the pcs that I found around the stator. There's parts of a spring that would be found on an oil/water seal. The drain plug.