ChadD

@SlammedRanger look forward to hearing your thoughts. 

Complete rebuild on a 2001 400ex . I don't believe there is a nut or bolt I have not touched on this thing. Anyway the problem I'm having is that no matter what I try it pumps all the oil out of the engine and into the oil tank. I've tried 1 quart in the engine and 1 in the tank, 2 quarts on the engine and none in the tank. I have even changed the oil pump with a brand new honda one. It wont even generate enough oil pressure the disengage the decompression release on the cam. Any and all help or suggestions are greatly appreciated.

Just recently bought a very used 01 400ex and i have blown it completely apart to paint the frame and just all around check every seal and bearing and try to fix some of the stuff that has been rigged. From what I understand the A-arm ball joints are not a serviceable item. I have seen the mod to cut the ends off then drill and tap and put a car tie rod end to act as a ball joint. I was just wanting to get you guys opinions before i start cutting something up that i may not need to. Thanks, Chad. 

5 hours ago, shadetree said:

forgot to say, just because you got it fixed ^^^, DOES NOT MEAN YOU CAN'T HANG HERE...AND LEARN FROM US !!. who knows..you might have to fix something else soon ?, what better way to know BEFORE..than to stick around here, and learn !! :-).

I'm not leaving. Still got tons to do. 

Ok guys didn't mean to leave you guys hanging on the edge of your chairs in suspense. In the process of taking the motor back apart some how the ball retainer triangle with the spring grew legs and walked off and hid. I mean I completely tore my bench apart and cleaned and reorganized the whole thing. Gone. Disappeared. 4 day wait for the part. Got everything back together. I thought might as well do the wheel bearings before I ruin a hub. So a trip to the local Honda dealer and $130 worth of ball joints and tie rod ends and a few hours of assembly and I just took my first ride around the yard. Everything did exactly what it was supposed to do. Just want to say thank you for all the input and help. I will never forget the "M5" gear in that transmission. Lol

Lol. Spoken like a true hotrodder. I know copper spray well. We have done stuff at the track and be like it will never ever last but we gotta try. And go many rounds just waiting for it to break. Lol

Dumb question I'm pretty sure I already know the answer but I'm gonna ask. This engine has maybe 5 minutes of idle time, new gaskets for the top end or can I reuse them?

Just now, shadetree said:

trust me, i've done a lot of stupid crap in my life time building atv engines/restore projects, it all comes with the job !..lol.

Amen brother, Amen.

1 minute ago, shadetree said:

lol, your not the first to install a gear backwards, and deff wont be the last !..lol. been there, done that= guilty !.

Still makes you feel stupid. Lol

1 minute ago, shadetree said:

after case is down, that washer then slides down again on the shaft , before you install the shifting parts. thought I mentioned this in my write up ?..lol.

You probably did, my brain has moving at 100mph trying to figure out the tranny issue. I will go back and re-read it. Thanks again.

The washer in question is identical to the one on the shift shaft.

Well just pulled the washer out and just set the case back on and bolted the star to the end of the shift drum, everything seems to be shifting like it should and I still have neutral. Dang M5 gear but let's hope it all works when I'm done putting it back together.

I suppose the star is supposed to take up that slack when it's bolted on so it wouldn't need that washer. But as it sits with the washer it actually seems to be in neutral.

Just now, toodeep said:

No washer on the shift drum. Do you have one on the shift shaft sitting on the snap ring?

Yes sir. This one was found laying on the bench under a rag when I was cleaning up so I could tear down the motor again.

Well I still don't know if it's actually right but I can hold one and spin the other now. 🍻 and I'll wait for what you guys say.

15 minutes ago, shadetree said:

if the tranny is in neutral ? , then both shafts should spin freely. in other words, if shift drum, all parts are installed correctly ?, you should be able to spin both the main shaft, and counter shaft 360 degree's both ways. if one of them lock at a certain point ?., something is wrong.

You remember that washer? It doesn't show one in my manual on the shift drum. I'm about to try it and see. What's the worst that happens I have to pull the shafts out for the 34th time today. Lol. It fits perfectly on the shift drum.

The do spin freely but not independently of each other. Maybe I worded that wrong. If it's in neutral should one spin but not the other.

Well I did find that the m5 gear on the mainshaft was on backwards. But when I put the shafts back in everything was still spinning. Correct me if I'm wrong but shouldn't the countershaft not spin if the shift drum is in the neutral position?

Shadetree, if you wrote that from memory then I'd like to know how many times you have done this little job. Impressive.

9 hours ago, shadetree said:

in this pic, looking straight down once its all in case, could you see all letters facing up on shift forks ?. if not ?, then one of the shift forks was upside down.

Yes and I even read through the manual and made sure that each fork went into the appropriate gear. I'm sure it something little I am over looking and it really ! me off.

It shifts, but the gears are still not correct. I'm gonna tear it all back apart in the morning. Neutral is still not neutral. 1st isn't 1st so on and so forth.

Well got the cases back together and everything required to turn the motor and shift it. Doing the same thing. Grabbed a cold one and shut up the garage and came in the house. Also found this hiding on the bench. Anybody have a clue where it might go? 

1 hour ago, bcsman said:

Bearings good in both halves especially in the trans areas??

They all turned smooth.

25 minutes ago, bcsman said:

Are you turning the shift drum completely both ways, don't just twist to make sure it moves?  It should move thru the gears both ways without binding, it does a little when the forks have to move sharply up in the drum grooves, but still not bind.....

Yes sir. It basically turns about 320 degrees.

I'm really concerned because it really looks like I put it together correctly the first time. But I guess we will see.