jstatham

Me too. Thanks for all your help and Merry Christmas amd Haply Holidays!!

No I had a typo 25x8x12 in front and 25x10-12 in rear.

I am running 25x8-12 in the front and 25x8 10x12 in the rear. I did add a 2 inch lift

I had about an hour after everyone left and we took it for a spin. We looked like the mosquito truck for like 2 laps and it finally stopped smoking. I think I am good to go!! Thanks for all the help. If you look at the second video at the end it looks like I need to adjust the tow on the left front. Is there a way to do that?

I did stagger the gaps. I did not measure the end gap. Rookie Mistake. Yes the guides seemed fine. I followed the 4 wheeler Doctor youtube video on a rebuilt step by step. Rod were fine and Piston came up flush. I hope to have time today to mess with it but the wife may have other plans.

I don't think so but I will check tomorrow. I did lubricate the valve seals. We have a bunch of family activities planned tomorrow and Christmas but I will post back as soon as I can. I don't think I am even going to bother taking off the muffler I am just going to go drive it.

You got me excited so I went out in the freezing garage and pulled the plug. It looks good to me. What do you think.

At this point I saw its not but I havent checked. It runs and feels strong. I hope its just oil in the muffler. You may have just saved Christmas. Fingers Crossed.

No I didn’t. They were the exact same as the one I took off that had the hairline crack.

When I get a chance I’ll take the muffler loose at the head and see what happens. Thanks

That makes sense but if I am burning oil as well then that not the issue right? I put all new valve seals in it. Where do you take the muffer loose at the head? I know 14 years ago when it was parked it was doing the same thing and it only does it when its hot.

Hello everyone. I rolled the dice and used the second replacement Ebay Chinese Jug. I got a new piston,rings,wristpin,etc and this time the bike looks like a mosquito sprayer. Anyone have any clue on to what could be wrong. When I cranked it up the very 1st time it smoked a little. I let it idle about 15 minutes then changed the oil and filter and it seemed to be ok. I then put everything back together cleaned it up and had it all ready for my daughters Christmas. I took it for a spin and it started smoking and burning oil like crazy. I am so upset that she is going to be disappointed. I have been talking to Jeep and thinks I should take the OE jug and the Chinese Jug to a machine shop and see what they say. One more thing this is a 1996 400 that I put a Top end off a 2002 450 would this cause any issues? All my research online says it should be ok. Any help will be greatly appreciated I am beyond frustrated. I have worked my can off on this thing to get it ready.

Sounds good.

Would you be interested in selling me that bottom end 400 motor you have and I possible meet you in April when your in Alpharetta and pick it up. Hopefully this motor will make it that long and I can rebuild it and have it ready.

Thanks Jeep I am in Powder Springs, Ga. How much would you sell that 400 bottom that you have? Where are you located? Also another factor is I don't have a workshop and have the ATV torn into 1 million pieces in my garage in my wives parking spot and that's not going to well since its winter and freezing.

I am pretty sure Vince came through ok because I have been emailing him about the crank. I found him on another thread researching my issue. I am torn on what to do. I am suppose to have this thing ready by Christmas and if I break it down and do the crank there is no possible way. I am also not sure I have the skills to completely rebuild it. I have done Boat motors, small engines and do my own auto maintenance but never done an ATV before. If I do roll the dice and just put a top end on it how long would I have before it needs rebuilt completely. If I can kick the can down the road 6 month to a year I would have a better budget and more time. What all parts do you replace when you do a bottom end rebuild. I am assuming crank, all bearings, gaskets and timing chain? Decisions,Decisions

OK I just broke it down and I believe the bottom of the rod is fine but I would like your opinion on the top. https://youtu.be/J9-Dp9mM1is

Thanks again. Here is what I am seeing in the manual. I'll post a video when I get it broke down. I am sweating bullets hoping its not bad.

Thank you I’ll check that while I am in there. What about side to side play? I sent the seller a message and they are forwarding to their engineers. I hope they don’t give me a hard time but there is nothing I could do to make hairline cracks in the jug. What kills me is where is located is a long was from the piston and I don’t see how how could get to where it’s pushing out strange. If you watch that video at the very end you can see it bubbling out.

Hopefully I will get it right this time. While I am in there do you know the specs on the Rod Bearing play and how to check it. I want to make sure I'm not wasting my time.

The kit will come with everything so I am going to put in the new rings and jug. They told me they have sold over 100 of these kits and mine is the 1st one with this problem. Lucky me.

They are sending out another tomorrow. Fingers crossed it will be good. Should I just replace the jug or do the piston and rings as well.. The piston and rings on it have only ran at 10 minuets at and idle.

They say the cylinder was brand new. They need to hurry I have to have this thing ready by Christmas.

I sent the seller a message and they are forwarding to their engineers. I hope they don’t give me a hard time but there is nothing I could do to make hairline cracks in the jug. What kills me is where is located is a long was from the piston and I don’t see how how could get to where it’s pushing out strange. If you watch that video at the very end you can see it bubbling out.

I can literally see it bubbling out from the casting . Looks like there is a hairline crack going down. You can see it in the video. It’s dry everywhere but there. It’s hard to film.