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?

44 minutes ago, Fishfiles said:

I am hoping it is oil in the muffler 

 

Did you stagger the gaps of the rings on the piston ? 

 

Did you stick the rings into the bore and measure the end gap 

 

Did you check for looseness in the valve guides  ?

 

Are you sure the connecting rod is not bent , did the piston come up flush with the deck ? 

 

 

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. 

Just now, Fishfiles said:

I have had it take 3 hours to burn all the oil out the muffler ----

 

it could be the rings need to set  especially since it is a cheap chinese kit ----- let it run for while --------

 

did you lubricate the new valve stem seals ??? ----

 

Is smoke and/ or excessive pressure  coming out the crankcase vent / blow-by hose ?  

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.

Just now, AKATV said:

Did you by chance check your piston ring end gap on all the rings in the jug before you installed them in the piston?

No offense - but being a China cheapie they might’ve had the wrong ring set in there or even piston for that matter

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.

2 minutes ago, jeepwm69 said:

 

If you're not in a rush to get it, we'll work something out.  I need to check with the wife and see if we're driving or flying in April (newphew's bday is April 1st).  If we fly then we should be coming through there again in late May on the way to South Carolina.

 

I'll shoot you a PM.

Sounds good.

17 hours ago, jeepwm69 said:

 

Oh man, I feel you there on being in the wife's view while trying to fix something. 

 

I'm about an hour SW of Memphis, so not really feasible to get it to you.  I have in-laws in Alpharetta but won't be over that way again until April.

 

I'll dig it out and see how the crank looks.  If it doesn't look bad I can pull it and ship it to you, but I wouldn't hold my breath on it being 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.

20 minutes ago, jeepwm69 said:

 

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.

Quote

Yeah, I emailed Vince checking on him and he said he came through the storms ok.   Lucky for him and for us.

 

Here's a 500 thread i did a while back.  Your engine shouldn't be too much different. 

 

 

Mainly what you're doing is taking it apart, CLEANING everything very thorougly, and putting it back together. 

 

If you see/ feel a bearing that's iffy, by all means replace it, but I have only replaced one main crank bearing out of probably 12-15 rebuilds I've done.  Most of the time cleaning them out and oiling them leaves me with perfectly serviceable bearings.

 

I replace the crank, timing chain, shifter seal, output shaft seals, reverse seal, and crank (under pullstart cage) seal.  Hondabond for the case halves and gaskets for the front and rear cover (if the covers come off without tearing the gaskets I reuse the gaskets).

 

You can put the top end on it and let the recipient run it.  What will likely happen is a rattle that will get progressively louder, and eventually your cylinder will oval and it will start smoking again.  I've been riding my 09 with a rattling wrist pin (smokes pretty good under load, but doesn't under light use) for a couple of years now.  I recently rebuilt an extra engine to swap in but held off as I loaned that Foreman to my daughter's boyfriend to use during duck season.   If he blows/ seizes the engine up, not a huge deal since I have a rebuilt unit ready to swap in.  Wouldn't have loaned it out if I'd already put the new engine in, so it worked out well for him LOL.

 

So running it as is will require a top end rebuild, sooner or later.  Depending on how bad it is, it might destroy the piston leaving it not-running.  More than likely it will just be loud and start smoking sooner rather than later.

 

So you'll have to decide whether you want to throw a top end on it knowing you'll be redoing it fairly soon, or fix it right the first time, but maybe be a hair late for Christmas. 

 

Where are you located again?  I have a 400 bottom end in the shop that I got with a pile of parts.  Crank might be good in it, but likely not or it wouldn't have been torn down and in a pile of parts LOL.

 

Point being, when you have an extra engine you can keep running/driving a wheeler while you take your time going through the bottom end.  Get it built right at your own pace, while still being able to use the ATV.  Then you can swap the engines out in a half a day, which minimizes down time on the wheeler.

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.