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toms99tj 08-06-2018 01:17 AM

03 400ex Not Starting
Ok so i picked up an 03 400ex and the guy said the one way starter clutch needed to be replaced. So i did that and got it going. I took it around the house parked it and then 10 minutes later went back out and started it let it idle and then it made a clunk noise and shut off. So I figured the one way went again. So i just put a new one in and it doing the same thing as when i picked it up. You go to start it and it just spins. The motor doesnt even try to crank over. I am at a lose and cant find any answers. Anyone have any ideas?

Here 2 help 08-06-2018 02:17 AM

When you say you replaced the starter clutch, what parts did you replace? Just the one way clutch, the clutch and hub or the clutch, hub and starter gear? It's also possible the flywheel key sheared and the flywheel is just spinning on the crankshaft,

toms99tj 08-06-2018 02:26 AM

I replaced the bearing and hub it goes in, both little gears and i replaced the flywheel key.

Here 2 help 08-06-2018 03:05 AM

You should have replaced the big gear with the hub that runs inside the clutch (part # 28110-HN1-A70) and the clutch hub (part # 28125-HN1-003 which includes the one way clutch part # 28126-HA7-673), but that would not explain the "clunk" when it stopped running. The clunk could have been the engine turning backwards when it died which would lock the starter clutch and try to turn the starter motor backwards or the starter clutch may have locked when you started the engine which would keep the starter motor spinning and possibly damage the starter motor/ Just have to do the diagnostics and determine the problem.

toms99tj 08-06-2018 11:20 AM

I put a whole nother bearing and hub in than the one i replaced originally. I think the clunk was when i first put it back i didnt put it on right and the big gear and flywheel were barely together, but now it is. I do now that when i put a ratchet on the flywheel there is compression. So the only thing i did not replace is the big gear. The guy did give me another starter with it. Would it be worth trying to replace that?

The other thing i know about this four wheeler was that is was bored out and piston was shaved. Thats what the guy told me. When i did get it running the valves tapped bad so i new i needed to and adjustment. Thats all i know about this thing.

Here 2 help 08-06-2018 01:42 PM

Well, I think the guy you bought it off of was an idiot. I am an experienced mechanic - I am self employed and have run my own shop for over 40 years. If the machine were mine, I would tear it down, check the piston to cylinder clearance and check the lower end of the rod. There is absolutely no need to "shave" a standard piston and high compression pistons are shaved to lower the compression for a variety of reasons. I would be quizzing the previous owner as to why the piston was shaved. Typically it costs about $200 per piston for shaving, so I don't believe it was done unless the PO was serious about racing.

If the big gear was not replaced, the hub that locks up in the starter clutch may be worn down to the point it is slipping. Sometimes if put the engine in gear and roll it backwards a little, it will lock the starter clutch and spin the starter backwards, then sometimes it will crank the engine normally once or twice more. Might try that and see what happens.

toms99tj 08-06-2018 02:14 PM

I think the guy before the guy I got it from did the work to it and he was a mechanic. I ordered a gear a little bit ago. I didnt wanna spend to much on this thing. I got it for $600. When I get home I will try to put it in gear and rock it and then try starting it. I was thing\king the same thing you said about the hub on the gear being worn down last night cause there was a small groove in it.

toms99tj 08-06-2018 09:22 PM

So i put it in gear and rocked the thing and tried to start it and it was the same. I then marked the bolt with white out and hit the start button and the mark was in the same spot. Im going with the big gear 8s worn down and slipping like you suggested. Also would the neutral switch habe anything to do with this?

Here 2 help 08-07-2018 03:15 PM

If it's not in neutral you have to pull the LH lever to get it to start in gear - test the switch by finding it (usually on the LH side above the shift shaft below and in front of the counter shaft sprocket) and with the key switch on, use a test wire to connect the wire going to it to ground. If there is two switches, one is for reverse and the other neutral. If you ground one and the reverse light comes on check the other the same way. If one light comes on but the other does not, check the bulb then start checking the wiring. The hot wire goes to the light and the switch grounds it to turn it on. If neither light lights, check the battery, fuse and key switch. The red wire at the switch goes to the battery through the fuse and when the switch is on it connects the red wire to the black wire.

toms99tj 08-07-2018 03:18 PM

The neutral switch wire just keeps going in and out thats all. i have to go order a new wire. im pretty sure my problem is the big gear behind the flywheel. i will find out tomorrow when it comes in.

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