Can't even pull the recoil rope out at all. Starter works but turns sort of slow any thoughts on what would cause this? Oh I just rebuilt engine too.

 

Welcome to the forum! Starter bendix is probably binding up. Just pop the recoil cover and check it out. Could just need a little cleaning,greasing up or replacement. Check the recoil too for any damaged parts. OPT

 

Well found problem. The cam gear spun 180 and needless to say broke cam and decompressor off in the process. Now for the real question when I rebuilt engine I put a head off of a 2001 magnum and the rocker cover for the 2000 Trail Boss are the cam and journal specs different on these years. Seems that when rocker cover is torqued down it binds the cam up fairly tight. I miced the broken cam and the journal the best I could and they both seemed in spec so at a loss for why it would bind like it did. Only thing I can think of is I used assy lube instead of the grease like manual calls for on the cam.

 

Cams show to have different part numbers on the Magnum and your Trail Boss! Should be same dimensions,but when you mix match parts you can get into a mess! Take your old cam and the Magnum cam to a shop and have them checked out against each other on dimentions!. Assembly lube is what I used,not grease! OPT

 

Update :
I have broken down and got a new head, rocker cover and cam for a 2000 trail boss coming. Will see if this corrects the problem. Will repost after I get it together.

For now I would say there is a difference in 2001 head to a 2000 rocker cover. What exactly it is I am not 100% sure but they don't seem to mix.

 

On a lot of machined parts(heads,cases,etc) it's best to stay with your year model! Part number differences between year models are there for a reason!Plus the rocker cover on a 2000 model Trail Boss and 2001 are completely different along with different head numbers on each year! Imagine the same thing on the Magnum 325! Same on engine and transmission cases.That's why engines cases are critical as far as alignment and sold as a complete set,but you can buy separate transmission left and right case halves on a lot of models,BUT seems like every time I did this(usually the chain side case half that was broken a lot) I had to ream out the shift fork shaft holes a little to make the case half work with the other side and not bind up! Keep us updated. OPT

 

Well the new head and cam solved all the problems. I guess there is a slight difference between 2000 and 2001 rocker covers. Machine is running like a champ and back on the trails.....
Thanks for the help

 

Having the right parts make a difference. Glad you got it running! OPT