Tinkered with it a little this morning, because I won't be able to bring it to a shop until Monday..... I noticed something I haven't before, when I take the spark plug out it turns over real easy with it's own battery, with spark plug in I have to hook up truck battery to get it to turn over.... is that a sign of anything ?

Also... the carb pilot screw... how far in/out should it be ? I figure there's some starting place... like bottom it out and then loosen it by 2 turns or something.... ?

 

You ever load test the battery? I've even had brand new ones bad straight out of the box.With a new starter and it takes a jumper battery to turn it over,then somethings wrong somewhere. Usually a good starting point is 2-2 1/2 turns out from a lightly seated position on the pilot screw on cv carbs.

 

Timing... how do I make sure the timing is correct and adjust it if needed ?

 

That's why I gave you a link to the service manual on my first post.It can help answer a lot of you questions and show you things to check out.

 

I took it to a local ATV shop, says timing is off, $375 for new chain and labor....hopefully that's all that's wrong and I'll be riding in a week. I'll come back and update this after I am riding it.

 

The mechanic now says it also has a bent valve.....so decision time, should I pay to replace valve too..... any advice or comments on my predicament.....?

 

This is from your first post so all depends on what you have into it,how much the shop wants to charge you compared to what the same machine like you have would have cost in good running shape.This is something that only you can decide.

 

Well I decided to pay for the repair and see how it goes. The mechanic replaced the timing chain, tensioner and then had to replace valve and get head machined... repairs cost $580. So for $1080 ($400 for atv, $580 for repair, $100 for new battery) I have what seems to be good 4x4 400. Hopefully it lasts for a few years with no more major problems and I'll be happy.. Thanks for all the advice and help.

 

Looks like you did pretty good,at least from a KBB perspetive.Kelley Blue Book

 

I have a 2006 can am outlander 400 4x4 that wont start, it has spark and a new fuel pump. It was running and the battery went bad and now it wont start without using starter fluid. It will run until it burns off the starter fluid and that's it. The plug is dry