The reason I removed the air box assembly is due to the snorkle collasping under load and restricting air flow. Knuts said that the direct K&N gives a 3hp increase, thats huge! (on a small motor) Is the acc. pump necessary I know 400EX's have them no there carbs but if it's hard to dial in thats just what I need! All kidding aside if thats what I need I'll get it, but I'd rather get the carb dialed in w/o it. I guess i'll try fatting up the needle.

JSsDS,
When I went to set the jetting, I used the old plugs to get the motor warm and then put new plugs in to get a fresh reading. All my connections are good as far as I can tell.
One other thing, when I took it out, my tach was acting up it read well at low rpm, but after 4g's it went wild so I took it off. My last ride I got water in it. I'm assuming it is water damage, but thats off the subject. (I think)

 

You need to reground your tach to make it work more accurate

 

Lakota,
The malfunction in tach just may be caused by the same thing that is making your engine run crappy. You could have a failing ign. box. try putting your original one back on and see if it still runs bad at full throttle. Also could be the coil.

 

I hope it's not the coil or the box! The coils look hard to get to and the CDI was $$$$. [img]i/expressions/face-icon-small-sad.gif[/img]
I still belive it's jetting related, because it was fine before I did the work. I'm thinking on the positive side.[img]i/expressions/face-icon-small-wink.gif[/img]

 

I assume you checked your gas tank vent line to verify that it is not pinched?

 

Scooby, Checked that, often overthought. I belive that the vent line is on the small side.
Tomorrow I'm going to start working on it again. Do you think it's the CDI or the coil?? I didn't mess with anything that would cause that

 

Double check both connections to the coils. Anytime you remove those connections, before re-connecting, you should close up the "connector jaws" a little bit to ensure a very tight fit.

How much water did you get on the tach? I have sprayed the back of mine with water before and it survived, although I try to avoid doing that.

Swapping known good components is a good idea to eliminate possibilities. FYI, I rotate my CDI box 180 degrees so that the wiring harness hangs down near the valve cover where I can reach it easily. Now I can swap CDI boxes quicker/easier.

 

That's a good idea. The last ride I took, it was raining and the tach got soaked, so bad It took a week and a half before the condensation dissapeared (please try to overlook my bad spelling)
Do you use electric grease on your connections?

 

dielectric grease is a good idea for corrosion protection, but most connections are aluminum.