2001 400ex starting problem
Jan 3, 2011 | 10:53 AM
#1
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Weekend Warrior
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2001 400ex starting problem
I just aquired a 2001 400ex from my brother with a starting problem. We were at Glamis last week and could not get the bike to start with the electric start, but would start up right away if you pulled/push started it, and it ran great.
The battery was fully charged and when it did get low we hooked it to the truck battery with jumper cables. The engine was cranking but never starting. We pulled the plug and it looked fine and it was getting spark but it looked weak to me (whatever that means, spark is spark right?).
I searched this forum and the closest I found was a person who changed their stator and that worked for them, but he wasn't getting any spark at all and after the initial pull start it would electrically start fine. This bike won't, it needs to be pulled/pushed everytime.
Any ideas? Thanks in advance.
The battery was fully charged and when it did get low we hooked it to the truck battery with jumper cables. The engine was cranking but never starting. We pulled the plug and it looked fine and it was getting spark but it looked weak to me (whatever that means, spark is spark right?).
I searched this forum and the closest I found was a person who changed their stator and that worked for them, but he wasn't getting any spark at all and after the initial pull start it would electrically start fine. This bike won't, it needs to be pulled/pushed everytime.
Any ideas? Thanks in advance.
Jan 4, 2011 | 07:41 AM
#4
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Resident Killer!
"A little nonsense now and then, is relished by the wisest men". Willy Wonka: 1971
Cigars! Earth ne'eer did breed such a jovial weed.
A Tiger Doesn't Lose Sleep Over Opinions of Sheep
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From: Landrum, South Carolina, elevation 986'
Can't help with your specific issue but spark is not spark. If you have a weak spark you should at least change the plugs and see if the spark is stronger. If not you should start from there. 
Jan 4, 2011 | 07:44 AM
#5
Shed Knocker Rider
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Couple things comes to mind....
1) Honda typcially jets their carbs very lean for emissions, especially the EX's, and bumping up the pilot jet helps a lot. But usually you only need to do this in cooler climates.
2) Because it bumps starts fine, could be that the valves need adjusted and are out of spec. Is their a "ticking" noise while it is running?
3) And if it's not that, it could just be low compression and time for a new top end. A bike with low compression will bump start a lot easier than it will start off a the electric start.
Hope this helps
1) Honda typcially jets their carbs very lean for emissions, especially the EX's, and bumping up the pilot jet helps a lot. But usually you only need to do this in cooler climates.
2) Because it bumps starts fine, could be that the valves need adjusted and are out of spec. Is their a "ticking" noise while it is running?
3) And if it's not that, it could just be low compression and time for a new top end. A bike with low compression will bump start a lot easier than it will start off a the electric start.
Hope this helps
Jan 4, 2011 | 07:48 AM
#6
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From: Land of the misfit toys
Sounds like a starter issue to me. Do the seals on the end caps look like they may be cracked, dried or just worn out? Could be getting dirt and sand inside and gumming (and sanding) it up.
Super easy to rebuild. Haven't had to take one off an ex before, so don't know how complicated that would be.
Super easy to rebuild. Haven't had to take one off an ex before, so don't know how complicated that would be.
Jan 4, 2011 | 08:01 AM
#7
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I'll agree with Moto.
It's either out of adjustment valves or low compression.
Not starting with the starter but starting by pulling it is usually a very good sign of low compression.
It's either out of adjustment valves or low compression.
Not starting with the starter but starting by pulling it is usually a very good sign of low compression.
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Jan 4, 2011 | 10:03 AM
#8
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Weekend Warrior
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Thanks for the replies.
I believe that the starter is fine because it is turning the engine over with no problem. It doesn't look cracked, dried, worn or dirty.
The carb has been rejetted along time ago and my brother cleans the carb every year. Also, once started the bike idles and runs fine. The plug looks good also but I will change to see if that makes a difference.
I'm not sure about the compression. I'll check that out tonight when I get home. What should I expect for a stock engine with a K&N filter and Yoshi exhaust?
I've never messed with valves before, so I wouldn't know where to begin with those. However, I don't here any ticking when it's running.
Thanks again for the suggestions.
I believe that the starter is fine because it is turning the engine over with no problem. It doesn't look cracked, dried, worn or dirty.
The carb has been rejetted along time ago and my brother cleans the carb every year. Also, once started the bike idles and runs fine. The plug looks good also but I will change to see if that makes a difference.
I'm not sure about the compression. I'll check that out tonight when I get home. What should I expect for a stock engine with a K&N filter and Yoshi exhaust?
I've never messed with valves before, so I wouldn't know where to begin with those. However, I don't here any ticking when it's running.
Thanks again for the suggestions.
Jan 5, 2011 | 08:37 AM
#9
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Weekend Warrior
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Problem resolved!!!
Turns out my bother used to have a kill switch on the bike. Well, when he took it off he bypassed the on/off switch on the handle bar controls somehow. I took the controls apart and cleaned them and the bike instantly started up. Not saying that dirty controls was the problem but wiggling something in that area temporarially fixed the issue.
I am now going to buy new handle bar controls and debating on whether to buy a whole new wiring harness and do it right or try and figure out what he did. There's nothing more irritating then someone that doesn't spend the time to do things right the first time!!
Thanks for all the help!
Any ideas on buying a new wiring harness?
Turns out my bother used to have a kill switch on the bike. Well, when he took it off he bypassed the on/off switch on the handle bar controls somehow. I took the controls apart and cleaned them and the bike instantly started up. Not saying that dirty controls was the problem but wiggling something in that area temporarially fixed the issue.
I am now going to buy new handle bar controls and debating on whether to buy a whole new wiring harness and do it right or try and figure out what he did. There's nothing more irritating then someone that doesn't spend the time to do things right the first time!!
Thanks for all the help!
Any ideas on buying a new wiring harness?
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