The cutting out or misfire sound is your CDI rev limiter. The aftermarket exhaust is wider than the stock. Unless the owner before you took it out, there should be a metal washer pressed into the exhaust pipe at the head. If it's there, then that would need to be removed. The engine has a tube that runs from the engine to the plastic airbox unit. When you install the after market air filter, you will have to do something with that tube. They sell filters that are about an 1nch and a half tall that look like mini K&N filters. That would install on the case where the tube was. Or you can run a long tube from the case to the handle bars. The stock airbox is a bad design flaw that acts like a scoop with a poorly designed air filter. If your kid normally rides behind you, chances are he's getting more than his share of dirt forced down the airbox. There is a strong chance that it could get by the filter, through the carb and reak havoc on you cylinder walls.

 

<div class="FTQUOTE"><begin quote>Originally posted by: edc7002

still no talk of big power gains huh ?!? is anyones bike moving faster than 26mph ??????????????</end quote></div>

Mine was doing 85 in the back of my truck on the way to its new owner!!

 

hey guys I guess I'm back dont know what happened just stoped recieving e-mail hits thought the thread went dead -----checked and seen we have some new players and some old ones who are still here -------GREAT------

 

And they said you couldn't make these things fast. Well, now that you have it sold all you'll have are the memories......Good Times.........good times. I can still remember the first time I was cussing at the little thing when it wouldn't get out of it's own way. AHHH yes the memories.

 

I felt sad to see it go. I couldn't stop telling the guy about how cool it is! And how it will beat an equal match with the CT Pipe on it![img]i/expressions/face-icon-small-smile.gif[/img] LOL. If I ever have another kid, I will look for another!!

 

For the stock pipe how are you guys removing the baffle that is inside. I'm not talking about the spark arrestor (already removed) but rather the solid plate with pee-shooter hole at the bottom. that sits about 4" inside the can I was thinking of just drilling several large holes in the plate but am looking for any other ideas...

Lowlife mentioned a restrictor (washer) where the header meets the head. I took mine off and there was nothing in there. I guess only a few have this restrictor in place

 

I have not drilled out the hole you mention but I can confirm that mine had no washer in the header pipe. I also bought mine new so I don't think it came with one from the factory. One thing I've noticed, I bought the KN filter and the bike now will not run above 1/3 throttle. I'm going to try a bigger main jet as it seems to be starving but will know in a day or so. The other annoying thing is the filter (KN RU 1040) has a much larger throat than the carb body. I just used the rubber piece from the old system as a spacer but clearly there has to be a better way.

Can anyone comment on how they made the kn filter tight to the carb - you can't just clamp it down as the diameter diff. is way too much? The rubber piece from the stock air filter works but it's not the best fix imo..

 

Sounds like you have the wrong K&N. Mine mates up perfectly to the carb.

If you haven't rejetted yet it will run to lean. You have supplied more air to the motor but no more fuel. Put the choke on and it will probably run better until you are able to rejet. I went up on the pilot (17.5) and main (75)

 

Yes, I did get the wrong filter. I was told to get an RU-1040 and instead of checking the inside diameter myself, I just ordered it. No problem, it can be returned and it was my fault for being lazy. Live and learn. The filter I'm getting now is KN - RC-2540.

Thanks again for the jetting tips. So far all I've done to the quad is the spacer removal - CT CDI unit and removed the spark arrestor. I didn't notice any difference with the spark arrestor out so I'll probably run it with SA to keep it legal in most CA riding areas. I'm considering getting the CT clutch mod as it makes the bike build more revs before engagement. *I assume it should help in sand and on slight inclines...

 

I just drilled big holes through that plate. Then used a magnet to get out what I could. The rest blew out with the exhaust.