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I purchased a used 2014 Rancher 420FM last year. I posted the other day about a exhaust pipe leak at the cylinder. I will be taking the quad to my mechanic next week for him to replace the crush washer to see if the leak will stop. Tightening the bolts helped the leak a lot.

I found another problem yesterday. I purchased a new seat, put it on and rode for about 4 hours, stop and go. I noticed my left upper leg was getting very warm towards the end of the ride. While taking the seat off I found that the left plastic tab is melted!!!(where it hooks to the frame). It's not the entire tab but enough that it's obvious something is going on to cause this.

This plastic seat tab is located above the exhaust.

The odd thing is that the OLD seat has only one tiny area that looks like it got too warm, but nothing like what has happened with my NEW seat.

What is causing the increased heat?? Is it the exhaust or the engine?? Could the 27 inch tires all around be causing this??

The only engine work done was rebore and rebuild of top end due to smoking and done my first rip-off mechanic. My new mechanic readjusted the valves and told me "they were not set right." It runs GREAT but I checked the spark plug last week and it was black with soot. It's running too rich from what I can tell.

I have ridden less than 30 miles since the top end was rebuilt. I ride mostly at low speed due to the terrain. Oil has been changed twice. New oil filter and air filter. Clean radiator with new fluid and fan works. No error messages.

Please help!
 

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Running rich will make them run hot , and you have a exhaust leak ----I put third degree burns on my leg riding with short pants and the steam from hitting the water got me good , be carful
 

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Running rich will make them run hot , and you have a exhaust leak ----I put third degree burns on my leg riding with short pants and the steam from hitting the water got me good , be carful
Thanks Fish! So it's a combination of those two things causing the problem? Got it. I hope my mechanic knows enough about the EFI system to fix the rich problem and has the equipment to do it.

I don't plan to ride it until it's fixed but thanks so much for the warning. Ouch!
 

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I wouldn't run it with an exhaust leak.....
I'm pretty sure running lean will cause the exhaust to get hotter and glow cherry red, not rich.
Thank you!! I did some more reading and found what you said. That helps me a lot. Now, I guess it's down to the exhaust being the problem.
 

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Discussion Starter #6
I was able to get the exhaust off today. That was not easy.

Here is a pic of the old crush washer. Notice how it's crushed more on one side that the other?? From 12 to 6 o'clock there is a "lip" and it is flat on the other side. Was this caused by someone tightening down one side before tightening the other??? Or, does it indicate something else is wrong??

Just looking I don't see any problem at the connection to the head and the and the mounting bracket on the pipe does not appear warped.

I'm waiting to hear from someone before I install the new crush washer. :)
 

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Discussion Starter #7
Valentine's Day bump....plz see my post, above. I'm sitting here holding this crush washer in my hand waiting for your help.:)
 

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is this the same question as before? only in a different way? i havent been paying enough attention... you can leak exhaust from the head, as well as where the exhaust hooks up. usually the warmer the engine gets, the hotter the leak. just a suggestion. it still has to do with loose, or a faulty gasket. so can the crush washer, be the problem. which way did the exhaust leak point?
 

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I would make sure the flat end flange of the exhaust is clean and flat , maybe some emery cloth and buff it , clean out the carbon build up inside the head where the flange mates ,be sure the copper washer stays in place when you insert the flange , put it together and snug the bolts evenly , start the engine and let it get up to operating temp , then tighten the bolts ( to torque specs if you like ) ---see what happens , then go on from there !!!!
 

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Discussion Starter #11
I would make sure the flat end flange of the exhaust is clean and flat , maybe some emery cloth and buff it , clean out the carbon build up inside the head where the flange mates ,be sure the copper washer stays in place when you insert the flange , put it together and snug the bolts evenly , start the engine and let it get up to operating temp , then tighten the bolts ( to torque specs if you like ) ---see what happens , then go on from there !!!!
Thank you! I didn't know about letting it warm up and then retighten the bolts. It's those little secrets I don't know about. LOL. I'll keep you posted.
 

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Discussion Starter #12
I'm with fish

Did you verify that was where the leak was from?
Yes, I really think so. Since I wasn't able to get my hand close enough, I took tight strips of paper and attached them to a long handled hemostat and held it in the area. That's the only place I could detect the leak - at the head connection, at the bottom. That was the area where I found that the bolt was looser than the top bolt. And, after removing and inspecting the crush washer I found it was not compressed evenly. I know it's difficult to see it in my photo.

I cleaned the exterior of the exhaust to the point is should be sterile. Even went over it with a magnifying glass. It's in great condition with minimal rust.

I did as @fishfiles suggested and did a little more cleaning and light sanding.

I'm going out now to put in the new washer and see what happens.
 

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All done and it WORKED! THANK YOU @fishfiles! Once again you came to my rescue.

I had to get a friend to help by tapping the exhaust in the grommets as I held the pipe in the correct position on the head. The pipe wanted to raise up about 1/16 inch so that it was not centered. Now I know why that old crush washer had more pressure on one side than the other and why the pipe was leaking. If I had tapped it in all by myself it would have been high. .

Now I just have to put him back together. :)
 

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Glad it worked out ----that bike sure is clean . Do you use it ? LOL
Not the past 2 1/2 months. I don't deer hunt anymore and it's illegal to hunt hogs at night during deer season, even with my special permit. Now that deer season is finally over I'll be headed out next week and it'll be covered in mud... LOL
 

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I remember when you first came to the site asking questions about kids riding , never thought you were a deer hunter

we are about to do a special hog hunt , a friends buddy has 22 hog dogs , Russian bear dogs , Catahoulas , Pit Bulls , Cures , GPS collars to a screen on the 4 wheeler , remote drones with video and obstacle avoidance that follow the lead dog , no guns allowed so the dogs don't get shot , knives only , should be fun

Check out this exhaust , look right at the pipe by the head , yours getting that hot ? LOL
 

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I remember when you first came to the site asking questions about kids riding , never thought you were a deer hunter

we are about to do a special hog hunt , a friends buddy has 22 hog dogs , Russian bear dogs , Catahoulas , Pit Bulls , Cures , GPS collars to a screen on the 4 wheeler , remote drones with video and obstacle avoidance that follow the lead dog , no guns allowed so the dogs don't get shot , knives only , should be fun

Check out this exhaust , look right at the pipe by the head , yours getting that hot ? LOL
Have friends that used to come to our place for hog hunting. Had catahoulas. Great dogs.

I went with them once and it was way too brutal for me to watch. Not because of the hogs but seeing the dogs get injured or almost injured was not my idea of fun. And those dog were covered in kevlar. It is an extremely dangerous way to hunt if you don't know what you're doing. So, as you warned me about the hot muffler, I'm warning you to be careful. An injured bore is a dangerous animal to approach.

I've killed over 500. Even after good 270 shot placement and being down for 30 minutes and followed by a 9mm shot between the eyes I've had them jump up and charge me. Again, please be careful.
 

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Deer seasons over here. I'm jealous of you hog hunters, stuck in the house waiting for riding season to come. $inches of snow this weekend predicted.
Good work on the atv but just so you know the exhaust is on the other side from the pic posted :)
 

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So you never mentioned the header pipe on that pic , did you notice that it is cherry red most likely from the carb being too rich
I'm sorry to correct you Fish but too rich will not cause an engine to overheat. A perfectly jetted engine will overheat under tough conditions.........especially an air cooled engine. Is is not uncommon to see high performance four strokes to glow red , especially at night. Now a lean engine will over heat exponentially as it get leaner. Think about a torch........more oxygen more heat until it goes out...........less oxygen, it gets cooler. I respect your opinions Fish but I was compelled to correct this because it is an important topic. We're still friends right? lol
 
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