First off... Hello everyone! I am new to the forum and just got my first quad the day before yesterday. It is a 2002 400ex and it runs and looks great, but not when i first picked it up. It had sat for about a year before i got it and started getting it running. My buddy and I cleaned the carb, replaced the jets, and cleaned the tank. Runs like an absolute champ now. My problem is i had rode it for about an hour or two on and off today with absolutely no problems. All of a sudden second gear starts acting up and making a clicking noise when going slow. Speeding up seems to make the noise go away. It never died out on me or popped out of gear, but it did/does jerk a bit. As i am new to this stuff... It is kind of hard to know if i am making sense here, but any help is GREATLY appreciated. I do not have a ton of time and money to put into it, but I am also not broke. Would love to be able to get this thing going good and have some fun with the kids and wife! Plus, we have a guns down bikes up ride through kansas city, MO. tomorrow. Note, I have yet to change the oil, but it was clear as day. I already got some fresh 10w40 to throw in it in the morning. Thought maby the oil had thinned or was the improper weight/kind? Again, any help is appreciated.
First quad, first problem.
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I don't know much about sport bikes, but since you just got your 400EX maybe you could read a free copy of the factory service manual while you are waiting for @SlammedRanger or other experts to find your thread. Welcome to the forums!
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4,390 Posts
Jerking in 2nd gear is not a good thing to have happen. To me sounds like your getting ready to lose 2nd gear all togeather. Which would be a very common gear to lose since its the gear you corner in and the gear alot of people just stay in all the time. The crappy part about this is you wont really know 100% till you go in and split the cases to find out. If its going in and staying in i would bet the shift forks are fine and the worm gear will be good. But the sliders that the forks hook on will have dull teeth on the side of 2nd gear and your slipping. Thats why you have the noise and the pluse in power. If you go on the ride your talking about just stay out of 2nd gear. But i would advise against it for fear of really destroying something real bad. From here your splitting cases and inspecting. The service manual will give you all the technical stuff. But i generally can tell if the dogs on the slider is bad by touching it. They should be sharp. Almost sharp enough to cut you. If they are rounded at all change them. Welcome to the forums! Feel free to ask as many questions as you like.
Thanks to everyone who replied, truly appreciative of the support. I changed out the oil today and payed close attention to how it sounded/acted. As i said before... It seems to only make the noise going slow in 2nd. I did not notice much jerking this time. I am going to take it to the ride tonight and skip 2nd. I will get it to my buddies mechanic tomorrow and hope for the best. Thanks everyone!
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64 Posts
Howdo mate. Just a quick thought to add to your check list. I'm not familiar with your particular model, do you have selectable all wheel drive? See if the noise is more pronounced in either setting? I'm thinking if it appears louder when it's just the rear axle engaged, bearing in mind the relatively slow speeds you're doing when you hear the symptoms, could it be confused for a rear prop shaft universal joint clattering? Its proximity being very close to the engine/transmission!
By engaging 4x4 & therefore reducing some of the driven load to the rear axle does it become quieter/smoother? Fingers crossed.
Chalkster
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163 Posts
Howdo mate. Just a quick thought to add to your check list. I'm not familiar with your particular model, do you have selectable all wheel drive? See if the noise is more pronounced in either setting? I'm thinking if it appears louder when it's just the rear axle engaged, bearing in mind the relatively slow speeds you're doing when you hear the symptoms, could it be confused for a rear prop shaft universal joint clattering? Its proximity being very close to the engine/transmission!
By engaging 4x4 & therefore reducing some of the driven load to the rear axle does it become quieter/smoother? Fingers crossed.
Chalkster[/QUOTE]
It’s a racing bike, so no 4wd, no rear differential, chain driven axle.
By engaging 4x4 & therefore reducing some of the driven load to the rear axle does it become quieter/smoother? Fingers crossed.
Chalkster[/QUOTE]
It’s a racing bike, so no 4wd, no rear differential, chain driven axle.
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