400 won't rev in gear? - Suzuki Z400 Forum : Z400 Forums
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post #1 of 12 (permalink) Old 05-10-2017, 08:54 PM Thread Starter
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400 won't rev in gear?

My father in law bought a 05 400 from a buddy at work for riding around his property in the Mountains, I had rebuilt a Raptor 350 for my 12 yr old that I had paid 1200 for and put about 500 in to get it into good running condition, he asked me if 1500 was a good price for the 400, I said it was ok depending on condition due to the 400 being a much stronger bike than the Raptor 350.

He dropped it off at my house to see if I could go over the bike, got it out of my truck and went to start the bike and it backfired out of the carburetor with a big fire ball and wouldn't start. Looked it over in the day, packed mud in radiator, dirty coolant, air filter not connected, gas leaking from gas peacock, gas leaking out of carb. Carb not even in boot to cylinder head, shot brakes and wheel bearings, basically I'm like what a POS.

I Did a list of things and still having trouble.

Took bike apart power washed all mud from radiator, flushed coolant, switched to Evans waterless, changed thermostat, added a tusk radiator cap with temp gauge.
Changed oil and filter
Installed eBay gas peacock
Bike did have full Yoshimura exhaust
Did the Pro Design Intake
Did eBay carb
Mikuni 160 main 30 pilot
Replaced plug and coil

Wanted to get running right before doing brakes and wheel bearings

The bike will start right up and sound very healthy, it will idle and in neutral you can rev and rev the motor
No issues, if you put in 1st gear it seems like it gets to about 3k rpm and starts to brake up bad, I have changed the plug, tried different coil, also tried a different cdi box, no difference, I think it's jetted ok but not sure my sons 350 has basically the same mods and I run a 155 main and 25 pilot and it runs great I figured the 400 would definitely need a little more fuel. Any suggestions.

THanks Jay

2006 Raptor 350- Sons
2005 KFX 400- Father-in law
2016 Sportsman 570-Mine
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post #2 of 12 (permalink) Old 05-10-2017, 10:53 PM
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There is a sensor at the shifter that senses gear position. I honestly don't know much about it but I know it has contacts. Do some searching on this.........sounds like the quad thinks it's in reverse as the reverse rev limiter does exactly what you are describing.
dtfm33 and amcf18 like this.

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post #3 of 12 (permalink) Old 05-11-2017, 11:49 AM
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Yes, search reverse rev limiter delete in tools.

'05 Z
94mm bbk, +4 stroker, Hot Cams, Vertex piston, FMF Power Bomb header and Power Core can, KW black diamond valves/dual springs, FCR39, K&N, Elka long-travel LT fronts and rear, Houser +3, +3/4 LT A-arms, American Star pro xs chromoly tie rods, Dyna non-programable, Tusk +3 axle.
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post #4 of 12 (permalink) Old 05-11-2017, 07:49 PM Thread Starter
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OK I will check into that thanks, does the jetting look close for the mods? I'm at sea level.
Thanks

2006 Raptor 350- Sons
2005 KFX 400- Father-in law
2016 Sportsman 570-Mine
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post #5 of 12 (permalink) Old 05-11-2017, 08:45 PM Thread Starter
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I did forget to mention the aftermarket carb I got didn't have a tps sensor so I just left that unplugged

2006 Raptor 350- Sons
2005 KFX 400- Father-in law
2016 Sportsman 570-Mine
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post #6 of 12 (permalink) Old 05-11-2017, 09:02 PM
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Seems close. The TPS won't matter. Start the Z, put it reverse, and floor it. Notice that "rev limiter" sound at about half throttle and it won't rev any higher. Does it sound the same in forward gears?

'05 Z
94mm bbk, +4 stroker, Hot Cams, Vertex piston, FMF Power Bomb header and Power Core can, KW black diamond valves/dual springs, FCR39, K&N, Elka long-travel LT fronts and rear, Houser +3, +3/4 LT A-arms, American Star pro xs chromoly tie rods, Dyna non-programable, Tusk +3 axle.
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post #7 of 12 (permalink) Old 05-11-2017, 11:23 PM
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ebay carb........like those zoom zoom carbs? No bueno

2005 Z-400 Mine (AKA "WHITE LIGHTNING")
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post #8 of 12 (permalink) Old 05-13-2017, 05:52 PM Thread Starter
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Yeah it is a similar one to that, the stock one was too far gone and I didn't want to spend 300 on a new one, I had pretty good luck with the same one on my kids Raptor 350, if anyone knows where to get an affordable stocker I guess I could go that route.

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2005 KFX 400- Father-in law
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post #9 of 12 (permalink) Old 05-14-2017, 06:30 AM
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sounds lean , what kind of jets are you using ?

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03 ltz400,95.5bore,+5crank,P&P,13.7:1,JE piston,spacer plate,RHC +1 intakes valves,RHC #208in&187ex cams,DRZ manual decomp,DID cam chain,no air box,Sredrum TB 42mm FCR,RAT stack,WB fuel screw,EMN needle,quick shot,06 clutch 450r drive plates w/trx400 ex springs,C2HB,ex thumber,trx450r air boot, Barker Performance pipe, trailteck flywheel,dynatek,NOLOGY HOTWIRES ,nerf bars,450r shocks, +4 swinger,lowered front & rear
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post #10 of 12 (permalink) Old 05-15-2017, 06:59 PM Thread Starter
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Mikuni jets, I have a 160 main in there I think a 170 is the biggest jet available for that carb
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post #11 of 12 (permalink) Old 05-15-2017, 08:36 PM
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not DynoJets ?

The White Beast
03 ltz400,95.5bore,+5crank,P&P,13.7:1,JE piston,spacer plate,RHC +1 intakes valves,RHC #208in&187ex cams,DRZ manual decomp,DID cam chain,no air box,Sredrum TB 42mm FCR,RAT stack,WB fuel screw,EMN needle,quick shot,06 clutch 450r drive plates w/trx400 ex springs,C2HB,ex thumber,trx450r air boot, Barker Performance pipe, trailteck flywheel,dynatek,NOLOGY HOTWIRES ,nerf bars,450r shocks, +4 swinger,lowered front & rear
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post #12 of 12 (permalink) Old 05-17-2017, 08:05 PM Thread Starter
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No I've never had much luck with dynojet stuff, actual Mikuni

2006 Raptor 350- Sons
2005 KFX 400- Father-in law
2016 Sportsman 570-Mine
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