won't start after mods? already searched. (lengthy)

[bmuh83]

so i bought a 2003 z400 a month or 2 ago.. (the guy said he used it to race) i've only gotten to ride it a few times before modding it and everything was running and starting great. i tore it down to install mods which were:

yoshi full exhaust (which requires a coolant change)
UNI filter on the aluminum box that sells on ebay
dynojet 150 main
RM kill switch (wired to start)
and a good pressure washing of everything (which I've read could be the cause)
.... i think that's all the mods that would/could affect the starting.

the motor will turn over when trying to start but simply won't fire.

things i've tried/checked:

--removed and throughly cleaned the carb with carb cleaner and canned air by pulling each jet individually spraying with cleaner poking with needle and blasting with air. also aired out the holes on the inside of the intake side of the carb.. i think those are the channels people talk about?
--pulled out the NEW spark plug and grounded to see if there was spark. it's good.
--removed air filter to make sure air was getting in. failed to start
--sprayed starting fluid on filter (while attached) and got a pop once when trying to start. once out of maybe 5 times...
--charged the battery MANY times
--changed the oil and coolant (i don't think is relevant)
--removed the RM kill/start button and put blob back to see if i had wired something wrong.. nothin..
--checked fuse. its good
--changed out the wiring harness with a 2006 harness to see if it was the CDI (had to change the whole harness due to the plug for the 06 CDI being a different smaller type than my 03) now this CDI could be bad as well since it WAS attached to a used harness i snagged on ebay...

The only thing i can think of that i haven't tried is the valve clearance only because 1) breaking into the motor isn't something i'm comfortable with 2) it was running fine just 3 weeks ago when me and a buddy went to Slade's park in Surry VA. (pretty sandy riding)

now last possible thing i can think of is when i was changing the exhaust out i had to remove the radiator fan, lower radiator hose, and some protruding cap on the front side of the head beside where the header goes in. when doing this i lost two of the clips that the radiator fan screws screw in to down in my oil bucket. when i was fishing these clip/nuts out i found a mesh screen with a spring attached to it in the bucket.

now this spring/screen could be from 1 of 3 toys. before doing my Z400 my friend was over changing the oil on his raptor and DR-Z. i asked him if it looked familiar but he said no. i tried fitting the spring/screen everywhere i could around the header parts i had removed but it didn't seem to fit anywhere?? i'm not sure if it was a coolant screen either since it was dropped into the oil bucket it was obviously covered in black oil...

i believe that covers everything.. please help with ANY suggestions..

Thanks you all
Ben

[beaverclever02]

Have you tried pull starting it yet? It sounds stupid but when I had my mototr open the only way I could get it to fire was getting pulled around the yard in gear, and than it took off and fine ever since

[CFM-Z440]

That screen does not belong to the Z. Is that DR-Z like a 125? It probably belongs above the oil plug for that.

Spark, fuel, compression, which one don't you have? Have you tried the petcock on prime to make sure the carb has gas in it? Did you forget to hook up the vacuum line?

[hollomonster]

Neutral safety switch?

[bmuh83]

Originally Posted by CFM-Z440

That screen does not belong to the Z. Is that DR-Z like a 125? It probably belongs above the oil plug for that.

Spark, fuel, compression, which one don't you have? Have you tried the petcock on prime to make sure the carb has gas in it? Did you forget to hook up the vacuum line?

Thanks for the quick replys every one! I have not tried to pull start it yet. I'll try that tomorrow when I get home

I know it has spark fuel and air from the intake. I don't have a compression gauge but it feels/seems good. I've tried the petcock in all positions (raptor 660 I forgot to mention on new mods list). And which vac line are you talking about? The one on the choke side of the carb towards the top I have plugged for the new petcock. (also new mod for the bike is a pull choke since I got rid of the blob.

The neutral safety switch? Is that in the blob re-wiring area? I have it wired to delete the clutch position switch for starting. And the neutral light comes on with the key.??

Thanks again you all

[bmuh83]

I haven't checked the valve clearance since I bought the bike and I know I should regardless, but that couldn't possibly be what is preventing it from firing is it? It was running and starting without hesitation last time it was out...

[CFM-Z440]

Valve clearance can do it. They can go without warning some times. I didn't realize you had the raptor petcock. I was just using some logical thinking since I knew you had the carb out.

Did you remember to pull the rag out of the intake when you put the carb back in? You wouldn't believe how often that happens.

[hondareconred]

maybe you gotten something wet that shouldnt of gotten wet. is fuel getting into the carb?

[bmuh83]

Yes, we'll I actually used the exhaust plug that came with my yoshimura pipe to plug the boot that goes from the carb to the head. However, had I forgotten a rag there I don't think I would admit it. Lol

I'll check the valve clearance after I try to pull start it.

After reading some of the stories on here about pressure washing the motor I was thinking it was the CDI or something but I'm still getting spark?? I'm not sure what is considered a good or bad spark but it looks like enough to me??

When opening the float bowl drain screw a lot of fuel will come out. I assume this means there is fuel flowing to it.. Sometimes my inline fuel filter isn't filled all the way up so I'll have to shake or pinch the line repeatedly to get it to fill. Is that normal?

I have fuel stabilizer in the gas I'm using(I forgot the brand but it's in a clear blue bottle)... It's the same gas can I was using 3 weeks ago when riding and the can was filled about 6 weeks ago roughly. Could the gas have gone bad?

[Derek13]

if you think that the power washing might have hurt some, there are products out there you can spray on all your connections that will pull any extra moisture out and allow there to be a good connection. I have loss of power problems sometimes with my snow plow and that stuff cleans it up good. Don't see why it wouldn't help you with the quad. that being said I can't remember the name of it for the life of me... but if you go into a hardware store and describe it i'm sure they will help, or your local plow depot will know.

good luck man. if and when you figure it out make sure ya keep us updated

[TuckerHardRide]

Is their water on the spark plug?
edit: never mind

[bmuh83]

As far as the connections being wet I used my shop vac to suck whatever it would out of the connections. Maybe it wasn't enough? But it still has spark.

You guys have all been helpful. I'll definitely keep you all informed. And please keep the suggestions coming. I'm out of ideas..

[biggiej42]

Check your valves.....

[TuckerHardRide]

Maybe some dirt got dropped into the jets while putting it back together, maybe your valves are shot, maybe your boots aren't securely fasted from head to carb or carb to airbox. Check the boots first and let us know. My quad wouldn't start after i put the fcr on because the boot wasn't secure enough.

[Mudslinger11]

I would also say check the valves, once they cup, they are done but, if the guy re-shimmed it to sell, you would get a few rides and they would cup more.