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Old 12-22-2013, 07:00 AM   #1
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Default Kfx 400 won't fire

Well my rebuild of the kfx was going great until I went to fire her up. Turns over sounds great but won't fire up. Iv checked and I have spark. I cleaned the Petcock and I am getting fuel to the carb at least.

Now I'm waiting on getting a compression tester. And I'm hoping it reads good.

So far iv replaced my cdi, voltage regulator, starter solenoid, and wiring harness.

Iv never delved into the realm of doing an engine rebuild if needed I'm going to attempt the rebuild my self. I do have the hynes manual and a digital cop of I believe the clymers.

How hard is this job for someone with no experience in engine rebuilds. And do I need any special tools to complete the job. What else should I replace while it's apart.
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Old 12-22-2013, 07:26 AM   #2
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You you have no or too low compression I would guess you need to change the rings and gaskets and clean the valves and change the valve seals. Did you check your valve settings?
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Old 12-22-2013, 07:33 AM   #3
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Valves in spec?
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Old 12-22-2013, 07:33 AM   #4
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Quote: Originally Posted by dgthomas67 View Post
You you have no or too low compression I would guess you need to change the rings and gaskets and clean the valves and change the valve seals. Did you check your valve settings?

I havnt gotten a chance to check much since not being able to fire it up. I might have some time today. I'm borrowing a compression tester and will get the readings and report back.

Any idea on how much the rebuild is going to cost me. I'm not real confident to do it myself. If I get a crazy high price I'm going to be forced to do it myself though.
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Old 12-22-2013, 07:35 AM   #5
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I'm going to have to figure out how to check valve spec. What do I need to do the job. I'm assuming a feeler gauges correct.
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Old 12-22-2013, 07:56 AM   #6
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Yes Feeler gauges. Look in the service manual I sent you. It will tell you what you need.
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Old 12-22-2013, 08:00 AM   #7
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Quote: Originally Posted by dgthomas67 View Post
Yes Feeler gauges. Look in the service manual I sent you. It will tell you what you need.

Okay I will do that when I get home. Ill grab a feeler gauge while I'm here. If I'm correct the tolerance is like .0039-.0071
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Old 12-22-2013, 08:14 AM   #8
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Here is a list of stuff and Part Numbers you would need to rebuild the top. Also you need to check the water pump and oil pump while you are doing this just to be safe.

13008-s008 - Ring Set - $31.86
11004-s006 - Head Gasket - $19.82
11061-s069 - Gasket Head Cover - $16.68
92049-s006 - Valve Seals - (Need 4) $3.13ea - $12.52
11061-s076 - Exhaust Pipe Gasket $8.37

Total without shipping - $89.25

This is to do it yourself. I had mine done at a shop and I forgot how much I paid. I am having it done right now to my 05 KFX 700 which has 2 cylinders and it is costing me $905.00 with parts and Tax. They are changing the rings and Valve seals and cleaning valves and changing gaskets. If should be cheaper for you. I was thinking it cost me around $325 to 375 labor. Buy your own parts. OEM Parts. That is what I do.

Cheapest Part are at Partzilla.com - OEM Powersports Parts from Honda, Kawasaki Polaris, Suzuki and Yamaha at discounts up to 80% off MSRP
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Old 12-22-2013, 08:15 AM   #9
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This link will give you a good idea of what's needed to check valve lash.
Checking Valve Lash/changing Shims - Suzuki Z400 Forum : Z400 Forums
By "rebuild" are you talking just the top end?
You can get big bore kits with cylinder, piston and rings for right around $300 if you look around some and it's not that hard to do.
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Old 12-22-2013, 08:22 AM   #10
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Thanks everyone for their help. It already has a big bore kit on it. So I'm assuming I would have to wait until it's disassembled to order the ring and such so I can measure the the piston. Tonight I will try to measure the valve clearance. And run a compression test. Is it possible it wot fire because the valves are out of spec or is a top end rebuild most defiantly in need. I'm sure I'll know more tonight. Am I correct that if I put a table spoon of oil in and the psi on the test goes up that's a tell take sign the motor needs a top end.
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