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Time to remove the fuel tank heat protector. Now remove the rubber strap on each side of the rear of the tank, and the 2 10mm bolts at the front of the tank and remove the tank from the bike. Put a rag underneath the line to catch the small amount of fuel that will drip out when you remove the line. Turn the fuel valve off, and disconnect the fuel line from the carburetor. With the plastic out of the way it's time to remove the fuel tank. Then pull the fender assembly forward slightly so that you can reach and disconnect the wiring for the headlights and ignition switch. Remove the 4 10mm bolts and 2 5mm allen bolts that secure the front fender assembly. Remove the gas cap, and pull the cover towards the rear of the quad then remove it. This unlocks the pin, allowing you to remove it. To remove the pins, pull the center section of the pin up about ½ inch. Start by removing the 4 plastic push pins. With the rear seat/fender assembly out of the way, it's time to remove front plastic. This will prevent the motor from accidentally starting later on. Unhook the negative battery cable and secure it where it can't accidentally fall into contact with the battery. Start by removing the rear fender seat assembly. You don't want any 'stuff' falling in the motor, and a clean machine is much easier to work on. Now that you have your tools assembled, lets get to work! Doing your own maintenance can be a very rewarding and fun part of ATVing, but remember to think safety! Before starting work I recommend thourghly cleaning the machine, and degreasing the motor. 005 inch.)Ħ) a clean place to work, with good lightingħ) fire extinguisher, safety glasses, etc (hey, you never know) You are probably wondering, "what tools do I need?".ġ) metric socket's and various ratchets/extensions (I prefer 6 point sockets)Ĥ) various screwdrivers (don't skimp, cheap philips screwdrivers do more harm than good!)ĥ) feeler gauges (make sure that the set includes both a. Little clearance) then it is possible to burn a valve,ĭamaging the valve, and possibly the cylinder head. You can do the job properly, either have a competentįriend show you, or take it to the shop and have themĭo it for you. Practices (in other words, don't hurt yourself… if youĭo, don't blame me!) I also highly recommend purchasingĪ service manual. Safe out there, be sure to follow all standard shop Of anyone with basic mechanical knowledge. In doing it yourself? You have come to the right place!Īdjusting your own valves is within the capabilities Time to adjust the valves on your 400EX? Interested