I had a blown piston in the end of last year. The cylinder had some scratching so I picked up the next size piston from wiseco to make it a 416. I then mailed the cylinder and piston to have it bored/honed to match. I replaced the timing chain, and found my cylinder valve cover had a broken engine mount so I replaced that. I then found that my valve guides were out of spec so changed them, and did new valve springs, seats, seals.

Long story short I broke a tooth on my outer clutch basket and replaced it with the wrong year basket, it was hitting the gear and I didn’t notice. I also put my cylinder scraper and compression ring on upside down so they were in the right spot but upside down. Didnt realize that either… :icon_ cry:

So I had it all back together and it ran seemingly fine. It wasnt smoking or rattling or anything. I rode it around a few hours and changed the oil didnt see anything out of the ordinary.

I took it out again and noticed it was not really picking up in 4th and 5th gear, then all the sudden while in 5th it just shut off. I restarted it but it had no power, it started but when I throttled it would rev up but wouldn’t move an inch.

So I spent today tearing it down and found the upside down rings and a scratched up piston, nicked ring, and cylinder walls were slightly discolored in a small area.

So what in your opinion do I need to do to get this going again. Would the ring having a small nick cause complete power loss? When I had it in 1st I was able to roll it with out the clutch pulled? Now that its apart the quad wants to roll when the crank is rotated.

Do I need to get a new piston and have the cylinder honed again? Or just new rings? What else should I check for before reassembling this thing? Whats the best way to be sure the bottom end is all cleaned of possible metal shards?

Thanks