Weldangrind's Beast Mods

[Weldangrind]

I finally got a chance to work on my Beast today, and here are some of the details.

I recently installed the new Mikuni carb, replete with a 25 pilot and 110 main. To complement the carb, I chopped the stock Beast muffler off and welded a flange onto the pipe to accept the Monster pipe that I bought over a year ago. I figured that the best way to weld the flange on was to drill a hole that's large enough for the pipe to pass through, and then weld it on the outside. The catch is that the pipe enters on an angle, so the hole in the flange needs to be an ellipse, like a slice of balogna.

This is the rough estimation of the pipe location:



This is the pipe as it passes through the flange:



This is a side view that demonstrates the angle:



I welded it together, ported the head pipe and painted the assembly. I used a nice fresh gasket. The last time I blew a gasket, it melted my winter riding pants. Now I use a new gasket each time.



I found an old XR200R heat shield that I like better than the cheap chrome junk. I installed it with stainless socket head cap screws:



I then filled up the engine with fresh Rotella T to the full mark on the sight glass:



For reference, here's the difference between the sight glass full mark and the cross-hatched area on the dipstick. In my estimation, there is nearly twice as much oil if you use the sight glass as a guide. The black Sharpie marks represent where the oil level is. This will likely apply to all Honda clone engines with a sight glass:



I installed the battery, hit the button and...nothing. Not even a click. :( I jumped the solenoid and the engine turns over, so it's not the starter or the battery. I plugged in another ignition switch and that changed nothing. I dismantled the starter switch and tested it; it has continuity. I checked the rear brake switch, and it has continuity as well. This really bums me out. Maybe I'll figure it out tomorrow. I haven't started this atv in 10 months, and I really wanna ride it.