Rodneya

First loosen the cable adjuster at the clutch perch. Put the clutch together without springs or screws and hold the pressure plate in position with your hand. Turn the adjuster until the pressure plate starts to move. Back off a quarter turn and tighten the locknut and you are good to go. Just ignore the arrow thing on the cases. Your clutch will work fine. Some guys get obsessive about the arrow lining up, just like they blame TORS for everything. There have been posts before about the Cascade adjuster being too short. Mine is from HJR, and it uses the original adjuster screw. You have to take the pressure plate off to lock the adjuster, and doing it this way works great.

If you get it ported, just remember that even with a big tank you will not be able to ride as far as the 4 strokes can on a tank. Porting turns a it into a real gas guzzler.

What color is the smoke, and what does it smell like?

The park brake has nothing to do with the TORS. TORS works between the throttle and carbs, while the park brake switch works with the CDI. They are totally separate systems.

To measure out of round and taper you have to measure in two directions at the top, middle and bottom of the bore. Calipers are not accurate enough, and you can not measure the middle. And it is not my advice, it is how every machine shop does it. Take a look at the stickies at the top of one of the forums. There is a copy of the manual you can download.

Why did you put in the 240 jets?

You will be wasting your time trying to measure with calipers. They will not work. Take them to someone who can measure them with a bore gauge. All the tolerances are in the Clymers. You should get one.

I could only manage to read up to where he has ported heads and ported carbs ?????????????????????

What elevation are you at. 260 seems lean.

How did you check compression. At 50 psi it should take a couple hundred kicks to start if it ever starts.

Not really sure what a borescope is, but you compression before tear down would have been a good indication of needing a rebuild. You cant look at the bores and tell if you need a re bore or hone unless you grenaded something. You need to measure the bores with a bore gauge top middle and bottom in two directions to measure taper and out of round. Don't try measure it with vernier calipers, you will be wasting your time. get it measured at a reputable shop or better yet send your jugs to a site sponsor. That way you wont get fucked over and end up buying junk like Namura pistons or something.

It will start with no exhaust. Not easily though, and wont rev. And it is stupid loud.

No lid will be just about the same as pods, but you will be able to keep your filer dry. When you take the cover off you jet up about 2 sizes, so you will notice a difference.

What head gasket are you using. Looks like silicone was used before.

Nothing to work on, Your Banshee came with an airbox that works just fine. All you need is a proflow adapter and K&N inside the airbox and you will flow the same as pods with the lid off.

The raptor is fuel injected, so it cant be jetted.

Check the key and kill switch first before you start ripping stuff apart

If the fuel made it to the pipes, the crank must be full. You will need to drain that first or it will never start. Check the carbs. Wrong float height or sticking floats and/or blocked overflow.

A guy calls his buddy, the horse rancher, and says he's sending a friend over to look at a horse. His buddy asks, 'How will I recognize him? 'That's easy; he's a dwarf with a speech impediment.' So, the dwarf shows up, and the guy asks him if he's looking for a male or female horse. 'A female horth.' So he shows him a prized filly. 'Nith lookin horth. Can I thee her eyeth?' So the guy picks up the dwarf and he gives the horse's eyes the once over.. 'Nith eyeth, can I thee her earzth?' So he picks the little fella up again, and shows him the horse's ears. 'Nith earzth, can I thee her mouf?' The rancher is getting pretty ticked off by this point, but he picks him up again and shows him the horse's mouth. 'Nice mouf, can I see her twat?' Totally mad as hell at this point, the rancher grabs him under his arms and rams the dwarf's head up the horse's ass, pulls him out and slams him on the ground. The midget gets up, sputtering and coughing. 'Perhapth I should refwase that. Can I thee her wun awound a widdlebit?'

You have a ported banshee head. Interesting

Can you post a picture through the intake side.

Its normal, the clutch plates stick together when the motor is not running. Mine did it sometimes with stock and aftermarket clutch And don't worry too much about the clutch alignment marks. They don't have too be aligned for the clutch to work correctly.

Check the gas cap breather and the fuel valve filter. You could be running lean due to the carbs running dry at WOT.

Mine came like that too and I did not have to drill anything. just leave off the washer where the locknut goes on.

Stay far away from that shop in future. People who make retarded excuses to cover their mistakes are a waste of time.