Bottom End Rebuild

[JOEX]

Broke the shifter shaft on the 400ex at St. Anthony's this week:(

Of course the cases have to be split, I was thinking the shift forks could be replaced while it's apart. Should all three of them be replaced or is there just one or two that usually show wear?

What else should should I have done while the cases are apart? Besides a stroker kit.

if you really didnet want to have to split the case I bet you could....


take a drill and drill out the remaining shaft, then tap the hole.

install a bolt in the shaft and lock it in with a locknut.

then weld a shifter to the end of the bolt.


really cobbed up. but I bet it would work.

[JOEX]

Originally posted by mittimj
if you really didnet want to have to split the case I bet you could....


take a drill and drill out the remaining shaft, then tap the hole.

install a bolt in the shaft and lock it in with a locknut.

then weld a shifter to the end of the bolt.


really cobbed up. but I bet it would work.
I had thought about that and may do it as a half azzed temporary band-aid.

I'd rather do it right and want to know what else to do while it is apart.

[Pappy]

doesnt mike boone sell bottom ends and the like?

[JOEX]

Originally posted by Pappy
doesnt mike boone sell bottom ends and the like?
I think so or someone does. That is another option i've considered but would I be in the same boat 6 months from now?

Knowing how some people treat their machines makes me not want a used bottom end:ermm:

[Pappy]

i was think more along the lines of time and getting you back in the saddle.

call colby up and see what he thinks, im sure he can rebuild it for ya fast seeing your da employee of da month:devil: :blah:

[JOEX]

Originally posted by Pappy
i was think more along the lines of time and getting you back in the saddle.

call colby up and see what he thinks, im sure he can rebuild it for ya fast seeing your da employee of da month:devil: :blah:
LOL!:p I wanted a recount:o :devil:

Getting it back together quickly this time of year would be nice and having a back-up motor would be a bonus;)

I'm still not sure what i'm going to do yet, thought of parting it out and getting something else. Whatever I do is going to take from the funds I need to build a garage so I have a decent place to do this stuff:ermm:

[Pappy]

march down to the honda or yamaha shop and snag a new quad. sell off your old parts and ride on.

when the wheels fall off the new one ..repeat:macho

[JOEX]

Originally posted by Pappy
march down to the honda or yamaha shop and snag a new quad. sell off your old parts and ride on.

when the wheels fall off the new one ..repeat:macho
If you make the payments:devil:

[Pappy]

Originally posted by JOEX
If you make the payments:devil:

hey buddy, i just create problems i dont fix them:D

[chad400ex]

Well Joe, I've been wondering about what you'd do since that thing snapped (for those that don't know me...I was there when it happened).

If it were me, I'd do a band-aid fix and get rid of the quad. I'd probably trade the sucker in at a dealer so that when someone buys it and it breaks again...they'll come back to the dealer, not to me. Bottom line is how much are you willing to spend to do it, and how much would you have to spend to upgrade to a slightly used 450R (or something else). You've got about $1000 worth of used tires and wheels sitting around too... Maybe do a little liquidation to get things back up to snuff. That porn collection ought to be worth something too!!! J/K :p

I know it's not wise to finance a toy, but with the trade in value of your current ride, the payments would be very small. You could still do the garage and when you get caught up from that, start doing accelerated payments on the new quad and pay that puppy off. Just my $0.02 :cool:

[JOEX]

Originally posted by chad400ex
Well Joe, I've been wondering about what you'd do since that thing snapped (for those that don't know me...I was there when it happened).

If it were me, I'd do a band-aid fix and get rid of the quad. I'd probably trade the sucker in at a dealer so that when someone buys it and it breaks again...they'll come back to the dealer, not to me. Bottom line is how much are you willing to spend to do it, and how much would you have to spend to upgrade to a slightly used 450R (or something else). You've got about $1000 worth of used tires and wheels sitting around too... Maybe do a little liquidation to get things back up to snuff. That porn collection ought to be worth something too!!! J/K :p

I know it's not wise to finance a toy, but with the trade in value of your current ride, the payments would be very small. You could still do the garage and when you get caught up from that, start doing accelerated payments on the new quad and pay that puppy off. Just my $0.02 :cool:
I doubt the trade in value would be much, the motor may be good except for the shifter shaft but the cosmetics are way low.

Also, I don't think dealers are too keen on accepting trade ins that have modifications, i'd be suprised to get $1500-2000 as a trade in:ermm: But I agree with you about letting the dealer deal with the problems;)

I really don't want a newer quad, well I do but I don't want the payment:p Those DS's were looking good at St. A's:devil:

The garage has to be done soon because I don't have room to do anything related to quads and remodeling at the same time:ermm:

[chad400ex]

Well...let us know what you decide to do. If you need help framing the garage (or with structural design work for your permit) you know who to call :cool:

[QuadJunkies]

Joe, did you ever get Er fixed??!!
I dont know what I would do if I didnt have my quad, its my solitude from the weeks stress!! :scary:

[INFANTRY RACING]

i haven't had a ex in a few years but i could have sworn the shift shaft slid out through the clutch cover side and there would be no reasong to split the cases.

[Chino]

Originally posted by INFANTRY RACING
i haven't had a ex in a few years but i could have sworn the shift shaft slid out through the clutch cover side and there would be no reasong to split the cases.


and you would be wrong

[mikeboone]

Originally posted by Chino
and you would be wrong

lol

The cases must be split to remove the shift shaft as it has two forks on the back.

Joex; did you get setup with new parts for bottom? New shift forks arent very expensive.

[JOEX]

It's almost back together. Installed the cam put the clutch cover on today. Just have to put the head on, hook up the electrical and exhaust. And all the other little stuff after that.:)

Sure hope it works:ermm:

[QuadJunkies]

Originally posted by mikeboone
lol

The cases must be split to remove the shift shaft as it has two forks on the back.

Joex; did you get setup with new parts for bottom? New shift forks arent very expensive. gears arent cheap either! :scary:

[JOEX]

Started it up today! Fired up right after I remembered to turn the kill switch on. The dual exhaust sounds awsome:cool: A few odds and ends to finish up then a trip to Sandlake Wednesday to break it in:)