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View Full Version : HOW TO relocate 400ex battery



j450rking
01-14-2007, 01:47 PM
here is how you relocate your battery to your air box in a 400ex (might work in other models)
1. you want to remove your air box from your atv

2. remove your air filter

3. draw a line like in picture 1,2,3 and 4

4.then use a dremel or cut off wheel to cut out the plastic peace

5. use dremel or file to smooth edges


6. place original battery box in place to check cut then remove when happy with your cut

7. take a peace of plastic or sheet metal and place it like in picture 1 and 2

8. then cut air box in 2 places like in picture 2 make shoure you don't cut the slits to long or wide or it wont hold as well

9. then place the battery box in place then place a small peace of wood under the left front edge of the battery box then remove battery box and drill 2 holls in wood and air box and bolt the peace of wood in place (you could use somthing else other than a peace of wood if you wanted to but that is what i had at hand)

10. place battery box in place (for the last time) drill some holes in air box and battery box and make shoure that thay line up

11. bolt or rivet battery box in to air box

12. drill hole in battery box were it will make contact with the peace of wood (from the inside)screw the battery box to the peace of wood

13.then drill a hole in the bottom of the battery box in the rear left corner and drill a hole in the peace of plastic or sheet metal and bolt or rivet the peace of plastic or sheet metal to the battery
box

14.your almost done seal the cracks around the battery box with red silicone cawk or rvt i think thats what it's called you can get it at napa or any auto parts store and let dry over night

15. then the next day paint over the cawk if you want to

16. place battery in the battery box and use the original battery strap to secure the battery by drilling a hole in the rear air box saport and bolt it in and srew the bottom of the strap to the peace of wood and your done


(warning) you may have to make your battery cables longer and it is also harder to remove and install the air filter with the battery box installed i used a K&N air filter witch might be shorter the the original so the original air filter might not work

pictures coming soon

j450rking
01-14-2007, 02:33 PM
picture 1

j450rking
01-14-2007, 02:43 PM
picture 3

j450rking
01-14-2007, 02:45 PM
picture 4

j450rking
01-14-2007, 02:59 PM
picture 2

j450rking
01-14-2007, 03:03 PM
i am sorry i don't have pics of the air box before the mod so i can't show you were to actualy cut but you should get the idea

j450rking
01-14-2007, 03:05 PM
finished producted

j450rking
01-14-2007, 03:09 PM
2

zdowell
01-15-2007, 10:27 AM
Can you take some pictures of the side of the box. Are you still able to use your air box lid?

j450rking
01-15-2007, 04:55 PM
i am pretty positive that you can use the lid i will check tomorow


i'll take some pics and post them on some time tomight

BOOSTED2V
01-16-2007, 12:11 PM
Looks good but looks complicated... Maybe you can post some better pics than these please. I want to see the inside of the airbox without the battery and a pic of the air box on the quad from the bottom rear so I can get a better idea of what you did. Thanks... -chad-

j450rking
01-16-2007, 09:09 PM
well i will give you some better pics but i can't take one of it on the wheeler b/c i am in mid build and i don't even have the frame right now

j450rking
01-16-2007, 09:17 PM
it's not that complicated it's just hard to exsplan here is some pics of the side of the air box like zdowell asked for

j450rking
01-16-2007, 09:19 PM
other side

j450rking
01-16-2007, 09:59 PM
here is some pics

bigballz400
03-03-2007, 01:54 PM
lol shakes head back adn forth

j450rking
03-03-2007, 05:33 PM
Originally posted by bigballz400
lol shakes head back adn forth


why whats wrong with saving $100 and haveing a nice little project

Toadz400
03-03-2007, 05:38 PM
Originally posted by j450rking
why whats wrong with saving $100 and haveing a nice little project

He's just mad because he didn't think of it first.

I've seen this done before and it's a good idea, as long as you are able to keep that battery nice and clean. Shouldn't be too hard compared to the stock location...

j450rking
03-03-2007, 05:59 PM
well it won't get dirty at all with my modded lid. i cut the lid with a dremel and used a hot glue gun to glue in a peace of my old outerwear

sportrax stu
03-20-2007, 12:14 PM
what is the benefit of doin this? just out of curiosity

j450rking
03-20-2007, 09:06 PM
it will make it easyer to take off and put on your rear plastic it will put the wheight of the battery in the center it will protect the battery more and keep it clean and it will make you wheeler lokk better but DO NOT do this mod if you have a long travle linkcage

another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

Justin#38
03-20-2007, 09:26 PM
i thought this was pretty damn cool nice job man!!!

j450rking
03-20-2007, 09:32 PM
thanks

sportrax stu
03-25-2007, 02:56 PM
another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

hey i can get one, do u have any info?!

jeremy_283
03-31-2007, 11:07 PM
that plastic mount is bound to break

j450rking
04-01-2007, 06:35 AM
that may be i have't used it yet so i don't know but if it dose break then i will just renforce it

400ex_BG_Rider
04-03-2007, 01:20 PM
Originally posted by j450rking
it will make it easyer to take off and put on your rear plastic it will put the wheight of the battery in the center it will protect the battery more and keep it clean and it will make you wheeler lokk better but DO NOT do this mod if you have a long travle linkcage

another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

Taking the plastic off and on is very easy, I don't see what's the problem with that. Putting the battery in the airbox pushes the center of gravity too much to the right side coze the battery and the exhaust balance each other out. My battery is packed in rubber very good so it will take a lot to make it dirty. So I think this is kinda pointless mod!

j450rking
04-03-2007, 07:30 PM
well i think it makes it look cool and i have an aftermarket pipe so it's not that bad

imo i think it is a good mod and i had nothing to do so i went to town on it

j450rking
04-03-2007, 07:37 PM
and that just your apinion and the 4lb battery is't going to make it off balence that much

Toadz400
04-03-2007, 11:04 PM
Originally posted by 400ex_BG_Rider
Taking the plastic off and on is very easy, I don't see what's the problem with that. Putting the battery in the airbox pushes the center of gravity too much to the right side coze the battery and the exhaust balance each other out. My battery is packed in rubber very good so it will take a lot to make it dirty. So I think this is kinda pointless mod!

I think it's a very good mod as I along with a lot of other people that have owned 400EX's have problems removing and putting the rear plastics back on because of the location of the battery. As for the center of gravity issue I doubt it makes that big of a difference that you could tell while jumping or cornering.

ninja
04-04-2007, 12:03 AM
Taking off and putting on rear fenders is the easiest thing to do on this quad. Not reason to relocate battery IMHO. It would be more for looks and keeping battery clean.

j450rking
04-04-2007, 06:59 AM
well i did it b/c i wanted it to be diferent and i don't think i'v ever seen it done in a stock box and it can't be that bad if all the aluminum air boxs relocate it in there

DF400ex
04-04-2007, 12:44 PM
my rear fender is a PITA to put on and remove, that's why I did it. I did mine slightly different though. I bent up a piece of aluminum to support the bottom, sides, and rear. That's what I have attached to the frame to support the weight of the battery. If anyone wants pics I can get some.

Bottom line, you have to reinforce your mounts so the weight of the battery doesn't crack your airbox.

400EXTRA
04-05-2007, 03:01 PM
never even would have thought of that

j450rking
04-05-2007, 09:02 PM
Originally posted by 400EXTRA
never even would have thought of that


thought of what?

hontr35
04-07-2007, 10:23 PM
Hey more power to ya! That's how good ideas get off the ground, guys like you just go ahead and do it and hey if it works great, if it don't just start over. Live and learn. I like it, beats my 138 buck aluminum one (for price anyway).

00 400ex
Tons of stuff

j450rking
04-08-2007, 05:51 AM
i like it but i know i need to make it stronger and it dose't look as nice as the aluminum ones but it will work


and i'll most likely get an aluminum one from insane performance anyway lol

maxitout77
04-09-2007, 06:16 AM
I think I'm going to have to try this on my 250EX :) My Battery gets wet and crappy all the time...

j450rking
04-09-2007, 06:29 AM
go for it just remember to make the mounts stronger:macho

j450rking
04-14-2007, 09:36 PM
hey guys i got a um airbox for cheap so my modded stock airbox is up for sale! $15+shipping it dose't have the intake tube b/c i had to use it with my um air box

REDRIDDER
05-04-2007, 02:21 PM
isn't putting a battery in the air box taken up valuable air space?That's why you drill holes,better filter,remove lid to gain more air right,imo its alright were it is,unless someone convinces me different,what are the advantages of this if any?

DF400ex
05-04-2007, 07:05 PM
I have plenty of space for air to flow and I have seen no power decrease. It's just easier to put the plastics on and off.

j450rking
05-04-2007, 08:45 PM
pretty much just easyer to put the plastic on and off and makes it look better. but it is harder to take the air filter in and out

honda6490
05-23-2007, 07:38 PM
Originally posted by j450rking
hey guys i got a um airbox for cheap so my modded stock airbox is up for sale! $15+shipping it dose't have the intake tube b/c i had to use it with my um air box

Send me a pic of that modded airbox you have for sale, I might be interested.

j450rking
05-24-2007, 07:18 PM
it's the same airbox from this post

pics on the first page and it comes with the modded lid i glued a old outerwear in the lid after i cut a large hole in it

airman88
10-28-2007, 01:18 PM
i decided to try this when i did my complete rebuiild on mine heres some pics

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4774.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4775.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4776.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4773.jpg

i have the rubber that goes over the battery to keep it from getting all oily but this was actually a pretty easy mod took about and hour or so...

Ruby Soho
12-14-2007, 05:05 PM
i did this aswell.. heres a few pictures of mine

Ruby Soho
12-14-2007, 05:06 PM
#2

Ruby Soho
12-14-2007, 05:07 PM
last one

j450rking
12-14-2007, 09:41 PM
looks alot stronger then mine:D hey ruby were do you live in ct?

Ruby Soho
12-15-2007, 09:38 AM
i live in newtown.

have you ever been to walden mx?

j450rking
12-15-2007, 05:07 PM
no my bro lives in farmington

400exMO
12-16-2007, 05:17 PM
man that's quite a bit of work. I just mounted all my stuff on my front frame rail. Added alittle weight to the front end for me.

airman88
12-18-2007, 02:03 PM
i did this mod and it turned out great heres some pics

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4776.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4775.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4774.jpg

Punkmaster Flex
10-17-2008, 04:50 PM
I love your zombie fenders. :o

RATPACK Z400
12-06-2008, 10:34 AM
I didn,t relocate battery but covered it with fender from front it looked factory when done easy to figure out if you have front fender that had been cut or broke laying around and it keeps battery clean wish I had pics just try it looks so sweet and when you do show pics .

v0lcom13sn0w
04-23-2009, 03:27 PM
well i have mixed feelings about putting the battery in the airbox... what i did is basically exactly what you said... it looked clean and everything but then when i went out and rode on the dunes i went over a HUGE razor back and bottomed out my bike and my swinger actually bottomed out so bad that it hit the airbox right where the battery was and basically broke the airbox in half and broke all but the top of the battery off where the terminals were... i didnt realize this until i was out in the middle of nowhere, turned my bike off, and it wouldnt start, i walk to the back of my bike and look under and the battery was no where to be found, i had to wait an hour till someone rode by which i flagged them down and they towed me back to camp... i dont know... my recommendation would be to get an aluminum air box and do this or just dont do it at all.

Young_Gun1
04-23-2009, 07:55 PM
this isn't really intended to be a mod for someone that does serious jumping cause the box is made that way to clear the swingarm under full compression

v0lcom13sn0w
04-24-2009, 11:45 AM
Originally posted by Young_Gun1
this isn't really intended to be a mod for someone that does serious jumping cause the box is made that way to clear the swingarm under full compression

exactly... i wish i woulda realized that before... ha

stuntin andy
10-27-2009, 08:36 AM
i have to put a 250x frame on my 300ex and it dosent have the bracket so im going to try this and fix the little problem with the shock >=)

j450rking
10-27-2009, 04:38 PM
i would definetly not do this mod if you do any serious jumping, my ex "when i had it" was for he most part a trail quad so i didn't have to worry about it and i actualy never used the modded airbox because i got my hands on a um one before my build was over and the um one was vary nice and didn't hand as much as the modded one did.

sorry v0lcom13sn0w that your battery got smashed.

and in all honesty these days if i had a ex again i would most likely relocate the battery to the front or even try to put it were the airbox snorkel runs through.

stuntin andy
10-27-2009, 08:21 PM
i was looking at it.... im gohna mount it on my grab bar >=)...ill let you know how it works if i can remember ...ive got it all planed out

j450rking
10-28-2009, 07:17 AM
If your talking about the front bumper then I wouldn't do that as that spot takes alot of shock from jumping and wheelies. I was thinking closer to the cross bar in front of the oil cooler.

Mustangous
10-28-2009, 07:23 AM
anyone with the um racing aluminum box have any issues with contacting the rear brake caliber. Thats why the indent is in the factory one... I notices some aluminum boxes had the battery mounted long ways in the box instead of side ways like the um. the ones mounted long ways have an indent made in the box for the caliber for the case if the suspension is compressed all the way it wont damage anything. I really like the um one. I may just build one out of aluminum and see what happens.

j450rking
10-28-2009, 02:22 PM
i had no problum and i had a blown rear shock and a 250r rear caliper which is just a mid larger so if anybody would hit i would have.

on a side not the 250r caliper was awsome as they are a twin piston and all you need to mount it is the 250r brake stay.