Let it BEGIN......Extreme Makeover

[lawdog800]

The time has come to begin the long journey of a complete makeover. We are starting with a 2000 400EX that we picked up this past fall. A specimen that has been ridden hard and put away wet. It is time to transform it from a once neglected beast to a (hopefully) piece of mechanical beauty and power...........A plan which includes a gusseted and powder coated frame, swing arm, a-arms if possible, and rims all in satin black. We have new Honda factory red plastic, a new seat, ASV levers, 450 shocks for front and rear (if the rear works), A full Pro Circuit exhaust is on its way. It will get some engine mods (Unknown what it is now so dont know what it will be..) It will get new Maxxus Razr tires, graphics are undecided at this time... I will update the post as time goes and with new pics as time goes.

So it begins......................

It all started as this...( yes that picture was taken today, (01-09-2008) in sunny Metro Detroit (Where is the snow..this sucks)

[lawdog800]

During disassembly to here, I have encountered several mystery fasteners, more parts to replace for correct fasteners.......

As of now.....

[hornetgod13]

Looks like you have a lot of work to do. I hope your pockets are deep. Good Luck. Keep us posted on your progress.

[klutch]

Cant wait to see the outcome =] I love rebuild threads

[lawdog800]

Deep Pockets is true.. Ive bought alot of pieces all ready and it doesn't seem like much until you add it up....EEEEKKK..lolOh well, His sister got the Brand New Arctic Cat DVX 400, so his will still be cheaper and he likes it better...

[hornetgod13]

I've got $3,250 in my 400ex and I haven't even touched the suspension yet. I'm not sure the Wife will take much more spending on my quad. She calls it the "Money Pit".

[lawdog800]

Hornetgod,
We saw your quad in the post, and I must say I hope ours looks even close to that good, That is awesome looking. I personally would like some shiney stuff, but the black will look good too. We definantly love the look of the new KTMs with the all black chasses and wheels......... As for suspension, all we PLAN on is just the 450 shocks which we already have...

[lawdog800]

New goodies........

[slim_shawn]

all 3 450r shocks will work, the rear has to be turned so that the resi faces the back though. then you can't run the snorkel. so just block off the hole where the snorkel goes in the airbox and get a k&n powerlid. but it makes a much better ride in the back

[hornetgod13]

Originally posted by lawdog800
Hornetgod,
We saw your quad in the post, and I must say I hope ours looks even close to that good, That is awesome looking. I personally would like some shiney stuff, but the black will look good too. We definantly love the look of the new KTMs with the all black chasses and wheels......... As for suspension, all we PLAN on is just the 450 shocks which we already have...

Thanks for the compliment. I will eventually get to the suspension once the Wife is in a better mood. I had 450R shocks on my quad and I didn't like them. At the time I didn't have the money to revalve/respring them. I turned around and sold them and went back to my stockers. 450R shocks are pretty stiff. They handle big jumps with ease but, the little stuff is painful to ride over quickly. When I upgrade the suspension, I plan on spending $1500 to $2,000 to get a nice ride that suits my riding style. For now I'm working on the motor (Hi-comp piston, Hotcam, HD Timing Chain, HD EBC Clutch). It's all torn down right now. I'm just waiting on the piston to arrive.

[lawdog800]

New Gusset Kit from BARE Performance.....e-bay purchase.......

Also We got to experience the DREADED Swing arm bolt............. It is locked solid. I drilled it out to just under 1/2 (last drill size before 1/2) then started with half inch and snapped drill off in hole...........LUCKILY it backed out with vice grips.........

[tman12345]

can't wait to see it finished, good luck.

[lawdog800]

Finally got the swing arm bolt drilled out enough to break it and drive it out and get the engine and swing arm removed..here is a pic of part of the bolt with a sleeve still rusted solid to it....

[lawdog800]

We also found MORE good news today.....The bearing carrier that was put in this quad this spring, before we got it (we only rode it once after getting it) the bearings are JUNK..HMMMM Obviously never bothered to use that little zirk fitting......

[lawdog800]

We also got the 450R shocks mocked up. I knocked the weld nuts out and ground a relief in the frame mount, like the 450's are, rather than grinding on the shocks.............

Next on the list is start cleaning and get the gusset kit welded in...and tear down the engine and see what IT needs.....

[lawdog800]

And Finally..........

[hornetgod13]

Great job on the swingarm bolt. Antisieze the crap out of the one you put back in.

My air scoops are going to look nice on your quad. You'll like how they look and fit once you got them installed.

If you have a little money left over I'd revalve and respring those 450R shocks before you ride. They are wicked stiff for trail riding. I tried every imaginable combonation of stock adjustments and still wasn't happy. They are great for jumping but, will beat you to death on fast trail riding.

[08400EX]

Originally posted by hornetgod13
If you have a little money left over I'd revalve and respring those 450R shocks before you ride. They are wicked stiff for trail riding. I tried every imaginable combonation of stock adjustments and still wasn't happy. They are great for jumping but, will beat you to death on fast trail riding.

Ditto! I put the 450R shocks on my 08 and never even rode it on the trails with the "tweaked" stock 08 shocks. For my ride this weekend I decided to put the stockers back on so I could pack the 450Rs to send them off to C&D. WOW, the ride on the rough trails was amazing. I didn't get a chance at this locale for big air, but overall I was having second thoughts about using the 450R shocks at all. It is weird because I was not happy with the front shocks on my 05 which is why I got the new take off 450Rs to have ready for the 08.

Gonna ride a few more places before I make up my mind to revalve/spring the 450Rs. They may hit Ebay :-) Of course all it will take is that one hard hit/landing that will change my mind!!

[Ruby Soho]

looking good!

my pivot bolt looked similar, but alot worse, we cut it off between the arms of the swinger and the frame, and the bolt was stuck in the collars we later for the heck of it tried to punch it out and eventually got it out of the collar (a small section) and it was so bad there was no possible way it would have came out as one peice

[lawdog800]

Our Pro Circuit exhaust arrived today, and we decided on a color and graphics for the quad.... Color is still going to be all satin black frame, wheels a-arms and swing arm,. We have a set of new scoops coming from Hornetgod13 which are black, and we decided today to do the engine also in black with polished stainless fasteners in the engine. We also found a old CEET graphics kit we liked and actually shows available in stock.

[hornetgod13]

I like that graphics kit. I can't wait to see my air scoops on your quad. I threw a little bonus item in your package. You might use it on your quad. It's nothing big.
I've done all the work on my quad too. My Son is 13 now and he likes to help occasionally. You are always saying "We this" and We that". Who's helping you?

[lawdog800]

The quad was actually gotten for my step son. I had bought dirt bikes over the past summer for off season training for their Sno-Cross racing (Step-son and step-daughter). She liked her CR85, but he wasn't doing so well on his CR125. Both bikes were probably the wrong style to learn on, but figured with the power of the snowmobiles they could handle it. Anyway he kept crashing his 125 and didnt want to ride it anymore. He jumped on a friends 400ex and was jumping it 15+ feet (distance) within a few laps around the yard we ride in. She got on the quad and was jumping it right away as well where she was only jumping maybe 2-3 feet on her bike. SO I made the decision to get rid of the bikes and get the quads. She got a new Arctic cat DVX400 and he got this one.

Since they have been spoiled with racing sleds and having me be a mechanic and they just ride, I have the last couple years making them help to learn. So I make him come out and help on the quad and let him make some of the color choices. He likes the choices but he is more conservative and I buy to much trying to make it to nice...He would be happy if it just ran.......

Im attaching a ew pics of our "OTHER" primary sport...First one is first race of year with all new look. We stripped both seds down and powder coated both chassis and rear suspensions from raw aluminum to black...

[lawdog800]

Pic of him from last season......He is the black sled.....

[lawdog800]

This is his sister who is now 13.....12 in this pic.....

[lawdog800]

Here is a pic of his sister in her "Model" pose this summer...remember she is only 13.......

[lawdog800]

This is our race transporter...2006 Dodge ram 3500 Mega-Cab and 2004 Featherlite 40ft trailer.....Graphics were done by my sister-in law at Majik Graphics in Clinton Twp., MI

[lawdog800]

And her quad..........

[lawdog800]

The 3 yr old ready to ROCK........Yes 2 red headed girls..Im in BIG trouble,.......

[lawdog800]

And finally......She would like to get a deal modeling for some of the MX gear catalogs.....

[hornetgod13]

I think it's great when you can get your kids involved in fixing their rides and not just breaking them.
My Son and I have built him a CRF100F (CRF120F now) that's been modded pretty heavily. We've done over 30 things to improve the looks or performance and he loves it. Here's a link to all the picutres and mods. http://www.thumpertalk.com/forum/garage.php?do=viewvehicle&vid=10281
When he out grows it, I'm keeping it as a pit bike for myself. I love riding it too.
I hope your kids know how lucky they are to have all those toys. "Peer Pressure Racing" I like that name! I bet your daughter could model for Dennis Kirk or Rockymoutain ATV. Send them some of her pictures.

[00.400ex#55]

wow some ones spoiled. hope they relise how lucky they are.

oh and nice truck btw. have a 1500 5.7L mega cab myself.

[lawdog800]

We got our new scoops today from Hornetgod13...thanks..they will look great

[f150mann]

wanna adopt me? :D

[blue_ex_rider]

That is what I am saying i will even let you claim me on your taxes haha. those are some lucky kids hope the bike turns out great.

[lawdog800]

I'll sum it up in 1 word........SPONSORS...............Without our sponsors, there would be no racing.....

[Myrkk]

Man that’s good stuff. Keep it coming.

[limetimeracerII]

Originally posted by lawdog800
The 3 yr old ready to ROCK........Yes 2 red headed girls..Im in BIG trouble,.......
I feel you on that one.:)

[lawdog800]

Pics of the scoops from Hornetgod13....(his pic)

[lawdog800]

pics of the exhaust we got...

[lawdog800]

We also bought a Yamaha R6 tail/brake light from e-bay that has arrived for this mod.......... R6 Brake light How to. (http://www.exriders.com/vbb/showthread.php?threadid=307005)

[Mercedes]

Hey hornetgod13 do you think I could get air scoops like that. Give me a price I would love to buy some from you.

[hornetgod13]

Originally posted by Mercedes
Hey hornetgod13 do you think I could get air scoops like that. Give me a price I would love to buy some from you.

You can buy a set from www.metalmasterfabrication.com They sell the black powder coated or polished versions right on Ebay too. They sell new for $45.95 before shipping off their website. Lawdog800 got these for $30.00 shipped. It's to great see they are going to mounted a awesome looking quad! I added the Honda Racing stickers myself. They bolt right on and the fact that there are steel rather than aluminum or tin makes them even more durable. If you look at the picture you can see where I rounded out an area on the bottom of the scoops to accomidate the rezzies on the 450R shocks I ran for a little while. They work great too with 400EX shocks installed too. I wish I could have kept them but, they simply won't fit with the ishocks suspension kit I just installed. I've got different scoops on order now and should have them installed in a week or so.

[lawdog800]

Here is the nerf bars and skid plate we bought from the classifieds here.....AC Blackline Pro Pegs

[hornetgod13]

If you call AC Racing they sell black, red and, silver nets. I have those same nerfs with black nets.

[coryatver]

Originally posted by lawdog800
Here is the nerf bars and skid plate we bought from the classifieds here.....AC Blackline Pro Pegs

those are not blackline. blackline is painted black

[trx400EXtreme]

Originally posted by coryatver
those are not blackline. blackline is painted black no their not. blackline just means they have removable pegs and nets all the way back. if you check there site they have the blacklines in black or aluminum.

[coryatver]

thanks for setting me straight

[lawdog800]

They were also bought used and the previous owner, blinkjs, had the Powder Coated Black chrome........I am having then re-done in black

[440challenger]

Nice build. Hope the powder coat holds up. the black powder coating that comes factory on them chips off in hunks. Im thinkign maybe a rhino liner textured finish would hold up better

[hornetgod13]

Those AC Blackline ProPegs can be difficult to install (lining up) Hopefully the previous owner bent them well enough so they bolt up easy for you. Mine took hours of bending, prying, and cursing to get them to line up and bolt on. Once they are on they are rock solid. Mine have tumbled down a couple hills and only have a few scratches in the original black powder coating.

[my88r]

Originally posted by hornetgod13
Those AC Blackline ProPegs can be difficult to install (lining up) Hopefully the previous owner bent them well enough so they bolt up easy for you. Mine took hours of bending, prying, and cursing to get them to line up and bolt on. Once they are on they are rock solid. Mine have tumbled down a couple hills and only have a few scratches in the original black powder coating.

if you get ac stuff that's fits your lucky.:p always bending and drilling with ac.:mad:

[lawdog800]

Well, Maybe I will be lucky since they have been on a quad before............

I can't hardly see to type..I ended up in the ER last night.. My friend welded the gusset kit into the frame, and even though I wasn't watching, I was nearby and ended up with flash burn on my face but worst is my eyes too. ER Doc put bunch of stuff in my eyes so they are now dialated and I cant see much but blur
My face looks funny since it is only red on the right side.....DOH!!!!!!

[quad2xtreme]

If you really want to make a huge improvement in the 400ex, switch to at least 2005 450r setup in the front.

Thanks to malibuj, I've converted both of my 400ex trail bikes. I just finished on the 2nd. I can instantly stop the front wheels on concrete now. I was playing around doing stoppies in the driveway.

What you need for the front conversion...

2005 450r spindles
2005 450r hubs
2004-2008 brake calipers and pads
2005-2008 tie-rods (about an inch or so longer than the 400ex tie-rods). The 2004 may work too. I didn't check the part numbers on that.

You will re-use the stock tie-rod ends, and the brake rotors.

If you want to make the setup even better, get the front master cylinder from a 450r too. The brake lever on the 450r is adjustable so you can easily get it closer to the bars for smaller hands.

You can switch the rear too. You just need:

2005-2008 brake caliper and pads
rear brake stay (holder)
450r rear brake rotor
rear brake rotor hub

I believe the brake line from a 450r would work better too. I think it is about 1-2 inches shorter than the 400ex line.

You can reuse the seals from the 400ex setup if necessary. I bought all my stuff used from ebay and it already had the seals installed.

You can use a 450r master cylinder too. The only thing you have to do is drill out the threads so the bolt will go through into the subframe nuts on the 400ex.

/Jon

[lawdog800]

do the 450 spindles bolt up to the 400ex a-arms, and the 450 brake hub works on a 400ex axle????

[quad2xtreme]

The spindles bolt right up to stock a-arms (that is what I use on both trail quads). The rotor hub for a 450r works with the stock 400ex axle.

The major advantage for switch the fronts is dual caliper brakes with more pad surface. The brakes are much easier to change to on a 450r. You just loosen one pin that holds the brake pads in place. You loosen the lower bolt that holds the caliper to the spindle and then remove the upper one. You just rotate the caliper to gain access. You easily spread the old brakes apart by inserting a screw drive and twisting it. I put a wrench in there and then do this one more time and the brake plungers will be all the way in. Drop your new brakes in place. Replace the pin (torque to 12-13 ft lbs), twist the caliper back into position. Put the upper bolt back in and torque to 22 ft/lbs and then torque the lower bolt.

The advantage to the rear is the rear brake rotor is about an inch smaller in diameter versus a 400ex rotor. This allows more ground clearance especially if you are going to run this setup on a track. I like it in the trails too. It doesn't buy me any more ground clearance but it does create more space before the skidplate hits it.

Also, goto Riva Yamaha and check out the prices on 450r parts versus 400ex parts. You can get rotors, calipers, master cylinder cheaper on the 450r. I just use Riva for looking up part numbers. I buy most of my Honda parts from Service Honda.

[quad2xtreme]

definitely make sure you price out new parts before shopping on ebay. I find used stuff on ebay that is more expensive all the time than Service Honda prices. The other thing to consider is buying parts one at a time on ebay versus all at once from Service Honda. You pay shipping once from Service Honda. Each ebay part can be like $10 shipping. It adds up quickly.

[lawdog800]

Very true about e-bay...I have watched several things go high there....Funy when I watched an item sell for $17.00 higher than the same seller had another identical one listed for buy it now.... Got to do research....

[lawdog800]

We got our graphics kit in today, and now need to get frame blasted and PCed.....problem is engine parts came in at dealer and $$$ a little short for a bit..need to go back to work and get some overtime.....:D

Also I disovered a problem today with the chasis skid plate and the gusset kit....Link (http://www.exriders.com/vbb/showthread.php?s=&threadid=334038)

[atvhonda-rider]

Hey man, lovin the input sounds like a great bike, and what lucky kids! Although im sure they appreciate growing up in the racing family. Hope your eyes healed up well ive had that before from welding its no fun. I'll have to post pics on my build when im done of before and after, although its taking longer than i'd like, im only 17 and trying to build your dream race quad on a barely part time budget sucks!

[lawdog800]

Here are a couple pics from last weekend racing in Cadillac, MI. We even had Yamaha factory Pro Yuji Nakazawa show up and race. He had a rough weekend though..his first race his throttle lever snapped, his second race he pulled a holeshot and put a half a lap on all the Local Pro's, in the 3rd race the pack went into the second corner and the guy on the inside went wide and Yuji got pushed off thetrack. He was chaging back but crashed. He did not race the final, dont know if he got hurt, broke the sled or just didnt want to take the $$ from the locals..Yamaha had a full crew on site including engineers..Pretty awesome all in matching jackets and such,.....

This is an updated pic of our DVX 400

[lawdog800]

Another view

[lawdog800]

The boy bustin the triple.......

[lawdog800]

The daughter running the corner with the Yamaha transporter in back ground

[lawdog800]

Finally got some $$$ and sent some parts off to Pappy to work on.....Sno-Cross budget is thin, so quad money is suffering since My play money is going into Sno-X fund....Right now Pappy has the center engine cases and the brake calipers, next will probably be cylinder and head for Moly coat, then machining, ect........Will post more pics when I get some more..

[04-honda-400ex]

So how's the 400ex coming along? I'd love to see some more pix on you progress so far.

[quad2xtreme]

Update on using the 2005 spindles and hubs...

I don't know the exact angle of camber but it is definitely angled inward more than with the 400ex spindles and hubs.

We went to Hatfield McCoy for a weekend of very fast trail riding...often max'd out in 4th and 5th gears. It was a bit twitchy compared to stock but it didn't feel unsafe to me.

As far as turning goes, nothing turns tighter than this. It turns sharper than a 300ex in the trails. I can tell you there is about zero need for reverse as you can spin the bike around on a dime.

I will take a picture and post so others can get an idea of the camber. I am not sure if it will cause the front tires to wear funny or not. I am thinking about getting one of the electronic degree tools so I can tell you exactly how many degrees inward the top of the tire is.

I am definitely happy with the mod but probably wouldn't do it for the track. Well, I would but I would get some after-market upper a-arms that allowed me to reset the camber.

/Jon

[lawdog800]

The build has hit a cash wall. I have been on sick leave since the 1st of the year from an ankle injury, so no OverTime and Snowmobile racing has been eating all my extra, so the quad got pushed into the shed until later. I am slowly working on getting parts coated and gathering other parts slowly, but Sno-X comes first.

I need to sell my stock exhaust and stock front shocks......

[lawdog800]

The Frame, sub-frame, swing arm, rear axle, brake hub, nerf bars,steering post, rims, rear caliper bracket, DG Headlight Guard, body brackets, motor mounts and nerf bar mounts all went to the local strippers today : Modern Stripping Technologies.
He said they should be done soon, and will then go to the Powder Coaters across the street from the strippers to all be done satin black. I got a great price quoted since I am a repeat customer there, They did our Snowmobile chassis as well...........cant wait to get it back, so it can sit and wait for more money to come in...lol

I will post pics when I get parts back.......

[lawdog800]

Well I got a big batch of parts back today from Powder. I went through a local powder company because of no shipping and got a great price. They are the ones that did my snowmobile chassis' last summer...........

[lawdog800]

Re-coated Nerfs...

[lawdog800]

More

[lawdog800]

Sory for the stuff in backgrounds, I picked it all up with our race trailer for the nice carpeted floor to spread it out on to avoid damage on the 5 mile ride home...

[lawdog800]

Here is the headlight guard. We havent decided if we will us it or not though......Opinions????

[hornetgod13]

It all looks great! I'll take it! Go ahead and get it all boxed up and shipped out to me right away. ;)

Someday I hope to do the same to mine. I envy you.

[lawdog800]

And the small parts......

[lawdog800]

Just an update....Some parts are coming together and more on the way. I am hoping to have the engine cases back in the next day or 2 from Pappy and start assembling the crank and transmission. The rest of the engine is at Pappys getting PCed and Moly Coated.
The front tires are on the wheels waiting, swinger has all new bearings installed and ready to go, I am waiting now for epoxy paint to come in and weather to break to get the a-arms painted. I had to order a new one today due to a torn dust boot and a small crack. I will get more pics of soon.....

[hornetgod13]

You can call AC Racing directly and order new nets for your Pro Pegs. They sell the nets in Grey, Red, or Black. I bought black ones for mine and they cost somewhere in the mid 30's.

I have the original grey ones that came with mine new (still in sealed plastic). You can have them for $20.00 shipped. PM if interested.

[tri5ron]

Originally posted by lawdog800
Here is the headlight guard. We havent decided if we will us it or not though......Opinions????

Gee, I'm not too sure if I like it or not, Hhmmm....
<a href="http://s111.photobucket.com/albums/n148/tri5ron/03%20400ex/?action=view&current=IMG_8249.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/03%20400ex/IMG_8249.jpg" border="0" alt="Photobucket"></a>
Yeah, I guess I do like it!
man!, you've got great taste :D

[zr7cat]

You got that beast done yet, lets see how she looks.

[lawdog800]

Front tires waiting.....

[lawdog800]

Here is a pic of the frame going together in the basement where it is warm........wife only a little mad....lol

[lawdog800]

another with the muffler just mocked up for pics......:D

[lawdog800]

1 more

[BigBore24]

are you gonna put it all together in the basement? if so, will you b able to get it out after its all together:confused: . looks really sweet. i have a dg headlight guard on mine and i love the way it makes it look

[lawdog800]

No on the full basement assembly...It was just nice to go through all the threaded holes with a tap to clean them up, and some basic assembly...It will be going to the garage soon...as soon as either the engine is ready or the a-arms which ever is first....

I just go my engine cases and calipers back from Pappy.....They look great...I will get some pics up later today...

[zr7cat]

Looks awesome, cant wait to see the finished deal.

[lawdog800]

Here are the Engine cases from Pappy after PC....Not a very good picture

[lawdog800]

Here are the Calipers again after Pappy PCed them....

[lawdog800]

Here is a Rear Rim with the New RAZR tires..I threw the hub in it just to show the red hubs and black wheels..

[jbm0121]

are you going to sell your old nerfs?

[hornetgod13]

The parts all look great. Pappy does great work. He's painted a couple things for me too.

Side note: Those air scoops you're selling, don't take anything less than 60 shipped for them or they are taking advantage of you.

[lawdog800]

The old nerfs are pretty much bent upand junk, and I was planning on the scrap yard for them

[lawdog800]

FInally some new pictures for you all to see...This build has taken some time, but is now coming along nicely......This is af NOW..hopefully I can get some more done tomorrow.....

[lawdog800]

more

[lawdog800]

The assembled engine..........

[lawdog800]

More of engine in frame.......nerfs just set in place to make sure I had brackets on correctly..

[lawdog800]

Another one...Please excuse messy garage

[lawdog800]

and yet another..........

[Cool Guy07400EX]

WOW! This quad is going to look great!! I love all the black with little bits of red. great job so far man! :D

[lawdog800]

Thanks..here is another from the rear......

[BigBore24]

looks amazing. i love the all black motor. is that shift lever pink?

[lawdog800]

No it is red anodized, but not very good..It looks pinkish though. It is a Tusk from Rocky Mountain ATV. I got it on close out for $9.99 so I figured I would try it.

[lawdog800]

Here are a couple new ones as of tonight.....

[lawdog800]

Here is another...please again excuse the messy garage.......too busy playing quad to empty and re-organize...

[lawdog800]

And finally........... Thanks again Hornetgod13 for the Scoops

[hornetgod13]

The scoops go perfectly with the powder coated frame.

Take it out and get it dirty!

[eastcoastpro20]

THAT THING IS AMAZING
Just my 2 cents, but i think a carbon fiber quad tech hood would look bad *** on there. But youll have to sacrifice your lights, but in my opionion it would be WELL worth it.

[lawdog800]

Yeah the hood might look good, but we want to keep the lights for trail riding...

Hornetgod13....Cant go get it dirty yet...Still hasnt been started, still waiting on parts......Parts Unlimited really screwed me up..My dealer ordered front wheel bearings for me and they never showed up. They called Parts with the ORDER CONFIRMATION NUMBER, and parts Unlimited said "We have no record of that order"..even though they gave my dealer a confirmation number....Tomorrow Im going out to Magic Racing (http://www.magicracing.com) to get the bearings because Parts only sent one set after all that.........AND the grips never showed up .......Maybe this weekend I can get it fired up, then it can sit until I can get it out and run it to break in the cam and engine..

[bbender85]

lol, too funny!!!! i just did the same thing... bought a well-ridden 400 in need of some TLC, tore 'er down, painted everything black, and made it look nice.

http://www.exriders.com/vbb/showthread.php?s=&threadid=347788

yours looks great!

[red_rider_069]

how much was it for poweder coat.. i dont know if i want one.. i'd like to know though..

[hornetgod13]

Originally posted by lawdog800
Hornetgod13....Cant go get it dirty yet...Still hasnt been started, still waiting on parts......Parts Unlimited really screwed me up..My dealer ordered front wheel bearings for me and they never showed up. They called Parts with the ORDER CONFIRMATION NUMBER, and parts Unlimited said "We have no record of that order"..even though they gave my dealer a confirmation number....

I wish I would have known. I could have sent you a set of 2 month old wheel bearings that I just pulled off my quad. I switched the front bearings over to a DLR conversion.

[lawdog800]

Hornetgod13, those look pretty cool....

Red rider 069...The powder cote was done in stages from different suppliers. I have $250.00 in the chassis and wheels, and another about $400.00 + to Pappy for the engine and calipers including Moly Cote on some items... Expensive but looks good........Besides a Retired Sgt. told me ....."It costs only nickles more to go first class...."

[lawdog800]

Here are some new engine plugs..I just posted a new thread to see if there is any interest in them as a purchase..

[hornetgod13]

Are you going use the silver nets?

The shifter looks pink and doesn't really go with the rest of your paint scheme.

[Pappy]

looking good!

[lawdog800]

Yup gonna use the silver nets..AC NEVER called me back about ordering red ones after 7 calls and 3 messages left for them...What customer service.....I agree on the lever, dont know what Im gonna do with it yet.....stock one was junk, so????

[bbender85]

so am i gonna see this on the dunes this summer?

[2001400ex]

Rebuild looks familiar! I wonder why! (was/am in process)

Can you please send me a PM with exact steps on how you removed your swingarm bolt? I would really appreciate it!

Thanks, and great work!

[lawdog800]

Dunes????? never know...I haven't been to Silver Lake in over 10 yrs I'll bet, maybe???Ill have to break out the old truck flags and make some mounts for the truck.......

Pics today with all the new plastics on.....I like the somple clean look, but probably tomorrow we will get the graphics on...hopefully....didn't get it running today.......was out WAAAAAAAAYYYYYYYYYY too late at a local motorcycle club party, then had to do the in-laws this afternoon for mother-in-laws b-day...

[lawdog800]

front...

[lawdog800]

It just looks so much better outside as compared to in the messy garage...next project is to fix garage....lol

[lawdog800]

finally from the rear..... I still have to finish wiring in the new tail/brake light which is from a Yamaha R6, I found today that the brake lever bolt was a standard bolt, not the nice collared bolt, and it also was a standard, not a 6mm metric thread as well....I dont know if the hole will hold after cleaning up with a 6mm tap, or I have some 8mm bolts here that I could use if I re-drilled and tapped the threaded hole larger..the rest of the holes are 8mm...

what company are those plastics from? I see they have the warning labels on them but I dont think they are OEM because of the side panels no having dimples in them. I love the color. I need some plastics and those looks great

[hornetgod13]

Looks great but, where's your bumper?

[lawdog800]

FoxHondaRider... The plastics are all Factory Honda Pieces.. The side panels are from a 2007 400ex and the rest is the 2000 stuff..

Hornetgod13.....haven't bought a bumper .....yet...:D




I decided I wanted to throw on the rear plastics and seat to see how it looks, and roll it outside to CLEAN UP the nasty garage a little bit....

[red_rider_069]

Originally posted by lawdog800
Here are some new engine plugs..I just posted a new thread to see if there is any interest in them as a purchase.. i am =)... pm me

[lawdog800]

Some pics from today with the graphics...I am having trouble getting them to stick where they had to bend over edges..they keep lifting even after heating...???

[lawdog800]

another view

[lawdog800]

The graphics are from CEET. I think I liked it without, and I would have put on just a black wing on the front tank side, but the kid likes them...They dont look bad this way either though.....

[lawdog800]

finally.........I also picked up a new front bumper today, but have to get it powdered...

[hornetgod13]

I like the graphics. Did they come with a matching seat cover. What bumper did you get? Does it look like mine?

Where's the new ASV brake lever at? Start it yet?

[lawdog800]

They did not come with a seat cover, and I actually got them for $29.95 which was a BIG +......The seat is a new factory honda seat from Hidy Honda off of e-bay........The bumper looks nothing like yours..it is still silver.....lol

[hornetgod13]

I meant the type. Pro Armor XC. When you putting the nets on?

[lawdog800]

I know..yes same Pro XC....... Nets..probably today... I told the boy HE has to do them......How much sag do they get????

[hornetgod13]

Originally posted by lawdog800
I know..yes same Pro XC....... Nets..probably today... I told the boy HE has to do them......How much sag do they get????

Quite a bit. I cut 3 to 5 inches of excess off each strap when I was done. Tell him to burn the ends so they don't fray.

[NickG5755]

400's lookinn good :D ithink to set the A** end of it off it would be cool to see you drill the rivets out of the T4 where the tag is and have the rest powdercoated...then rivet the tag back on...jsut an idea...ive never seen a black t4.. like you said it only costs a few nickels to go highclass (or something liek that)..

very nice build tho

ohh yeaaa she needs handguards!!!

[lawdog800]

The quad lives.. I got some smoke in the pipes yesterday, just for a minute, until I can get it out and ride it easy to break in the cam. I dont think anyway that you would just let free rev for 30 minutes at over 3000 rpm's????

The brake lever is waiting for the new pivot bolt. the master cyclinder pivot bolt was lost at some point by a previous owner so a 1/4-20 was just forced into the hole. I re-tapped to 6mm and hope the new bot and nut will hold securely, if not I will drill and tap to 8mm hole......

[Cool Guy07400EX]

Are those the pegs that came with the nerfbars?

[Speedy 400ex]

[QUOTE]Originally posted by lawdog800
[B]The quad lives.. I got some smoke in the pipes yesterday, just for a minute, until I can get it out and ride it easy to break in the cam. I dont think anyway that you would just let free rev for 30 minutes at over 3000 rpm's????

I lot of guys are saying that it is better to break the motor in hard. its spoused to help the rings seal better. But thats just what i heard.

[416exfreak]

I break my motor in the same way im going to ride it.

I run maybe a half tank never going past half throttle, then after that I rape on it just like ive been riding it for years.

Seems to work pretty good...:ermm:

[lawdog800]

The 30 minutes at 3000 rpm is Hot Cams cam break in procedure......

[lawdog800]

I just found my old thread and noticed I never put on the new pics with the final graphics. The ones originally shown never would stick so they refunded my money and I went with the Stock 2001 Honda pieces....

http://i550.photobucket.com/albums/ii435/lawdog800/PICT0126.jpg

http://i550.photobucket.com/albums/ii435/lawdog800/PICT0123.jpg

http://i550.photobucket.com/albums/ii435/lawdog800/PICT0130.jpg

[CJM]

Very nice, I wish my plastics were that shiny and clean still.

What handlebar and bend is that btw?

[lawdog800]

Those pics were right after project was finished so brand new Factory Honda plasics and graphics.. No clue on the bars as they were on it when we bought it. The quad has only been ridden a couple times the last couple years as my son is away at college.

[Stickman400]

I like the black air shrouds with the Honda logo on them, looks like they should come like that. I also love the black engine and all the allen headed bolts. Very nice 400.

[lawdog800]

Thanks