Operation 416 is underway!!

[Honda#4]

Well today is the offical day my motor rebuild starts, everything went good and came out great. I'm just at the stages of cleaning the motor up for tear down. I'll post pics up tommorrow

Motor will be getting the following

JE 416 Piston running 11: comp
CRF 450 Cam Chain
Hotcam Stage 2
Port & Polish Head
3 angle Valve job
Namura Gaskets
New Valve seals

[Ruby Soho]

sounds like its gonna be awesome!

oh and to answer you question on aim (i was photoshopping when you signed off)

yeah its fine to tilt the engine

[mcwilly]

Cool! Who's gonna do your porting?

[buster024]

If you don't mind me askin', what made you decide on a 416 versus the 426 or 440?

[Honda#4]

I'm gonna have C&D do my porting, I went with a 416 for relieablity reasons I know the 426 and the 440 can be relieable also but I didnt wanna go that big and have to spend money on a new sleeve and such. This is my first rebuild so I dont wanna tear the whole motor apart. I just feel like taking steps in the motor process not jumps.

[TRXRacer1]

Originally posted by Honda#4
This is my first rebuild so I dont wanna tear the whole motor apart. I just feel like taking steps in the motor process not jumps. You don't take anything more apart to go big bore. I chose the 416 too because I wanted to try this before I went big and I didn't want to get into porting yet. Mickey Dunlap says porting on a 416 or smaller has very little benifit. No regrets, it's been a fun motor. Next time I'm going all out on a 430.

[Honda#4]

Well I've been without power on my quad now for a good year so I think the 416 will be a blast, I'm confident that i'll have enough power for a while after all I can always go higher. I'm not really a power hungry person I just want enough to rip around on.

Another thing is gas I wanted something that still runs on pump gas not gonna spend money on race gas.

[TRXRacer1]

Originally posted by Honda#4
I'm confident that i'll have enough power for a while after all I can always go higher. I'm not really a power hungry person I just want enough to rip around on. I hear that! This was my plan exactly, I can go bigger later.

Keep us updated! Sounds like a good combo you got here.

[Honda#4]

Here's a few pics of the stuff I bought last week.

[Honda#4]

Gaskets

[Honda#4]

Heres just a pic of the Cam spec card

[Honda#4]

The CRF Cam chain I ordered will be here on Thursday.

[Honda#4]

Caught a snag, one of the three valves is not loose the rest are, its one of the intake valves. I have the motor at TDC but it wont loosen up what do I do?

The one thing I can remember is when it was at the dealer the guy told me he adjusted the valves so the thing would run.

[TRXRacer1]

Originally posted by Honda#4
Caught a snag, one of the three valves is not loose the rest are, its one of the intake valves. I have the motor at TDC but it wont loosen up what do I do?

The one thing I can remember is when it was at the dealer the guy told me he adjusted the valves so the thing would run. You're just tearing it apart now right? Loosen up the adjuster on that valve and continue with the tear down. It's possible that the last person didn't properly tighten the adjuster and it went out of adjustment. I've seen that a couple times.

[Honda#4]

Thanks man, I just finished up cleaning it today. I really have no intention of forcing myself through this process so I wanna go slow but steady. I'm in no need of getting it done quickly so I can ride it's all muddy and theres still snow on the ground.

[Honda#4]

I got the Cam out and took out the decompressor pin and spring out also.

[hornetgod13]

Like it was said before, it sounds like that one intake valve was out of adjustment (might explain your lack of power).

Just take you time and follow the maintnance manual I'm sure you have. I learned a lot about the motor during the tear down and build up.

I love how my Wiseco 11:1 416EX with Stage 1 Hotcam performs.

I was where you're at now about 2 months ago. Don't hesitate to ask a question or two if you need to.

[j450rking]

thats about the same thing i had before my hybrid build. minus the port and polish. it's a great stup and it wasn't that hard to do but the problum i had was the battery would run down vary fast do to the higher comp and no auto decompressor. i would sugest getting a busa battery and that should help. just make sure to torque everything correctly and check it twice! santa has a good thing going there lol.

[Honda#4]

Thanks Hornet, I've been doing just that, actually taking more time to organize than working but thats better then parts being everywhere, hopefully tomorrow I should be to the point where the cam chain is out.

[400ex28]

Good luck on the build... building motors is always fun :macho

[hornetgod13]

I bag and tag all parts and keep all hardware with it particular area. It makes assembly so much easier.

The best tip I can give you on assembly is ensure the flange bolts on the cam sprocket are thread locked and torqued.

[j450rking]

yeah make sure you orgonize eveything thats the best way not to mess anything up

[Honda#4]

Here's the pics from yesterday that I didnt get a chance to post

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Hows this for organization?

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Bolt Guide

[400sEXridr]

hey looking good. good thinking on the cardboard for the bolts ive never seen that before but i like it. when i did mine i went with the 406 11:1 with the stage 2 and i love it. plenty of power on tap. im sure youll be happy. good luck!!!

[Honda#4]

I'm just doing what the clymer says, they even have the cardboard trick in there.

[hornetgod13]

With the Hotcams, you won't need to reinstall the stock decompression small plunger and spring.

You going to change the valve seals? Do you have a valve spring compression tool?

[Honda#4]

Thanks for the heads up Hornet about the decomp plunger and spring but I knew that already, yes im going to change the valves seals but im gonna let Colby handle that, there's only so much I can do being that I farm and stuff, i'd like to be done in the next three weeks with it permitting that I get time to do it.

[Honda#4]

UPDATE!! Got my cylinder head off and the cam chain, the nut thats staked went off like butter on corn other than a few cuts on the hands everything went good and came off neatly. What do you guys think of my valves and such? the intake ones sure have alot of buildup on them and the exhaust have a mild tan to them. IDK if this is normal but the piston is brown?

[Honda#4]

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[400ex28]

Lookin' good so far, everything looks normal. That head is going to look brand new when you get it back from Colby.

[400exBRAAP]

hey.. honda#4, what are the chances that i could get the stock decompression plunger and spring from you? im putting my stock cam back in, and i lost those 2 parts... or are you gonna need to be using them??

[Honda#4]

Well for now I wanna keep it untill I get the build done just in case something goes wrong I have all the parts, but the Cam im gonna use does'nt need it.

On a funny note when I first saw the cam chain im like what a cute liitle chain. I think I might actually use it for a necklace LOL.

[Honda#4]

UPDATE!! Got the cylinder off, the head gaskets and base gaskets are all cleaned up off the parts. so now i'm gonna be waiting for a bit, Cam chain comes in today so I guess i'll put one good thing on.

One question though, it seemed like there was an gasket sealer or adhesive to make the gaskets stick when I started to clean it off the head, whats the best glue or sealer for all the gaskets?

[Honda#4]

Here's some pics

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[TRXRacer1]

Originally posted by Honda#4
UPDATE!! Got the cylinder off, the head gaskets and base gaskets are all cleaned up off the parts. so now i'm gonna be waiting for a bit, Cam chain comes in today so I guess i'll put one good thing on.

One question though, it seemed like there was an gasket sealer or adhesive to make the gaskets stick when I started to clean it off the head, whats the best glue or sealer for all the gaskets? You don't want anything heavy but a thin coating of copper coat from Permatex is by far the best dressing you can give your gaskets. I've been using it for 10 years now and won't put a gasket in without it on an engine build. If you've never used the product it sprays on a very thin layer of actual copper. Very cool stuff and available and most auto parts stores. One can will last a long time.
http://www.permatex.com/images/DisplayImage.asp?210|/images/ProductPhotos/80697.jpg

[my88r]

Originally posted by TRXRacer1
You don't want anything heavy but a thin coating of copper coat from Permatex is by far the best dressing you can give your gaskets. I've been using it for 10 years now and won't put a gasket in without it on an engine build. If you've never used the product it sprays on a very thin layer of actual copper. Very cool stuff and available and most auto parts stores. One can will last a long time.
http://www.permatex.com/images/DisplayImage.asp?210|/images/ProductPhotos/80697.jpg

whats your opinion on hondabond.

[UNBROKEN]

Originally posted by 400exBRAAP
hey.. honda#4, what are the chances that i could get the stock decompression plunger and spring from you? im putting my stock cam back in, and i lost those 2 parts... or are you gonna need to be using them??

y u puttin stock back in ?

[UNBROKEN]

HONDA#4 was that the original topend from ure 03 ?

[Honda#4]

Yea it's the original topend. For some odd reason one of the head bolts is a diff color unsure why.

Thanks TRXracer1

Well my cam chain will be here on Monday, kinda sucks cuz I wanted to put it on tonight o well.

[400exBRAAP]

idk why.... i'm just putting my motor back to stock cuz i wanna keep it reliable and stuff. i dropped an intake valve... so im gonna put it as close to stock as i can, besides the pipe i have on it.... i dont wanna sink any more money into it.... if anyone has the decompression plunger and spring and they wanna get rid of it... ill take it from ya.....

[oleboy87]

looks good man..

[Honda#4]

looks good man..

Thanks Man

[gojk]

Have you thought about replacing the head studs? I decided to take the short cut and not replace them. Sure enough, 2 weeks later I was ordering them and putting them in. Look for For Dirt Only, they sell heavy duty studs, that when installed correctly should hold up a lot better than the stockers.

I was only running the Wiseco 11:1 also....

[Honda#4]

I thought about it but most of the threads i've read people havent put them in there 416's but anything is possible I guess. For now i'm sticking to what I got.

[hornetgod13]

I did some pretty lengthy research before I did my 416 and I decided not to go with heavy duty studs.

I read in several threads that anything at/or under 87mm and 11:1 the studs were not needed.

If I ever go any higher in piston size or compression than the HD studs are going in.

I highly recommend you ensure you follow the maintnance manuals torque requirements. Under or over torqueing the cylinder studs or head nuts will certainly lead to a stripped stud and blown gasket.

[gojk]

I followed torque guidelines to the T. But none the less, the Exhaust side head stud is infamous for pulling and that is exactly what happened with mine. If you want to risk it, go for it, I mean it only takes 15 minutes to have the head off to replace them if it does happen. I just wanted to throw the idea out there just so he thought of it before he had it all back together.

[BigBore24]

in my opinion the biggest reason for headstuds pulling out is overtightening. i know gojk you said you followed the tightening to a t but could someone else have overtightened them in the past? with a 416 i think you could go either way. when you are torquing the nuts down to 33 ft lbs. pay close attention to how solid the studs feel. if they feel in any way like they are a bit weak. then change them. i used helicoils on my 440 bout a year ago and has held up well. before i did that i had no problems until i overtightened the nuts:ermm: .

[Honda#4]

If I would have went to say a 426 yes then I would have put them in, but like Hornet said anything under 87mm doesnt require them and like him I did lotz of research to be sure what is needed. I think if everything is properly torqued I dont think i'll have a problem, but I know things can just let loose at times.

Thanks for leting me know GOJK

I cant wait till I start bolting stuff together, it's been atleast a good year sense ive been without significent power so i'm really excited how this is all going to work.

[TRXRacer1]

Originally posted by my88r
whats your opinion on hondabond. Total rip off for $15. Don't get me wrong, the product is nice but you can find the same stuff for 40% of the price from Permatex. It's just another product that Honda puts their name on with a high price tag and sells because they know people will buy their name.

[TRXRacer1]

As far as the HD studs go, they're a rip off too. The only thing wrong with the stock studs are the size of the threads in the cylinder. Steel inserts give stock studs the bigger foot print they need in the aluminum for a bit less then the HD studs. If you're good with heli-coils you can use them also like BigBore24 did. Same thing, bigger foot print, more grip, problem eliminated.

[my88r]

Originally posted by TRXRacer1
Total rip off for $15. Don't get me wrong, the product is nice but you can find the same stuff for 40% of the price from Permatex. It's just another product that Honda puts their name on with a high price tag and sells because they know people will buy their name.


i don't where you buy there stuff. but i paid $5 for mine:huh

[Honda#4]

I'll just buy the permatex brand sense I use there antiseize, there products are top notch.

Man what does a person do to pass time waiting for parts?

[TRXRacer1]

Originally posted by my88r
i don't where you buy there stuff. but i paid $5 for mine:huh Apparently the wrong place! Haha

For $5 it's a good product. It's totally different from the copper coat I was talking about. Copper coat is something you use as a dressing on your gaskets including the head gasket where Hondabond you can make a gasket with and you don't want on a head gasket.


Originally posted by Honda#4
Man what does a person do to pass time waiting for parts? You surf this place! :p

[UNBROKEN]

^ it kills time i like to go back and read the never ending exhaust threads and oil threads ...

[Honda#4]

I guess aparently them threads are never outta style LOL! Yesterday I read 85 posts of 416 rebuilds and that was enough so I went out and cleaned where my motor sits in my frame. I'll probably clean and polish my exhaust.

[Honda#4]

I was looking for that Copper coat stuff online on my local autozone site and they dont carry it, so whats the second best stuff to use to seal everything up good?

K&Katv sells some Bel-ray assembly lube does anyone reccomend this? and can you use it on gaskets and such?

[TRXRacer1]

Originally posted by Honda#4
I was looking for that Copper coat stuff online on my local autozone site and they dont carry it, so whats the second best stuff to use to seal everything up good?

K&Katv sells some Bel-ray assembly lube does anyone reccomend this? and can you use it on gaskets and such? Do a product search for part number 80697 at Autozone. Most stores carry it.

Assembly lube is what you use for pre-lubing parts like your camshaft.

[Honda#4]

I punched the number in and it says it aint available so IDK what to do.

[Honda#4]

Well finally my CRF cam chain and my cutch nut came in so heres a few pics, now im just waiting for my credit card bill to come so I can get that paid then i'll be sending out my head and cylinder to get bored, P&P and valve job done.

I compared the CRF to the stock and im very happy with the way its built very beefy if I must say.

[Honda#4]

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[red_rider_069]

nice, glad your taking the time to take pics and post:macho

[red_rider_069]

nice, glad your taking the time to take pics and post:macho

[Honda#4]

Well theres many on here that enjoy reading rebuild threads and if I screw up on something I can just look back on here and see what I did wrong, so I dont mind taking pics. So far this engine rebuild process has been the best experince I ever had it feels good knowing I can rebuild my quad without problems.

[lilhouskey]

I definitely appreciate the step by step, im planning on doing a STD bore 11:1 with a stage 2 hotcam in my ex and this gives me some confidence to try doin the work myself

[Honda#4]

First thing is BUY A CLYMER manual thats the best thing you can do for yourself then you pretty much wont have a single problem with anything. It's very easy trust me this is coming from a guy that has'nt ever worked on a motor. And one more minor thing it's also good to eat and have a positive attitude before you work so you dont get hungry when your working. Main thing is if you got a problem just ask

[Honda#4]

UPDATE!!!

Well I got on the phone with C&D Racing today so my cylinder and head will be shipped out tomorrow im so excited right now im speechless.

[Honda#4]

UPDATE!!!! Getting the motor today, I'll be sure to take pics of everything I see then off to get reassembled.

[madmax400ex]

Originally posted by Honda#4
First thing is BUY A CLYMER manual thats the best thing you can do for yourself then you pretty much wont have a single problem with anything. It's very easy trust me this is coming from a guy that has'nt ever worked on a motor. And one more minor thing it's also good to eat and have a positive attitude before you work so you dont get hungry when your working. Main thing is if you got a problem just ask
I have never seen the clymer manual, but i have a haynes and it sucks. I am always rereading and asking questions on this forum, and the pictures are horrible. I'll have to take a look at the clymer manual.
Question for you honda#4 - How much do you think it would have costed you (estimate) if you took the motor in to a shop for all that work?

[Honda#4]

Well to ship the whole motor to Colby is an extra $250 plus all the other costs which for me was $430 but would differ from person to person simply cuz diff people like diff things hope that makes sense, back to the question I would guess around $750. I know to take it to a dealer would easy be $500+

I have a Haynes manual also and it's junk worst manual I ever read, reading the Clymer is like reading a toddlers book the pics are makes sense and the wording is straight to the point.

[madmax400ex]

Originally posted by Honda#4
Well to ship the whole motor to Colby is an extra $250 plus all the other costs which for me was $430 but would differ from person to person simply cuz diff people like diff things hope that makes sense, back to the question I would guess around $750. I know to take it to a dealer would easy be $500+

I have a Haynes manual also and it's junk worst manual I ever read, reading the Clymer is like reading a toddlers book the pics are makes sense and the wording is straight to the point.
I know, haynes is absolute junk.
Thats crazy about the price, i can see why you are doing it yourself. I think next year i am going to build up my motor and wasn't sure if i should do it myself or not. Your thread is definitely giving me some good advice - thanks.

[Honda#4]

Dont be scared of doing it yourself it's very easy the clymer manual will make it soo easy on you, I was abit scared at first tearing mine apart but after reading the manual for a week and plan things out in my head I was ready to dig in. It may seem like a big task in the book but really to me it isnt bad at all and rather short, I went slow cuz it was my first rebuild so I wanted to label everything I saw and take pics but I know where everything is now so it will go that much faster, plus im an organized fool.

[Honda#4]

Well heres the pics everyone has been waiting for, Colby packed everything very nicely but on a small note one of my head stud dowel bushing is missing wasnt in the box when I got it but was sent to him, no blame on Colby probably just a mishap hopefully he has it. Here's the pics

[Honda#4]

2 intake port job:eek2:

[Honda#4]

here it is my bad

[Honda#4]

3 Exhaust port

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4 Can anyone say Crosshatching?:eek2:

[Ruby Soho]

lookin sick

the ports look great but how will it perform? hurry and get it together lol I wanna here how it runs. Looks really good though.

[Honda#4]

I'm hoping it will perform great, One minor problem though one of my dowels that slip over the head studs is missing I'm thinking Colby tried keeping it as a momento LOL! So the build will be delayed a tad above that but otherwise i'll work on the piston and cylinder and clutch basket and stuff tonight hopefully nothing goes wrong.

[Honda#4]

I kinda got my piston on but confused on which way its suppose to face, theres no IN mark like the stock piston had so IDK which way is it suppose to face?

hey Igot a question for you about the piston. How much does it weigh compared to stock?

[Honda#4]

IDK what the stock piston weighs but my JE one is 293 grams. Got some pics for yas. Just wondering if this gap in the piston is normal? it sealed perfectly fine when I put the piston on

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[Honda#4]

Does anyone have another way besides using a clutch holder tool to hold the clutch hub? I almost got it tight but cant click the torque wrench.

[Honda#4]

Updated pics

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Kinda scary:D

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Last one

[HondaRaceReady]

You should have gone with 12:1 compression. My buddy has 12:1 on his 250x, and said he never had any problems running 93 octane gas in it. I know they're 2 different bikes, but at most, you might just have to use a little octane boost. I think that would probably work fine.

[lilhouskey]

To me it makes way more sense to stick with 11:1 and 93 octane to keep it reliable and have way less chance of grenading your engine

[HondaRaceReady]

I know higher compression puts more strain on the bottem end of the engine, but these engines are built tough. If you can make a 400ex into a 440 12.5:1, I think you should be fine with a 416 12:1.

[lilhouskey]

Originally posted by HondaRaceReady
I know higher compression puts more strain on the bottem end of the engine, but these engines are built tough. If you can make a 400ex into a 440 12.5:1, I think you should be fine with a 416 12:1.
Just because you can do a 440 @ 12.5:1 it doesnt mean its reliable. I got a buddy with a high comp std. bore yfz and it hardly ever starts or runs properly and he runs VP. and yes you can build a 416 @ 12:1 but its not gonna be as reliable as the 11:1 which still isnt as reliable as stock especially on pump gas. these quads are built tough and reliable but thats Std. bore and Std. compression.

Originally posted by lilhouskey
Just because you can do a 440 @ 12.5:1 it doesnt mean its reliable. I got a buddy with a high comp std. bore yfz and it hardly ever starts or runs properly and he runs VP. and yes you can build a 416 @ 12:1 but its not gonna be as reliable as the 11:1 which still isnt as reliable as stock especially on pump gas. these quads are built tough and reliable but thats Std. bore and Std. compression.

I agree leave it all stock and take care of it good and it will easily last you over 20 years on the same spark plug and all. But the crowd of 400's we tend to like to say "I wanna go fast I wanna go fast" so yeah most arent stock lol. My uncle has the same quads and 3 wheelers all Honda's he grew up riding, and they still run today and he still uses them today and not a thing was changed since he bought them and they all run fine. I think the fourtrax 200sx is from 1987 and the ATC350x is from 1985. I choose to not leave mine stock because I like a littl more power to uncork it so it really gets up and goes. I dont mess around much engine wise but when the time comes for an overbore I already know I am going to a Wiseco 406cc 10:1. Power wise I will gain a little bit and a 406 will still have plenty more overbores when needed in the future. After the 406 its a 416 so I have plenty of years ahead before I need a new sleeve and stuff.

[HondaRaceReady]

I guess it really depends on what you're looking for. If you want something to last longer, I guess 12:1 compression isn't as good as 11:1. I think of it this way. If I can get at least 3 years out of a 416 @ 12:1, then I'll be happy. I'll just rebuild it when it needs it. I don't care, I'll resleeve the cylinder until it's time for a new one.

[Honda#4]

When I planned on doing the build I did my homework and read countless threads about 416 motors running 11:1 comp so I figure hell I wanted to be reliable but with a more power so I did and to make it even better I went with a ported head so this thing should rip when im done, I also didnt wanna go full bore with power sense i'm not that power hungry I mostly relie on my suspension to make me faster plus I figure it's not worth building a badass motor for someone like me that just wants to rip around without seeing parts flying off the machine.

[my88r]

Originally posted by Honda#4
When I planned on doing the build I did my homework and read countless threads about 416 motors running 11:1 comp so I figure hell I wanted to be reliable but with a more power so I did and to make it even better I went with a ported head so this thing should rip when im done, I also didnt wanna go full bore with power sense i'm not that power hungry I mostly relie on my suspension to make me faster plus I figure it's not worth building a badass motor for someone like me that just wants to rip around without seeing parts flying off the machine.

with your new setup. what octane gas are you running???

[Honda#4]

I plan on running 93 in it, if that aint enough I researched the Klotz race gas additive pretty good so i'd try that if I need to go futher it's suppose to be better than the nitro booster stuff that you find in walmart and such.

[BigBore24]

looks like your doing a very good job. good to see you have patience...thats what it takes to do it the right way

[HondaRaceReady]

Was it time for a rebuild when you decided to go 416, or did you just want more power?

[Honda#4]

O YEA it was time for a rebuild, the guy that had it before me decided on not to run a foam filter and just the metal cage I didnt realize untill I went to go and clean the air filter come to find out there wasnt one so I ordered one but the damage had already been done. Basically the rings were gone and I still ran it like that till 4 weeks ago when I said enoughs enough I could'nt at all do a wheelie or have enough power to slide the rear around so I plucked the motor out and here I am.

[gcart2]

Originally posted by Honda#4
O YEA it was time for a rebuild, the guy that had it before me decided on not to run a foam filter and just the metal cage I didnt realize untill I went to go and clean the air filter come to find out there wasnt one so I ordered one but the damage had already been done. Basically the rings were gone and I still ran it like that till 4 weeks ago when I said enoughs enough I could'nt at all do a wheelie or have enough power to slide the rear around so I plucked the motor out and here I am.

Um wow. no filter? previous owner must have been a smart guy.:p :huh

[Honda#4]

Yea, he couldnt even go to the dealer to have them press in two new wheel studs instead he used two hex bolts which are pain to tighten up.

The quad was only ridden a few times by his wife.

[sideways]

im in the middle of the exact same buildup except im doing 10:1 comp. my question is, what crf cam chain did you get? crf450? after seeing the pics, seems like it's a heck of a lot better and while everything is apart, might as well do the cam chain. also, did you hit any snags while putting it back together? my biggest downfall is i got the honda service manual instead of the clymers.... D'oh!

[Honda#4]

I bought a 02 CRF 450 Cam Chain but after a thread about it a few weeks ago you can use any year CRF Cam chain.

I took the extra time sense it was my first rebuild to label bags and take pics so I know how everything all lined up so to answer your question I didnt at all hit a nag everything went in good except Colby had a problem getting one of the dowels off the head stud. The Clymer manual though made this rebuild so easy with the pics and the steps very easy to read.

I do have to give all the credit to Colby at C&D Racing for all his hard work and all the emails he had to put up with and the minor problem he had with my dowel but everything came packed wonderful and I got a few extra things with it.

When time to rebuild my shocks and such C&D will see'em

[Honda#4]

Here's the last of the pics till the motor is in.

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[Honda#4]

I had just boughten the Motion Pro Clutch hub wrench and that worked so good when torquing the clutch center nut up I definently reccommend it, took less than a minute to torque it.

[alex10]

Does it run yet?

[Honda#4]

It did for 5 seconds till I saw it had a leak by the base gasket, back to square one again. Look at my other thread "5 seconds turned to nightmare"

[Brauap]

Hey (ITS ALIVE AGAIN!)

I am finally rebuilding my 400EX (Needs it bad now, smoking after decel of throttle)

And this is my plan for the engine:

JE 416 10.8:1 kit (off of eBay)
Port & Polish

Maybe:
Hot Cams Stg. 1

But I have a few questions..

I am making mine for a hardcore trail/XC quad so bottom and mid are my key points.

Where does the Hot Cams add to?

What does the CRF450 Cam Chain add? Just more strength?

What is a 3 angle valve job?

Thanks a ton! Also, did you ever get the worked out?

[Honda#4]

Yea it all works just trying to get it jetted, a stage 1 would be great for bottom to midrange power,the CRF chain is alot stronger and alot cheaper than a EX chain, 3 angle job just refers to the 3 angles that the valves are cut at.

Need anymore info i'm glad to tell ya.

[tsargent4]

hey i see that you haven't got your jetting matched up yet...i live in southern indiana and just recently built a 416 and can't seem to get my jetting figured out. i have a JE 10.8:1, Stg 2 Hotcam, GT Thunder HD studs (work great), FMF Powerbomb header and Powercore slipon, Uni Filter w/ lid on. As of now I am running a 160 or 165 main, 40 pilot, and on 4th clip. I didn't go with the valve job or port and polish as it doesn't help much on the 416, but let me know what jetting you come up with...surely it won't be much of a difference from indiana to michigan...

[tsargent4]

my bad...wisconsin...

[400ex28]

Originally posted by tsargent4
hey i see that you haven't got your jetting matched up yet...i live in southern indiana and just recently built a 416 and can't seem to get my jetting figured out. i have a JE 10.8:1, Stg 2 Hotcam, GT Thunder HD studs (work great), FMF Powerbomb header and Powercore slipon, Uni Filter w/ lid on. As of now I am running a 160 or 165 main, 40 pilot, and on 4th clip. I didn't go with the valve job or port and polish as it doesn't help much on the 416, but let me know what jetting you come up with...surely it won't be much of a difference from indiana to michigan...

Just curious.. where are you located at in Indiana?

[Honda#4]

I feel that the port work that Colby did to my head was a great increase in power thus I think is worth it. I'm getting a bunch more jets from a guy on here so it will be a few days before I get them.