NEW GUY does 400ex Re-build

[DirtyBirdRacing]

I got my Ex after last Christmas rode it for 3 months and then it sat for a while. Soon after I parked it my brother totaled his 250ex and my friends 350 warrior motor went so I had no one to ride with and going out by myself was getting boring so decided to paint my frame... and this is where the project started. I work a min paying job and am going to school 4 1/2 hours away from my quad so it is a VERY VERY slow process. Mainly due to the lack of $$$$

Some of the things I want to do...

Graphic Kit (Grim reaper with skulls)
Hid light kit
Break Disc (looks like a saw blade)
Throttle & Break covers (says "400EX")
Red billet Gas cap
K&N Oil filter
Custom Warning labels (yes its fast no you can’t ride it..ect)
Polished Stainless Bolt kit
Battery box DG
Change ALL bearings with ALL balls
Two Brothers TRX400EX V.A.L.E. M-7 Slip-On Exhaust
DG Fat Full skid plate
Red Skull grips
Red Moose Racing levers
Red Chain roller
Skull Shock covers (match my skull seat cover)
Million color LED ATV KIT (from LED GLOW)
New Chain and Sprocket set
Set(4) ITP SS12 Sport Chrome & Black rims (going to paint the black red)
Universal LED Taillight
New front and back tires
Painted frame (Red met)
Tusk Comp series bumper
Tusk bumper skull insert
And I have been thinking about a Sparks Advanced Key


http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/15a05347.jpg
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[DirtyBirdRacing]

http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/0a70c20d.jpg
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[DirtyBirdRacing]

http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/d9bf6977.jpg
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[DirtyBirdRacing]

http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/49988f91.jpg
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[DirtyBirdRacing]

http://i128.photobucket.com/albums/p185/lord-inuruku/77187bdc.jpg
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...And this is where it is now...
http://i128.photobucket.com/albums/p185/lord-inuruku/0ebff217.jpg

[CJM]

Its gonna look cool but imho I rather spend the cash on suspension and engine mods.

Mine looks so so, plastics cut up front/beat up, frame is painted gray with some spray paint, stock bumper.My only bling is my tusk nerfs. But, while it looks so so I can go VERY fast.

Just my opinion, you want some go before you got the show kinda thing.

[DirtyBirdRacing]

I have been looking in to suspension lately what would you recommend I put on I ride trails/woods 100% of the time and do like to jump it a little.
And as fir the motor I like the idea of boring it out, makeing it faster but I'm worried about the reliability of the motor I usually go reall far in the woods and don't wana risk breaking down.

[honda400ex2003]

if the bore and install is done correctly there is no problem with reliability. There are quite a few of us on here that have thousands of miles on 416s and such. I am one of them, i have over 2000 miles on mine so far in the past few years.

The frame looks good, i dont know about painting all of the boots and such though. That may come back to cause problems in the future. I would rather see everything come off if possible and painted separately. the nice thing about leaving it together is that you dont have to clean paint out of the bolt holes. at least you did the sub frame and such separately.

Keep us updated on the project!

steve

[426kidz]

yeah, I was in shock when i seen he just painted it all.lol :eek: :( :eek: :confused:

[CJM]

If you want a better suspension get some honda 450r shocks and search on how to modify the frame slightly so they fit. If you got the cash +1 arms would be ok as well.

Basically tuning the suspension right using the 450R shocks will make it ride that much better. All I did (im 200lbs so lighter guys might find them to stiff depending on how and where you ride) is adjust the preload to lower the ride height about an inch and a half (450r shocks raise the ride height 1 inch or so anyways), put my compression to fast and rebound to fast. Only thing thats holding me back is the back shock now, it bounces to much.

As for engine mods: at least 60 or more hours on my rebuild with no issues. See my signature for whats done, but I run that every time very hard with no issues and use 93 pump gas. Every single person I know that I let ride mine wants to setup theres the same way.

It is fast, I can keep up with my 2 buddies mildly modded 450rs quite well.

So long as you do it right (which actually its rather easy) it willbe fine. Biggest thing is the carb must be jetted right or you can ruin everything from being to lean. That being said its worth every penny I have into it, its fast and it handles rather well. About all thats left to be done is to add +2 arms up front to match the back, +2 with stock wheels is still small enough to fit on the trails around here.

[DirtyBirdRacing]

Well Christmas is over and im soon back to school. the frame is being put away and stored untill I can get another break from school. Its a 4 1/2 hour drive from school to where I keep my quad stored. I would bring it with me cause there are trails near the school. But there is no storage places close by that would be convient to use and that would cost me more moeny that I dont really have to be spending. I will keep this up to date with any parts I buy and post pictures of them.

If any one has any ideas of things I should do to the EX while I have it apart please let me know ^.^

[honda400ex2003]

bearings in the carrier and swinger up front where it bolts to the frame.

thats about the only thing that i would do as long as nothing is broke or loose anywhere else. Check the rest of the bearings too and if they are wore out, replace them.

steve

[TheLane]

Only thing im worried about is it looks like you painted it with the hubs on.... :huh: might cause some problems

[DirtyBirdRacing]

Originally posted by TheLane
Only thing im worried about is it looks like you painted it with the hubs on.... :huh: might cause some problems


Yes I did, The only thing I didnt pain at the same time was the back part of the frame. What problems might I run in to?

[DirtyBirdRacing]

Originally posted by honda400ex2003
bearings in the carrier and swinger up front where it bolts to the frame.

thats about the only thing that i would do as long as nothing is broke or loose anywhere else. Check the rest of the bearings too and if they are wore out, replace them.

steve

I have the wheel bearings, Swing arm bearings, and the carrier barrings ( I need the seals cause they were in bad condition ) I was thinking of getting the stearing stem bearings because they make a little noise but dont know if its worth the money just to make them quite plus with the 2bro exhaust I might not hear it any way :)

[2001400exrida]

the steering stem bearing is kind of important. they're only like 20 bucks for bearings and seals, not a bad price.

[DirtyBirdRacing]

Originally posted by 2001400exrida
the steering stem bearing is kind of important. they're only like 20 bucks for bearings and seals, not a bad price.

Ill take a hint and not be a fool. I'll order them when I get the chance.

[DirtyBirdRacing]

UPDATE ( Ill be posting something on it in the comeing months. )

I have recently moved from wilkes barre PA to WV. My quad is still in PA at my friends garage sitting how I left it. I wanted to see if there was trails around here before I went trought the trouble of bringing it here. due to a lack of money I havent been able to touch the thing since i started this thred :(

Quads been apart for close to a year now and still not completed. been out of work for a while just got a new job 3 days ago hopeing to get back on buying parts so I can put it back together. I learned my lesson IF I ever do this again to any quad im going to buy 100% all the parts BEFORE I pull it apart. it has been killing me not being able to ride.

Here it is in its current state.
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/IMG_7585.jpg

Things I Still need before I can set the motor back in and have it on wheels.

- Bolt kit
- Paint Swingarm
- Paint axel
- Paint side case
- Paint motor
- Sparks key
- Both side case gaskets
- Swing arm Bolt and nut
- carrier seals
- tie rod
- front shock

[HondaRacing83]

im not trying to be a dick here, but if i were you, id do this for a mod list.
-Fat bars or Flexx bars
-Stay with the 2bros slip on
-450R front shocks
-STAY AWAY FROM TUSK PRODUCTS. except for their nerf bars with the heel guards
-tusk nerf bars w/ heel guards
-tires
-odi lock ons
-sparks +6 timing key
-Pro Armor bumper
-Ive always like maier wrap around hand guards, id suggest those or acerbis
-graphics if you want, personal liking
-dont get itp ss112 rims or whatever. personally i think they look dumb on sport quads. leave stock rims, paint em black or whatever or get some beadlocks
-parking brake blockoff
-uni foam filter
-little personal bling wherever youd like
do me a favor and dont be one of those dudes who put mud tires on a sport quad though. please, stick with holeshots or razrs or x-rexs or somethin

[DirtyBirdRacing]

Originally posted by HondaRacing83
im not trying to be a dick here, but if i were you, id do this for a mod list.
-Fat bars or Flexx bars
-Stay with the 2bros slip on
-450R front shocks
-STAY AWAY FROM TUSK PRODUCTS. except for their nerf bars with the heel guards
-tusk nerf bars w/ heel guards
-tires
-odi lock ons
-sparks +6 timing key
-Pro Armor bumper
-Ive always like maier wrap around hand guards, id suggest those or acerbis
-graphics if you want, personal liking
-dont get itp ss112 rims or whatever. personally i think they look dumb on sport quads. leave stock rims, paint em black or whatever or get some beadlocks
-parking brake blockoff
-uni foam filter
-little personal bling wherever youd like
do me a favor and dont be one of those dudes who put mud tires on a sport quad though. please, stick with holeshots or razrs or x-rexs or somethin

Im always open to ideas of waht I should do with it.
Have you had problems with tusk products or are they poor quality the only reason I was going with them was cause I think the insert would go good with the graphics I wanted

Graphic kit (item # 130554509583 )
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=130554509583

Bumper insert ( item # 180519489810 )
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=180519489810&viewitem=&sspagename=STRK%3AMESINDXX%3AIT

Parking break block off, what is that? really basic thing im sure but I have no idea if there is one on it or where it goes at all. and what does it do?

Nerf bars I cant stand the look of them, mainly how far they stick out iv been looking for a pair that was just a little past the pegs.

And as for the rims I asked a member on here if they could Photoshop them on a picture I sent cause I dont know how i feel about them. my buddy is buying a set for his warrior that he re did so ill get an idea with his if the photoshop doesnt work out.

I have updated the list of things I want to do to it. ill post that up later tonight.

[DirtyBirdRacing]

My NEW list of what im planning on doing. not really going in to the motor just yet. I recently joined the Navy so im not going to be rideing a lot anyway and am planning on doing a build with a CBR1000R motor when I get out so just want this one to look nice lol yeah alot of money going to waste in some people opinion ( and in mine a little lol )


-Tusk Front bumper
-Bumper skull face plate
-Battery box DG
-DG fat full skid plate ( engrave "if you can read this please flip me over" on bottom center plate )
-Two brother’s exhaust
-Polished Stainless Bolt Kit
-Protech Gas Cap Red aluminum
-Aluminum Gas Switch
-Hand grips red skull grips
-Moose Comp Lever set
-Break rotor saw blade
-New Fender clips
-LED Rear Tail Light for Yamaha R6 03-05
-K&n Oil filter
-Throttle/break covers
-Chain guard
-ITP front and Rear tires
-ITP Sport rims
-Front and Rear Breaks
-New Chain
-New Sprocket Set
-Aluminum Heal Guards
-Billet Oil Stick
-Aluminum Air Vents
-Aluminum Air Box
-Chain roller and slider
-Steel Braided Clutch Cable
-Steel Braided Throttle Cable
-AMR Racing Graphic Kit
-HID head lights
-Tie Rod
-Left Crankcase Gasket
-Right Crankcase Gasket
-Throttle Case Gasket
-2, O-Ring, Rotary case
-Slider Chain Guide
-Swing arm Bolt and nut
-Sparks +6 Key
-New front suspention ( un knows what im going with )
-LedGlow Light kit


THE MOST POINTLESS THING I WILL PUT ON IT
Smokerider Smoke screen kit

[Speed37]

that list is about $400+,my friend.

[finsteratv]

i think you should definately do more suspension work and dont get the SS wheels go with some nice aluminum ones or beadlocks. even some nice cleaned up stockers. im more of a clean looking quad that rips other then a pretty trailer queen haha. i think if you have a good balance it should be pretty awesome!

[HondaRacing83]

tusk products just arent the great and dont look good imho, please go with a pro armor bumper or blingstar, or prm. prm summit will look badass. im assuming your getting itp gncc's get itp beadlocks. id suggest some roll design fat pegs. get new bars, yours look terrible..

[CJM]

Originally posted by HondaRacing83
tusk products just arent the great and dont look good imho, please go with a pro armor bumper or blingstar, or prm. prm summit will look badass. im assuming your getting itp gncc's get itp beadlocks. id suggest some roll design fat pegs. get new bars, yours look terrible..

My nerfs would beg to differ with your statement. Aint busted yet and its easily been a year of riding every weekend if not more.

[DirtyBirdRacing]

Originally posted by Speed37
that list is about $400+,my friend.

HAHA I wish it was somewhere close to $400 :( the price changes here and there but a VERY rough EST is $2,500

AND IT IS ON ITS WAY AGAIN JUST ORDERED $100 in parts today All from CheapCycle ^.^ so glad I am finaly getting money to get this going again.

2, Tie Rod
Left Crankcase Gasket
Right Crankcase Gasket
2, O-Ring, Rotary case
2, O-Ring [81x3]
Swing arm Bolt
Nut, U [14mm]

[DirtyBirdRacing]

Got a Chance to order some more parts the other day,

-Sparks +6 Key
-Stock 400EX shocks < For the time being they were cheap and I need it to just get the wheels back on mine shocks blown
-Bumper insert for Tusk Bumper
-Clymer Manual
-Fender clips, Just cause lol
-COLLAR, FR. ENG HGR-------------/
-COLLAR, R. ENG HGR /
-COLLAR, L. ENG HGR > Dont know what else these are called<
-COLLAR, R. ENG HGR /
-COLLAR, L. ENG HGR-----------/
-Gasket for my throttle case
-K&n Oil filter

--NEXT TO BUY--
Things for the 450r carb
Stainless Bolt kit
New chain ( D.I.D most likely )
New Sprokets ( JD steel )
New front and back breaks
New Break rotor


I sould start uploading more pictures soon, I just firgured people didnt want to see pics of stock parts comeing in lol. In the next 2-3 weeks The Swingarm and Axel will be getting painted, Ill have pictures of that up when I can.

[DirtyBirdRacing]

Just Picked up!
-Set of 05 450R shocks Only 5 hours on them (thanks Latemodel32)
-450R carb adapter (thanks zrpilot)
-New break Rotor
-New breaks all around

I will be getting pictures on here as soon as I can, I'm just trying to get a pile of parts before I start putting them on so I can go at it for a few hours and have it on wheels and running again :D

[DirtyBirdRacing]

Pictures comeing tonight, Swing arm being painted,

Ordered
Stainless Bolt kit
Moose Comp red lever set
JT steel stock front and back sprockets + O-ring chain


Next on list
2Bros exhaust.

[DirtyBirdRacing]

Well I have some pictures my friend sent me of my 400 lights dont all work in his garage, and it was on my friends cellphone so yes they are a little crappy, I will try and ask for better ones out side later on. but here it sits now,

Swing arm painted and on, Saw blade Break Disk/rotor on (will ask for good pic of that, Rear shock on, Front shocks on, I belive he just put the stock shockes on for now to get it up on wheels. I have like new 450R shocks that will be put on before it is ridden. crapy old tires and rims on it just for now they will be getting changed before I do any/serious rideing. Its looking a little like a ATV now... rather than random parts in a box ( well all over the floor )

http://i128.photobucket.com/albums/p185/lord-inuruku/005.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/004.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/003.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/002.jpg

[Stickman400]

I take it you like the color red? lol

[DirtyBirdRacing]

A little bit... lol im hopeing when im done i dont/ didnt over do the red and have to change alot of things over to black.

[DirtyBirdRacing]

Update!

Just recived my 2Bro M.7 exhaust and rear PRM grab bar, i had them sent to my house in WV not to my friend with my 400 in PA due to Tax on items saved 20 just haveing them shipped here and will be installing them when i go to pick up my truck in the beganing of DEC, so for now i just have pictures of them not installed :)

http://i128.photobucket.com/albums/p185/lord-inuruku/861ea43e.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/310d80da.jpg

http://i128.photobucket.com/albums/p185/lord-inuruku/81f89bc1.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/7995635e.jpg

The pipe that came with my slip on, Do you think that is going to reach my Stock head pipe? i dont remember how long the stock one is it has been way to long since i saw my baby :(

[powerbomb400]

It will fit just fine. That is what I've got and I've really like it. Had a titanium 4 on my powerbomb header. I liked it but it was alot louder than the 2 Brothers. My wifes 250ex has got the 2brothers silencer and I liked the sound of it so I got one for my 400ex. Seemed to help bring more of the low end torque out. Follow the directions that come with it and it will bolt up with no problem.

[DirtyBirdRacing]

ok thanks, Its been so long since I have seen my 400 that I wasnt sure where the stock pipe ended lol

[jkosakowski]

How does that grab bar go on isnt the stock one part of the subframe?

[dxcody]

its has C shaped clamps that go around the stock grab bar.. I wondered the same thing but if you look in the picture you can see the bag of bolts

[jkosakowski]

I see i might have to get one of those lol
:)

[DirtyBirdRacing]

Yep, Just C Clamps around the stock one, I'm worried about it chipping off all the paint I just put on to it I figured I could just wrap the sub frame where it will clamp on to with clear or electrical tape? do you guys think that will be fine or have any other ideas?

[jkosakowski]

You could do that or you could get little rubber strips that stick on the backside and tighten it down against them.

http://www.grainger.com/Grainger/Rubber-Strip-1TXP5?cm_mmc=GoogleBase-_-Raw%20Materials-_-Rubber-_-1TXP5&ci_src=14110944&ci_sku=1TXP5

Something like this ^

[CJM]

Rubber weatherstripping, 2 bucks at your hardware store.

[jkosakowski]

^ thats excatly what i was thinking and couldnt think of were to get it thanks lol

[CJM]

Originally posted by jkosakowski
^ thats excatly what i was thinking and couldnt think of were to get it thanks lol

Welcome.

[DirtyBirdRacing]

Yeah thats ALOT better of an idea, thanks guys.

[dxcody]

yea that is deff on my wishlist now too!

I just want something bigger to grap onto unloading/loading it in my truck and when you get stuck and have to pull it backwards they help too i think.

[powerbomb400]

Their six-pack is nice. We put them on ours to carry 1gallon gas cans. What I like about their racks if you flip it the smaller tubing will bend before the sub-frame does. They also have good prices and promptly ship when you order something.

[DirtyBirdRacing]

Well After fighting with my mom telling her not to buy me anything for Christmas I finally gave in and let her have a peek at my Wanted Parts list... So I know what I'm getting for Christmas now ( cause i had to order them for her cause she is scared of Ebay :P ) Only rule was i can not install them un till after Christmas cause i have to un wrap them Xmas day :( no fun lol
Ill post pictures of them when they get here but for now heres the list

Throttle and break covers, Black with 400EX in silver etched in to them and
Graphic kit, Wanted to post a pic of this :P Cause i love these (they show it on a newer style mine is an 01)
http://i128.photobucket.com/albums/p185/lord-inuruku/Skullset.jpg