First Build! (beginner in a shed)

[MisterGraphic]

Hey Guys,

I'll start posting picture of my build in this thread.
All the parts are here and needs to be assembled! :)

Here is a picture of my machine before I started!

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_2.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_1.jpg

[MisterGraphic]

Picked up the frame from the powder coating shop yesterday.
Didn't want something too flashy so I chose silver with sparkles.
It's hard to take a picture of the shine so here's a few shots.
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_6.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_5.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_4.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_3.jpg

I'm very impressed with the results!

[riotact]

Looks sweet so far!!!

[NacsMXer]

Very cool, i'm digging the metallic effect on the frame :cool:

[MisterGraphic]

Thanks!

The swingarm,a-arms, Nerfs, Shifters,
Motor Mounts & Bumper are all gloss black.

It should make a nice contrast :)

[jcs003]

nice PC. your quad looked good to begin with. cant wait to see her finished.

[finsteratv]

whats the mod list?
looks good!

[wild250rman]

you keeping the yellow?

[MisterGraphic]

Yeah It's definitively staying Yellow!

Mod List :
- +4 Axle
- New Rear Hubs (stock)
- +2 Steering Stem (from ebay)
- Front Steel braided brake lines
- 426cc with 11:1 Compression
- Stage 2 Hot Cam
- Cometic Gasket Kit
- Full Exhaust System

I've been riding it stock for 3 years so
it's time to add power! :)

Pictures made it look good, the frame was
half gray half black, the nerfs were peeling pretty bad!

[wild250rman]

Originally posted by MisterGraphic
Yeah It's definitively staying Yellow!

Mod List :
- +4 Axle
- New Rear Hubs (stock)
- +2 Steering Stem (from ebay)
- Front Steel braided brake lines
- 426cc with 11:1 Compression
- Stage 2 Hot Cam
- Cometic Gasket Kit
- Full Exhaust System

I've been riding it stock for 3 years so
it's time to add power! :)

Pictures made it look good, the frame was
half gray half black, the nerfs were peeling pretty bad!
will look real good yellow. looks like you have a good plan there. good luck with the build.

[MisterGraphic]

Got a few things together this afternoon,

Got myself a cheap Parts Cleaner at Princess auto, it fits neatly in my recycled sink/work counter
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_7.jpg

Installed the Steering Stem Bearing
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_8.jpg

Picture of the Swingarm Bearing Assembly (might be useful for reference)
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_9.jpg

Close-up of the order
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_10.jpg

Subframe, Burgard +2 A-arms, Hubs, 450r Shocks with dual rate springs & Tag Bumper installed
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_11.jpg

Front View
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_12.jpg

I'm bringing my swingarm to get the bearings pressed as
I ruined one of the spline bearings trying to push it in.
More expensive to ruin parts than to get it done right.

Will get more stuff done tomorrow :devil:

[MtnEX]

The recycled sink is awesome!

I wonder if momma wants a new counter top and sink?

Then daddy will have a recycled sink for a work bench/parts washer.

[MisterGraphic]

The sink even better in summer, I connect the
garden hose and have running water in the shed
(5 gallon pale underneath)

No running water when it's -10C outside though!

[MisterGraphic]

Got some work done today!

Here's pic to compare the 450r footpegs, bolts on with no mods.
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_13.jpg

Motor before I cleaned it
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_14.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_15.jpg

After engine cleaner + car wash pressure washer
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_16.jpg

Stem Mount
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_17.jpg

Nerfs & Pegs
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_18.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_19.jpg

Putting the rubber back on the powdercoated shifter
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_20.jpg

After
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_21.jpg

Brake Lever Installation
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_22.jpg

Brake Cylinder & Reservoir
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_23.jpg

Rear Shock & Battery
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_24.jpg

Air box, oil reservoir & cooler, wiring harness
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_25.jpg

It's coming together!
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_26.jpg

Tomorrow I'll get the motor ready for HD stud installation and the piston bore.

[finsteratv]

in the first pic whats the big black tube behind your bumper? extra "cargo" area ? haha

LOOK GOOD

[MisterGraphic]

Thanks for the comments :)

Yeah, I needed extra storage 2 years ago.
We did a 2.5 day trip/camping so we needed room for tools. (approx. 380km)

Here are pictures my friend took, best drive I ever had!

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/6773_249531580421_578020421_8233354_1449708_n.jpg

(tow strap, mini-pump, spare chain, tools, tire repair kit and tie wraps!)

And one of the complete setup
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/6773_249531265421_578020421_8233303_7107416_n.jpg

(photo credits : Peter)

[finsteratv]

never seen that for extra storage maybe ill try it out this summer :cool:. can beat camping and riding together :D

[MisterGraphic]

There's a thread with an Ammo Box storage, that's also a good idea if you need more storage.
I wish I could find one that's not as deep.

[RATPACK Z400]

Next time put bearing in freezer then tap in ! Simple Green consentate on motor let it sit then power wash/scrub brush will get brown haze off.

[MisterGraphic]

Totally forgot about the freezing! I'll try next time around.

Thanks for the Simple Green suggestion, I never tried the product.
I'll bring it back to the car wash and check how good it works!

[MisterGraphic]

Got a few things done,

Washed the 10 years old nets... Just like new! (Threw them in the washing machine with jeans)
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_27.jpg

Mocked-up the exhaust for fun
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_28.jpg

Got the swingarm from the shop and installed the rear end
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_29.jpg

Other side
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_30.jpg

Was getting too heavy for milk crates
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_31.jpg

Starting to take the motor apart
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_32.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_33.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_34.jpg
Oops, sorry for the blurriness
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_35.jpg

[CJM]

I see your smart, you do the cardboard and bolt trick :D

Looks good, gonna do a HD timing chain and replace the guides and whatnot.

[MisterGraphic]

haha, just following the instructions in the book!

There is no play what so ever in my chain and the guides are like brand new so I'll keep them for a while.

Thanks for the comments, appreciated :)

Denis

[CJM]

Thats good to hear. I noticed mine was worn out by seeing the guides were kinda chewed up slightly and my friends was worse-his were coming apart at the bottom especially and flaking off rubber.

[MisterGraphic]

Dropped the motor off at the engine shop to get the Head Studs installed and cylinder bored ! Should be ready next week!

Hopefully I'll be able to go for a little drive in 2 weeks

I'm only missing my steering stem and my front brake lines.

[Shawthy33]

Keep up the good work, like the progress so far.

[MisterGraphic]

Thanks man,

Here are two other pictures; first time I open up a motor so here's my questions:

Is it normal the valves are very "crusty" with a thick layer of carbon on them ?
Same question goes for the upper part of the piston.

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_36.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_37.jpg

[ridehonda400ex]

What octane gas were you running? If it was like 87 then it might have ethanol in it, I think like 15%, I've heard ethanol will cause carbon build. And your going to get some build up on the piston

[MisterGraphic]

I always put Premium and it's supposed to be around
91 octane to 93 octane depending on the gasbar....

[ridehonda400ex]

Hmmmm well id say just take the piston out since your getting a new one anyways. Then If I were you and I had money id get some new valves, get them re-seated...etc and clean everything up real good. And while you got the motor out you should clean it real good

[MisterGraphic]

Yeah the piston is replaced with the
426 piston (88mm). My friend will make
sure the valves seal properly by turning
them with some sort of valve compound.
We'll make sure to clean everything
while we're doing that.

[MisterGraphic]

Got my +2 Steering Stem! will install it on my lunch break!

[MisterGraphic]

Air Filter and Stem

out with the old :
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_38.jpg

In with the new
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_39.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_40.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_41.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_42.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_43.jpg

Had to that very fast because it's -18C in the shed....Brrrr

[evan402]

geez i cant even imagine working on my quad in that weather. Some definite dedication!

[Shawthy33]

You won't regret the Uni Filter but I would get some Filter Oil on it before you run it, definitely helps with the performance of any air filter

[MisterGraphic]

The trails are groomed during the winter here so I'm actually
"losing" riding time... That's why the dedication is there!

The filter is smothered in oil in the picture, I soaked it real good
with the Uni oil and put in in a plastic bag to massage the oil in.
Do people run Pre-filters on the Uni ? (Like the one I had on the K&N)

Also, concerning the steering stem, seems like there is a lot of
flex from side to side. I can literally see the stem bend when
pressing from side to side on the handlebars, is that normal ?

[sc400ex_rider]

if you didnt clean the top frame/sub frame bolt bosses to bare metal it will not start. the battery grounds to the sub frame then through the main frame to the engine. a lot of frame repaints turn into no start, no charging issues. also make sure you coil is mounted to bare metal just to be sure. after you sand off the paint, smear a little grease on it to keep away rust.

[Shawthy33]

Originally posted by MisterGraphic
Got my +2 Steering Stem! will install it on my lunch break!

What did you go with for a Stem?

[MisterGraphic]

It's a Chromoly +2 stem from ebay.
Welds, and everything seem top notch, but it seems to flex a lot.

http://cgi.ebay.ca/Honda-400ex-2-Steering-Stem-Chromoly-W-Bar-Clamps-NEW-/260419551914?pt=Motors_ATV_Parts_Accessories&hash=item3ca23702aa#ht_627wt_907

Might have to do with my handle bars that are too high for the +2 stem (I'm running ATV Mid)

[Shawthy33]

At $249 couldn't you go with a Burgard or Laeger or a trusted brand rather than Ebay?

[MisterGraphic]

Sent an email and called Burgard and never got a reply.
Would have been 75$ more with Houser because I need to
purchase the bar clamps separately.

Time will tell how bad I got screwed...
I'll make sure to follow-up if it breaks or anything.

[MisterGraphic]

Picked-up my Cylinder at the machine shop
and received the front brake lines.

I'll be putting that together and lapping
the valves this weekend! :)

Sooooo close!

[MisterGraphic]

Lapped and installed the valves in the head.
(Q tips where used so the compound didn't go everywhere)
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_44.jpg
Put back the cylinder.
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_45.jpg
Installed Head and Valve Cover
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_46.jpg

Had to do that twice because I forgot 2 dowel/pins under the cylinder....
of course I noticed after the cam was installed and the timing was set....
Oh well, it goes faster the second time over.

The valves are set and the motor is in the frame now!
Just waiting for my main jet to arrive.

[MisterGraphic]

Stuff I installed today....
- Front brake lines (still need to bleed them)
- New CR High bend handlebars (lower than my ATV mid bend; felt like a giraffe before)
- Chain (set chain / lubed)
- Clutch cable
- Exhaust
- Added oil in the motor

few pictures, some blurry are but wtv...
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_47.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_48.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_49.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_50.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_51.jpg

Only thing missing is my Pilot Jet before
I install the carb and try the first start.

[MisterGraphic]

sc400ex_rider

I just saw your comment about the subframe contact and
I'll have to take it off to sand between the frame and subframe.

Really good point!

Hopefully my Pilot arrives tomorrow so I can try the first start!

Thank! :)

[MtnEX]

WOW!... What a megaphone midpipe on that Sparks exhaust! I had no idea they were made like that... I guess I never noticed before.

[AtvKid4Eva]

400ex Sparks pipes are awesome!

[MisterGraphic]

Thanks guys,
it's the Sparks X-6 (not the big core)

[MtnEX]

Originally posted by MisterGraphic
Thanks guys,
it's the Sparks X-6 (not the big core)

OK, so maybe it is not that I haven't noticed before... maybe it's that all I have ever seen is the one and not the other.

[MisterGraphic]

Everything is together!
I'm going to get gas now!!!!!!!

[MisterGraphic]

Started on first try!! Such a great feeling!

I'll post pictures of the complete 4wheeler
later, probably after I design the graphics.

It idles well but I haven't had a chance to really try it
because I didn't want bug the neighbors with the noise.

[MisterGraphic]

Went for my first drive today, it's running a little lean so I'll change the needle clip.

(backfires when I let go of the throttle)

[MisterGraphic]

Here's a quick picture outside,
I'm hoping the graphics will "set things off"

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_53.jpg

[MisterGraphic]

Here's a quick sketch of the possible graphics.
The gold wheels won't happen anytime soon because
it's winter and there's no point for now.

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_54.jpg

[MtnEX]

I like it... it's different...

Looks cold up there!

[MisterGraphic]

Thanks man, I appreciate the comments.

The graphics are giving a retro feel and I think
it works well with the styling of the bug eye.

[Shawthy33]

Do orange wheels like the real repsols....that might be kinda cool.

[MisterGraphic]

I'll have to re-photoshop that, It didn't look as good as on the bike,
because the plastic are Yellow and not mostly orange like the Repsol CBRs...

[Shawthy33]

True, a maier orange plastic set and full Repsol graphics would be insane, not exactly budget friendly

[MisterGraphic]

Yeah, I'm not gonna spend that much money just for a color change.
My yellow plastic are pretty scratched up but atleast there is no cracks
and they're cheap...:P

[MisterGraphic]

Edited : I posted the timelapse videos 2 post down.
(I was able to slow them down)

[MtnEX]

Hah! That was cool...

[MisterGraphic]

I was able to make the timelapse videos a little slower.

In the second one you can see I'm
bleeding the brakes with a transparent tube.

I read about the technique on the 450r
forums and it worked perfectly. (Not bad for 2.99$)

Basically, make sure the reservoir stays full of fluid,
open the bleeder and suck on the tube until the brake fluid
shows up in the tube. (tube attached to opened bleeder)

Don't forget to press on the brake lever or you'll be wasting your time...haha


http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/th_Timelapse5.jpg (http://s53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/?action=view&current=Timelapse5.mp4)

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/th_Timelapse4.jpg (http://s53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/?action=view&current=Timelapse4.mp4)

[yama450yfz]

That thing looks sick kind of retro I like it.

[400exmxrider15]

Did the simple green really clean that cylinder up, or did you just buy a new cylinder???

[MisterGraphic]

The cylinder was dipped in chemicals at
the machine shop before the bore.
I'm guessing it was Acid of some sort.

I tried simple green on the engine but
it didn't work that great.

Thanks for the comment guys!

I went for a drive today and it works pretty good. It may be time for a new
clutch because it seems to slip when
I'm at more than 3/4 of throttle.

[trx400Rider]

how much were your a-arms?

[MisterGraphic]

A-arms were 450$ + Shipping & Customs
from Burgard Cycles.

Great product but I would recommend you
call them first before placing your order.

[MisterGraphic]

Ordered a new Clutch today!
It should solve the "won't go faster than 80km/h problem"
It should arrive in the next few days.

It was the stock clutch from 2001 so I just bought a new stock one,
10 years ain't bad, and this 4wheeler is mostly for trail riding.

(Was hitting the rev limiter as soon as I pressed the throttle to more than 3/4)

[MisterGraphic]

Hey everyone!

Installed the clutch and then realize something worst was happening.

There is another thread about this but here's the "résumé".
Cam Sprocket screws came loose and it ruined my cam sprocket,
screws, cam. The timing chain got damaged on the side but thankfully it didn't break.

Today I finished putting everything together (again).
New Cam, crf450 timing chain, guide and sliders, cam sprocket and new cometic gasket kit.
Went for a little a drive and it doesn't sound too good when I get near full throttle,
It's almost like it's hitting the rev limiter early or bogging/loosing power.

Anybody know what it could be ?

[JOHNDOE83]

to rich maybe?

back down a few sizes on the jets and see if it gets better?

[JOHNDOE83]

It may be to lean?

[MisterGraphic]

I really hope it's just a jetting problem... (Lean or Rich).
I'll probably just bring it to a professional to make sure it's running perfectly. :)

Working on the mechanical stuff wasn't too difficult but
this will really make a difference and save a lot of headaches.
I'll let you guys know the outcome and/or what he does!

[bkb88]

Did you make sure and put red locktite on your cam sprocket bolts this time? I have a feeling that's why they came loose to begin with and would definitely be worth taking the valve cover off again to do so if you haven't already.

[MisterGraphic]

Yes, this time I used Red Locktite and the parts were cleaned/dried
before I applied/torqued it. (The blue one didn't work the first time around...)

I'll up my main jet one or two sizes and see if it changes anything :)

[CJM]

FWIW I always used blue loctite on mine and never had an issue. Red is near impossible to get the bolt/nut off without intense heat.

[MisterGraphic]

Then it must be because the parts weren't well cleaned,
because I used the blue one and it came off anyway.

Not much I can do about it now... Live and learn I guess!

[bkb88]

Awesome, glad to hear it! I have used red and haven't ever had an issue with removing the bolts. I think the torque spec on is only like 14ftlbs if my memory serves me right. I have had sprocket bolts come loose just like MisterGraphic and I want to know they're in there for good! :)

[MisterGraphic]

For everyone else doing this for the first time, this means you
have to make sure to clean your parts and dry them properly
before using any kind of locktite.

[MisterGraphic]

Hey everyone,

Yesterday I upped my main jet to a 158 and it runs worst.
I noticed when I get on the throttle it smokes black.
I'm assuming it's running rich so I ordered a 152 and a 150 main jet.

I'm running a #40 Pilot and the AF screw
is out 2.5 turn with the needle on middle clip.

Any input appreciated :)

[MisterGraphic]

Ended up giving up and I brought it to a shop. The mechanic said the float is not adjustable and it needs new parts so it doesn't flood when in full throttle.

He said the parts are 75$....I think I'll just buy a 450R carb off ebay. I already have the adapter here...

[dxcody]

man, this whole thing is just awesome.. i love seeing a old machine be restored. you really did it the proper way too, some guys (cough cough me) are too stupid to admit when it is time to take it to the shop but you really did a great job man, the 450r carb will serve you well but jetting will be totally different then what you have now if i remember reading about this correctly, since you have the bore, and cam, a 450r carb should work well.

[MisterGraphic]

Thanks man, appreciate the comment :)

I wonder what will be a good starting point for the 450 carb jetting, Any one have suggestions ? I'm at 183M over sea level.

(Mods are in signature)

[dxcody]

well i personally dont even have a clue buddy, wait until CJM, or Ron, or steve get on here, they should be able to tell ya.

[MisterGraphic]

Well, I did a lot of reading and I'll start with these settings when I receive the carb.
48 Pilot, Middle clip Needle, 178 main, 2.5 turns out on the A/F Screw. (Elevation is 183m or 600ft)

If anyone has other recommendations let me know :)

[CJM]

That sounds about right. Pilot might be slightly rich, but its not possible to tell till you run it. Ive seen anywhere form a 52 down to a 45 pilot, depends on the quad and the area your in.

Jetting should be close, figure maybe a few sizes down. With my 400ex carb and my done up 416 im using a 170 main and 42 pilot and I could go up one pilot size since it pops slightly still.

[honda400ex2003]

Originally posted by MisterGraphic
Well, I did a lot of reading and I'll start with these settings when I receive the carb.
48 Pilot, Middle clip Needle, 178 main, 2.5 turns out on the A/F Screw. (Elevation is 183m or 600ft)

If anyone has other recommendations let me know :)

replied on your pm.

id start 180 52, 2.5, 3rd notch. probably end up at a 178 or 175 with the rest the same.

imo the 48 pilots are too lean on these things with the 450 carb to even mess with buying them. even with my 50 i am at 3 turns out on the f/a when it gets colder.

steve

[MisterGraphic]

Thanks for the quick replies !!
Now I just have to wait from my carb from Service Honda. Everything takes long to arrive to eastern Canada.

I'll take pictures of the install, this thread is getting boring...haha

[rooster300ex]

What happend to the shocks u had on it in the pics??

[MisterGraphic]

Still have them they are for sale locally,
If anyone is interested I would ship them out for the right price :)

I could post more pics this weekend if needed (close-up and stuff)

[rooster300ex]

How come u took them off and put the old ones on??

[MisterGraphic]

I found them too soft for my setup,
They were setup for XC on a 450r with stock a-arm.

Being for XC and the fact I have +2 a-arms make them a little too soft.
They would need to be used on regular a-arms or be revalved for proper weight I imagine.

[finsteratv]

how much for the shocks??

[rooster300ex]

Originally posted by MisterGraphic
I found them too soft for my setup,
They were setup for XC on a 450r with stock a-arm.

Being for XC and the fact I have +2 a-arms make them a little too soft.
They would need to be used on regular a-arms or be revalved for proper weight I imagine.

Oh I c. Thats to bad man.

[rooster300ex]

I would get em revalved them made the quad to me.

[MisterGraphic]

Yeah I imagine that would be a good idea, but I have so much money in this 4wheeler already I don't want to spend more.
Plus I haven't "outridden" the KFX450R shocks because I don't get to drive the 4wheeler often.

I paid the TRX450R shocks $330 on ebay...then when they arrived here they charged me 130$ for customs... Since they would need revalving I don't think I could send them for that price....but 280$ would be good. The dual rate springs on them reatail for 225$ + installation/taxes.

I don't really know what to do..lol

[rooster300ex]

Looks like it turned out to be a good build though. How do u like the kfx shocks? I have 450r shocks on my 300ex with DJC shock relocater. I was gonna go with the kfx's.

[MisterGraphic]

I really like the KFX shocks,
They were a little shorter but I don't mind being a little closer to the ground.

I did a little bit of jumping (15' double) and they never bottomed out)

There is a local track here I just found out about, I'm hoping I can practice there, I always land on my back wheels and I really need practice...lol

[CJM]

KFX/YZF shocks are very nice, sits lower yes but much softer than 450r shocks.

[dxcody]

nick @jet suspension told me that 450R shocks are the best stock shocks

[CJM]

Originally posted by dxcody
nick @jet suspension told me that 450R shocks are the best stock shocks

What makes the yfz shocks better is they are softer and already progressive-but the 450r shocks can be reworked much better in the end.

[rooster300ex]

Originally posted by CJM
KFX/YZF shocks are very nice, sits lower yes but much softer than 450r shocks.

They are softer thats what I need the 450r shocks on my 300ex are pretty stiff. They are on the softest setting and still to stiff, but are better then stock 300ex. I need to sell my 450r shocks and get some kfx's.

[dc01]

Originally posted by dxcody
nick @jet suspension told me that 450R shocks are the best stock shocks



I have JET Suspension 450r shocks and my buddy has YFZ shocks, both on 400's, and my JET shocks are 100% better than his. The YFZ shocks feel to spongy, when you come into a turn it wants to nose dive but were both 200lb riders. But I have never rode on stock 450r's before either.

[MtnEX]

All stock shocks suck until they are revalved... and about any other stock front shock that will fit from anothe sport quad is better than the stock 400EX front shocks.


Who makes aftermarket suspension stuff for the 400EX these days anyways?

[CJM]

Originally posted by MtnEX



Who makes aftermarket suspension stuff for the 400EX these days anyways?

No one, the shocks are garbage. Why honda cant figure that out IDK.

[MisterGraphic]

Since we're talking shocks,
Anybody ever tried these ?

I love how they look

http://cgi.ebay.com/ebaymotors/Works-G-Series-Front-Reservoir-Shocks-Honda-400EX-_W0QQcmdZViewItemQQhashZitem1bfe4f5561QQitemZ12023 0729057QQptZMotorsQ5fATVQ5fPartsQ5fAccessories#ht_ 2381wt_941

[MtnEX]

dead link already :(

[MisterGraphic]

wow that was quick,
Search for "Works-G-Series" on ebay, it's a remote-rezzie shock set.
I absolutely love the colors....I'm just wondering about quality, the price seems too good to be true.

[CJM]

Works are some better shocks, but personally Id rather spend the coin and revalve/respring a set of stock 450r fronts and a rear 400ex shock. Total cost for triple rates is like 700 bucks and then you truly know they are setup for you and your riding style.

[chronicsmoke]

^x2

[MisterGraphic]

So I received the Carb from service Honda,
Call the honda dealer for the Pilot and they only sell the 48.

Jets are us won't deliver to Canada...What are my options ?

[MisterGraphic]

Just messaged "Carbparts.com" to see if they can help :)

[MisterGraphic]

Worked a little on the 450R carb tonight :)
Still missing SlowJet and Throttle Cable...

Used the ZRPilot Adapter and it fits great!


http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_55.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_56.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_57.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_58.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_59.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_60.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_61.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_62.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_63.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_64.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_65.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_66.jpg
http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_67.jpg

[MtnEX]

Nice....

Everyone seems to love the results of the R carb.

[MisterGraphic]

Ordered Jets from pjmotorsports.com/

I called and they gave the best customer service ever.
I'm going on vacation so I'll receive the jets in a few weeks.
(decided to save a few $ with snail mail)

Will keep you guys posted in july...lol

[chronicsmoke]

Originally posted by MisterGraphic
Ordered Jets from pjmotorsports.com/

I called and they gave the best customer service ever.
I'm going on vacation so I'll receive the jets in a few weeks.
(decided to save a few $ with snail mail)

Will keep you guys posted in july...lol

What jets did you order? I might be replacing the stock 05 carb off my 450 with an FCR and putting the 05 carb on the 426. We have similar mods, so when you get 'er dialed in post your jetting specs.. pwetty pweeeeas :p

Good shots of the carb adaptation too btw. Keep up the good work!

[MisterGraphic]

I never ran the 450r carb and I never tuned a carburetor before.
I ordered the jets based on forum members recommendations.
They did it before so hopefully their experience will save me a few headaches!

Here's what I ordered :
Pilot : #50 and 52
Main : 172, 175, 178, 180, 182, 185

I ordered more than I need because the shipping price was the same
wether I order 1 or 7 jets....The jets will take about 3 weeks to arrive and I didn't
want to repeat that process...(I chose to go with "Snail Mail" to save a couple of $)

Thanks for the comments :)

[MisterGraphic]

Oh yeah, and I'll post the final settings for sure!

[MisterGraphic]

Hey everyone, Just got back from my holidays and installed the carb.

I received my jets from PJ Motorsports and could not be happier
with their customer service. They took longer to arrive because of
the CanadaPost strike but they treated my like a friend.

It started up, won't idle and backfires pretty
wildly when I get halfway with the throttle.

on the 450r carb, is the idle screw manual ? (with the little plastic nob ?)

Right now it's set as follows :
180 main, 52 Pilot, 2.5 turns out, needle on 3rd clip.

Any suggestions ?

[HondaRacing83]

Take your main down a little

[MisterGraphic]

The idle is now fixed and it stays started,
First 1/8 - 1/4 throttle works well so my
Pilot is probably close to correct.

Brought the main down to a 178,
helped a little, then brought it down
to a 175, helped again a little bit.

Is there anything I should do with
the Air-fuel screw ? Right now it's at
2.5 turns out.

I thought the Main jet was only for the
last quarter of throttle, my bog is early
mid throttle I didn't even try full throttle yet.

Input appreciated :)

[CJM]

Pilot and a/f screw should be fine, 2.5-2.75 turns out is about ideal for most.

Main really begins to control around 1/2 throttle and by 3/4 its mostly the main.

Needle really controls the mid range, I like mine at the 3rd notch from the flat end-no bogs that way.

Id try adjusting your needle to be less rich perhaps, maybe 2nd clip. That fails go down a jet size, maybe a 172.

Whats the plug looks like so far?

[MisterGraphic]

To be honest I haven't looked at the plug
yet, I was hoping to get it running half decent
before looking and fine-tuning.

I'll try the needle tomorrow :)
it does feel like it's flooding mid-throttle, so that should help.

Appreciate all the help

[MisterGraphic]

found 2 more pictures from the carb installation :) (sorry for the blurriness)

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_68.jpg

http://i53.photobucket.com/albums/g61/omgvwgolf/2001%20400ex%202011%20Build/400ex_69.jpg

The 4 wheeler has been working very well
now, I'll check my final setting and post
them once I get the chance.

[MisterGraphic]

Hey Guys,
The 426 ran good all summer, but now I get hard cold start. How could I remedy this situation?
Only differences from summer: Temperature, and I put the airboxe cover on

Thanks for the help or hints! :)

[MisterGraphic]

Bump for my last question

[honda400ex2003]

jet according to the temp changes.

you might be able to get away with turning your f/a screw out about 1/2 a turn and pump it a couple more times to get it running at the very least but a bigger pilot would be suggested along with a jet thats 2 sizes bigger than what you run for the summer. that is if you are jetted around 70 degrees and are running below freezing or right around there though. check the jetting for temps chart.

steve

[honda400ex2003]

you can also reach in and use your choke. just take your seat off and reach up in there to get it warmed up a bit, as you start to let it off see how it runs. if it stays running well let it go, if not, it needs a bit more time.

i do that usually along with the 1/2 out on the f/a and it seems to work ok for the few times i ride in the winter.

steve

[MisterGraphic]

Thanks Steve,

It's having a hard time starting with the
choke and I didn't bother trying without
it... (I usually always need it when it's
below -10C).

I'll try taking out the A/F screw a bit and
see if that works.

[jkosakowski]

Are those gt thunder 450 shocks? How do you like them?

[MisterGraphic]

I think they are, I bought them on ebay.
They are too soft with my +2 arms
because they are setup for XC on regular
a-arms. I have an ad for them in the
classified section.

http://www.exriders.com/vbb/showthread.php?s=&postid=4198272#post4198272

[Fix29]

Great looking EX man, you did a nice job on the build

[MisterGraphic]

Thanks, appreciate the comment :)

[maddmaxxx]

mr graphic; i replied to your 450R shock ad, in the classifieds


-i posted my email addy [but used 'at' instead of @]


-im in michigan...


-would appreciate your time guy:)

[MisterGraphic]

I replied to your email with a price for shipping :)