400ex Resto/Mod

[mattl31]

Figured I'd show all of you guys what I've been up to over the cold months...I've had this quad for about 4 months now, and like my normal self just couldn't leave it alone. What was supposed to be a tear-down to replace a few bearings and worn parts turned into a full out build. Here's where I am so far, and I'll be updating as the parts come rollin' in :)

Before: 2000 400ex, 11:1 Wiseco Piston, Stage II Hotcam, K&N, White Bros. E2 Slipon, AC nerfs

After: 2000 400ex, 11:1 Wiseco Piston, Stage II Hotcam, K&N, UM Performance Airbox, UM Performance Oversize Oil Tank, 05 450r Carb, FMF Powerbomb Header, FMF Titanium 4 Exhaust, Lonestar Antivibe Steering Stem, American Star +2 +1 Pro-X A Arms, 450r Front Shocks, G-Force Adjustable Width Axle, Speedlinez Stainless Braided Lines all around, Powder Coated Frame, Subframe, Motor Mounts, Swinger and Misc. Parts, 83-84 ATC 250r PRM grab bar added, Pro Armor Front Bumper, AC nerfs.

My pathetic stock steering stem:
http://inlinethumb49.webshots.com/45808/2158352460103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2158352460103197556YHBveb)

Pile of parts:
http://inlinethumb55.webshots.com/14838/2754508830103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2754508830103197556KlxjVJ)

Mocking up the ATC 250r grab bar. Notice all battery mount tabs etc. have been removed:
http://inlinethumb24.webshots.com/29207/2007437410103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2007437410103197556jxftdx)

http://inlinethumb14.webshots.com/23181/2843110700103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2843110700103197556etVVLK)

http://inlinethumb52.webshots.com/47411/2020527290103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2020527290103197556HmfAXu)

Wiring harness stripped and ready to be rewrapped:
http://inlinethumb36.webshots.com/419/2696859220103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2696859220103197556PFVDkm)

Wiring harness re-wrapped using a non-adhesive harness wrap:
http://inlinethumb52.webshots.com/17395/2414678340103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2414678340103197556zHigEy)

Front hubs and spindles cleaned up
http://inlinethumb52.webshots.com/5811/2970703890103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2970703890103197556vxDwEU)

Swingarm linkage cleaned up:
http://inlinethumb32.webshots.com/25631/2218936350103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2218936350103197556bJImuK)

[mattl31]

Few parts back from powder, gloss black:
http://inlinethumb57.webshots.com/44152/2239362440103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2239362440103197556Nlwzoj)

Brake calipers and brackets sandblasted:
http://inlinethumb29.webshots.com/46620/2615090410103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2615090410103197556HvPKWy)

Stock skidplate before:
http://inlinethumb29.webshots.com/14556/2117360660103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2117360660103197556FYBedB)

Skidplate after:
http://inlinethumb10.webshots.com/46089/2261188510103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2261188510103197556XzcQJE)

Polished Nerf (right):
http://inlinethumb14.webshots.com/28877/2925822140103197556S600x600Q85.jpg[/URL

Frame back from powder:
[URL=http://sports.webshots.com/photo/2908631600103197556rGdQYP]http://inlinethumb10.webshots.com/25737/2908631600103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2925822140103197556cVsUoG)


http://inlinethumb12.webshots.com/26123/2960166330103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2960166330103197556kxQFSf)

Lonestar Antivibe Stem:
http://inlinethumb51.webshots.com/37810/2830042600103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2830042600103197556cjrROI)

Stem installed:
http://inlinethumb62.webshots.com/45757/2260905440103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2260905440103197556xsxkRu)

[mattl31]

Grab bar installed:
http://inlinethumb55.webshots.com/25910/2870993370103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2870993370103197556KeTXFH)

http://inlinethumb16.webshots.com/29519/2722927160103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2722927160103197556yZAVUs)

Motor back in:
http://inlinethumb38.webshots.com/44581/2543623650103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2543623650103197556PlZZNo)

Powdered Brackets:
http://inlinethumb49.webshots.com/28656/2593441980103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2593441980103197556dUwPuZ)

Upper Motor Mounts:
http://inlinethumb22.webshots.com/3669/2221654920103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2221654920103197556kePqtm)

Overall:
http://inlinethumb53.webshots.com/47860/2262296590103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2262296590103197556cQCuIH)

Swinger, Shock and Linkage in:
http://inlinethumb28.webshots.com/47771/2899276700103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2899276700103197556MKDvou)

http://inlinethumb58.webshots.com/46649/2085120800103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2085120800103197556VqPcrA)

http://inlinethumb43.webshots.com/27818/2965536930103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2965536930103197556JQpRlA)

SPAL 4" puller fan on the oil cooler:
http://inlinethumb26.webshots.com/6809/2310298410103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2310298410103197556WdLacs)

[mattl31]

http://inlinethumb33.webshots.com/7584/2276170300103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2276170300103197556cmZfBu)

Polished up the UM air scoops:

http://inlinethumb29.webshots.com/23260/2035410780103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2035410780103197556jPLtEb)

http://inlinethumb32.webshots.com/44831/2880814770103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2880814770103197556ItMypy)

Thanks all for right now! A-Arms and Axle will be the next thing installed. Be sure to let me know what you guys think!

[mattl31]

Got a few more guys! Almost done.

FMF Ti-4
http://inlinethumb24.webshots.com/30359/2291602410103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2291602410103197556Ejlgzw)

FMF Powerbomb Header
http://inlinethumb36.webshots.com/19555/2935970510103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2935970510103197556RpHrmq)

G-Force Extended Hubs Color Matched
http://inlinethumb10.webshots.com/44105/2423555480103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2423555480103197556ihMihz)

http://inlinethumb23.webshots.com/6934/2789661980103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2789661980103197556CEusFw)

American Star +2+1 Arms Installed
http://inlinethumb06.webshots.com/44677/2748198370103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2748198370103197556GxuVrT)

http://inlinethumb45.webshots.com/47788/2170525920103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2170525920103197556fupHal)

Threw on the stock plastics to see what we were workin' with. Looks good but still going to change it up I think.
http://inlinethumb09.webshots.com/5064/2217222360103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2217222360103197556zXLJZA)

http://inlinethumb14.webshots.com/47693/2556770640103197556S600x600Q85.jpg (http://sports.webshots.com/photo/2556770640103197556DehmNG)

[MtnEX]

Nice work...

[mattl31]

New 05-07 Headlight

http://inlinethumb59.webshots.com/27002/2791177980103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2791177980103197556EUVPmC)

Pulled the head off to do valve seals and saw that she was injured. Had some scarring on the cylinder walls, but the piston was in good shape. Luckily I got away with a hone and new set of rings

http://inlinethumb37.webshots.com/47460/2971226490103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2971226490103197556DoFrZa)

http://inlinethumb62.webshots.com/47805/2616004740103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2616004740103197556UeVzec)

http://inlinethumb40.webshots.com/45735/2951561610103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2951561610103197556mlmZSk)

http://inlinethumb29.webshots.com/47004/2849813500103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2849813500103197556tGzKdg)

http://inlinethumb27.webshots.com/45658/2734439050103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2734439050103197556QtgRap)

New Plastics Came! Maier 05-07 White Carbon Fiber, Stock Headlight, Stock Hood, Stock Tank Cover

http://inlinethumb19.webshots.com/45010/2462258300103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2462258300103197556FHCqIx)

[mattl31]

http://inlinethumb28.webshots.com/29019/2823401650103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2823401650103197556ZccYWg)

http://inlinethumb43.webshots.com/16426/2124586490103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2124586490103197556XfTKZN)

Ignition Key relocated to where the 05+ reverse switch would normally be

http://inlinethumb64.webshots.com/47231/2037565820103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2037565820103197556hramrZ)

http://inlinethumb23.webshots.com/45206/2919019410103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2919019410103197556dFGnPC)

Wiseco 11:1 Piston bed blasted, cylinder honed

http://inlinethumb30.webshots.com/19229/2065214470103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2065214470103197556SPASVU)

http://inlinethumb53.webshots.com/32628/2784824220103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2784824220103197556KSFGkK)

[mattl31]

http://inlinethumb53.webshots.com/32628/2784824220103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2784824220103197556KSFGkK)

GraphicMX graphics installed

http://inlinethumb16.webshots.com/45839/2891717350103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2891717350103197556ajeEUm)

http://inlinethumb40.webshots.com/34087/2181569350103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2181569350103197556GPoHZI)

http://inlinethumb34.webshots.com/46881/2565484870103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2565484870103197556czyDpp)

41mm FCR carb with billet air/screw know, R&D powerpump II, and NOSS billet adapter

http://inlinethumb03.webshots.com/46850/2357088590103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2357088590103197556wNNoPX)

http://inlinethumb57.webshots.com/46264/2774009410103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2774009410103197556eSSYRI)

[mattl31]

Plastics on the bike

http://inlinethumb35.webshots.com/45346/2816219150103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2816219150103197556lzdfIH)

http://inlinethumb60.webshots.com/46203/2339375240103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2339375240103197556cSQAsU)

http://inlinethumb25.webshots.com/44760/2118368700103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2118368700103197556XAUPOc)

6000K HID's

http://inlinethumb36.webshots.com/45923/2450465430103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2450465430103197556rGtKUC)

On dirt tires and stock wheels plasti-dipped in black

http://inlinethumb52.webshots.com/47795/2492030340103197556S600x600Q85.jpg (http://good-times.webshots.com/photo/2492030340103197556LoLfSM)


Should have some real pictures tomorrow! Let me know what you guys think!

[MtnEX]

I thought you were done posting for a bit, but it is just getting better... lol...

[mattl31]

haha! that's all i'll have till tomorrow. carb will get some detailed install pics tomorrow, and after that I'll just need a chassis skid!

[TORO1968]

Looks really nice!!! :)

[liex21]

Nice clean build and am I the only to notice the beer cap table haha always wanted to build one.

[426kidz]

I always see the wireharness all taped up...I work for a comp and we make any size spiral tubing to wrap it up with if you guys are interested I can hook you guys up for cheap!!!:) looks good nice job!

[mattl31]

Originally posted by 426kidz
I always see the wireharness all taped up...I work for a comp and we make any size spiral tubing to wrap it up with if you guys are interested I can hook you guys up for cheap!!!:) looks good nice job!

theres nothing i hate more than electrical tape! luckily this stuff is non-adhesive and will only stick to itself. no residue!

[426kidz]

yeah its anoying...good, i just noticed and know tape can be a pain

[trx400Rider]

Where would I be able to get one of those billet air/fuel knobs for the regular 400ex carb?

[mattl31]

Originally posted by trx400Rider
Where would I be able to get one of those billet air/fuel knobs for the regular 400ex carb?

im not sure they make them :ermm:

hopefully someone else will chime in

what was the point of beadblasting the piston?

[mattl31]

i re-ringed it and honed it. basically a rebuild minus a new piston since mine was in good shape. figured there was no sense in putting a piston with carbon buildup back into a brand new motor so i had the machine shop clean it up,

[NacsMXer]

Wow, great job on this build. It's looking sweet now :cool: :D

What did you do to clean up the front spindles/hubs and linkage so well? That stuff looks better than new lol!

[mattl31]

Originally posted by NacsMXer
Wow, great job on this build. It's looking sweet now :cool: :D

What did you do to clean up the front spindles/hubs and linkage so well? That stuff looks better than new lol!

luckily my front hubs were in pretty good condition, but I just used walmart brand engine degreaser and shop rags. it took a while but the paint (or powerdercoat maybe?) was in good shape.

the aluminum bits like the spindles and linkage i just hit with a red scotch brite pad!

[MtnEX]

This thread blows now. I came back to it for something for a friend and all the pics are gone.

I hate when people do great things and link the pics to the thread, and then dump them.

[Stickman400]

I like when people dig up old threads that I never saw because they were before I joined this site. Seeing old builds that were really good, like the black and red build that IMSROLL450R did was awesome. Just looking at the descriptions this looked like it was another good one, but alas, TEMPORARILY UNAVAILABLE is all I see, what a shame.

[quadmanw]

http://www.exriders.com/vbb/showthread.php?s=&threadid=451732&perpage=10&highlight=winter build&pagenumber=1

like this? :devil: