400ex build for the wife

[dsm_racing]

I talked my wife into letting me buy a 700xx, so we're downsizing to one 400ex. As a result, I'm combining our best parts into one bike that she will keep and then putting together another 440 that I will sell. Here's the build for her bike.

I started by stripping down our parts bike and gusseting the frame. Then I wanted to get it powder coated. I called around to the local places and they wanted $350 to powder coat just the frame! I said forget that. I had a hobby kit and I decided that I could build an oven for less than they wanted to coat one frame. So that's what I did. Here's the oven I built. Interior dimensions are 4' deep, 3' high, 2' wide.

http://inlinethumb46.webshots.com/45805/2903099340083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2903099340083129407AcvJYh) http://inlinethumb20.webshots.com/44371/2424353530083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2424353530083129407igXZbX)

I built her a 440 2007 reverse motor with 89mm 11:1 Wiseco piston, Stage 2 Hot Cam, EBC clutch, and Moose high output stator. You can also see some of the gusseting I did in the second picture.

http://inlinethumb10.webshots.com/46217/2004561570083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2004561570083129407wUdlfn) http://inlinethumb28.webshots.com/44379/2134589660083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2134589660083129407YVEAzZ)

It's got a 3" extended swingarm with LSR carrier bearing.

http://inlinethumb56.webshots.com/42807/2225456990083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2225456990083129407GlcoGI) http://inlinethumb34.webshots.com/45793/2043904200083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2043904200083129407cJeTLD)

I tore the dust cover removing the A-arms, so I bought some replacements from Energy Suspension. We'll see how these work out.

http://inlinethumb03.webshots.com/45506/2026567610083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2026567610083129407VJVJDn)

I made some pretty good progress on the assembly this weekend. Hopefully in a few more hours I'll have it finished up. Is there a good thread somewhere on how to strip down the wiring harness?

http://inlinethumb58.webshots.com/46009/2392773340083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2392773340083129407XVOFPJ) http://inlinethumb09.webshots.com/48136/2261779120083129407S425x425Q85.jpg (http://rides.webshots.com/photo/2261779120083129407ClsCUU)

[426kidz]

Keep up the good work...looks real good and awesome oven!!:D

[finsteratv]

little off topic but..hows the 700xx? trail wise does it stall out easy. plus how fast would you say it coasts in first. thanks :p

[426kidz]

how did you heat the oven ??

[dsm_racing]

Everyone loves the oven. :) I made it out of sheet metal and an old oven I swiped out of an abandoned house trailer that was being demolished. That's where the elements that heat it are from.

finsteratv, I love the 700xx. I had problems with it stalling at first, but I dropped a tooth on the front sprocket and took care of that. I'm running a Layton medium swaybar upgrade and I love the combination of handling and suspension.

[finsteratv]

thanks DSM! i've narrowed it down to the 700xx and 450r for future bikes. just reading up on them!

[jcs003]

very cool PC oven.

[jelrod05]

what are the part numbers for the dust covers from energy suspension

[dsm_racing]

The part number for the dust covers is 9.13104R. You can get them special order through Auto Zone or online here:

http://www.energysuspensionparts.com/proddetail.asp?prod=9.13104

[BenHonda400ex]

Hah. What happen's when her atv is faster your's? :D Are you going to do anything to engine on the 700XX, like exhaust?

[dsm_racing]

She's barely over 100lbs, so the weight advantage of the bike plus her weight advantage over me will probably put her right with my 700xx. She should be a pretty fast girl. :devil:

I got it fired up yesterday. I'm heading out now to finish it up. Hopefully I'll have more pictures up today or tomorrow.

[dsm_racing]

<a href="http://rides.webshots.com/photo/2558738770083129407dVEsyz"><img src="http://inlinethumb37.webshots.com/48228/2558738770083129407S500x500Q85.jpg" alt="IMG_5978"></a> <a href="http://rides.webshots.com/photo/2977656480083129407cvqEcF"><img src="http://inlinethumb19.webshots.com/43410/2977656480083129407S500x500Q85.jpg" alt="IMG_5979"></a>

<a href="http://rides.webshots.com/photo/2441164960083129407eIdOFF"><img src="http://inlinethumb33.webshots.com/45920/2441164960083129407S500x500Q85.jpg" alt="IMG_5980"></a> <a href="http://rides.webshots.com/photo/2985009040083129407ynwilp"><img src="http://inlinethumb19.webshots.com/45842/2985009040083129407S500x500Q85.jpg" alt="IMG_5981"></a>

<a href="http://rides.webshots.com/photo/2692357160083129407uoHJQT"><img src="http://inlinethumb34.webshots.com/46113/2692357160083129407S500x500Q85.jpg" alt="IMG_5986"></a> <a href="http://rides.webshots.com/photo/2321921360083129407pYNUxD"><img src="http://inlinethumb27.webshots.com/46490/2321921360083129407S500x500Q85.jpg" alt="IMG_5988"></a>

<a href="http://rides.webshots.com/photo/2654528190083129407JYeKiM"><img src="http://inlinethumb15.webshots.com/44750/2654528190083129407S500x500Q85.jpg" alt="IMG_5989"></a> <a href="http://rides.webshots.com/photo/2034009920083129407bFxykC"><img src="http://inlinethumb36.webshots.com/47651/2034009920083129407S500x500Q85.jpg" alt="IMG_5994"></a>

Thanks to Steve (honda400ex2003) for the jetting help. He nailed it the first time and it starts and runs great.

[HondaRacing83]

i think you otta get her some decent plastics.

[BenHonda400ex]

Originally posted by dsm_racing
<a href="http://rides.webshots.com/photo/2558738770083129407dVEsyz"><img src="http://inlinethumb37.webshots.com/48228/2558738770083129407S500x500Q85.jpg" alt="IMG_5978"></a> <a href="http://rides.webshots.com/photo/2977656480083129407cvqEcF"><img src="http://inlinethumb19.webshots.com/43410/2977656480083129407S500x500Q85.jpg" alt="IMG_5979"></a>

<a href="http://rides.webshots.com/photo/2441164960083129407eIdOFF"><img src="http://inlinethumb33.webshots.com/45920/2441164960083129407S500x500Q85.jpg" alt="IMG_5980"></a> <a href="http://rides.webshots.com/photo/2985009040083129407ynwilp"><img src="http://inlinethumb19.webshots.com/45842/2985009040083129407S500x500Q85.jpg" alt="IMG_5981"></a>

<a href="http://rides.webshots.com/photo/2692357160083129407uoHJQT"><img src="http://inlinethumb34.webshots.com/46113/2692357160083129407S500x500Q85.jpg" alt="IMG_5986"></a> <a href="http://rides.webshots.com/photo/2321921360083129407pYNUxD"><img src="http://inlinethumb27.webshots.com/46490/2321921360083129407S500x500Q85.jpg" alt="IMG_5988"></a>

<a href="http://rides.webshots.com/photo/2654528190083129407JYeKiM"><img src="http://inlinethumb15.webshots.com/44750/2654528190083129407S500x500Q85.jpg" alt="IMG_5989"></a> <a href="http://rides.webshots.com/photo/2034009920083129407bFxykC"><img src="http://inlinethumb36.webshots.com/47651/2034009920083129407S500x500Q85.jpg" alt="IMG_5994"></a>

Thanks to Steve (honda400ex2003) for the jetting help. He nailed it the first time and it starts and runs great. Is the back end suppose to be squating that low? I love the way it's looking.

[jcs003]

whats up with the rear suspension. it looks almost bottomed out?

[freeman79]

what kind of pipe is that? you like it?

[arsenal35]

you wouldn't happen to have a extra swing arm you would wanna part with??

[dsm_racing]

The rear is dropped with an ATV Engineering adjustable linkage. It drops the center of gravity.

The pipe is a Two Brothers. I bought it last year from Stewart's Buggies in Waynoka, OK while we were out at Little Sahara. Her bike had been running a junk slip-on that it had on it when we bought it and I put this one on for her. I like it well enough that I put it back on instead of the old LRD full exhaust that I had on my bike.

The plastics are Maier and I thought they were in pretty good shape. Sounds like someone doesn't like blue. ;)