2 new 400ex's, got some ?s

[dukedrummer89]

So I decided I wanted to ditch my scrambler and get a real quad. So I went out a bought a 2006 400ex. Bought from the original owner. Approx less than 100hrs, of course no way to confirm or deny. The good, pretty clean, brand new rear tires.

The bad... Its been sitting for two years, fuel system is gummed up. Plastics are pretty scratched up. Clutch cable is frozen up. Battery is dead. I was able to hear it run before bought it, it barley ran... and i was stuck way back in the guys garage.

For the low price of $1500
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/005.jpg

Got it home, pulled it apart, cleaned the carb and put in a new plug. Then I got the clutch cable freed up with some pb blaster. Runs great now.

http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/CIMG9303.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/CIMG9302.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/CIMG9304.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/CIMG9305.jpg

Monday morning I ordered some parts for it. New battery, clutch cable, carb rebuild, jet kit, k&n, hmf slip-on, and of course an oil filter and gn4 honda oil.

Then I saw a parts 2001 400ex today for $1300... its got a blown head gasket, but its also has
stage 4 elka piggy backs front shocks,stage 4 elka piggy back long travel rear shock, lonestar +3 swingarm,lonestar chrome steering stem,itp front and rears with razors about 50-60%, 450r a arms, brand new renthal bars with hand guards and tether, bumpers front and rear, nerf bars, 05 red plastic decent shape. and a t4 pro circuit pipe. bunch of other lil stuff.

engine has brand new dirt digger clutch, big bore 416, stage 2 hotcam, worked head

So now im in the process of swaping all the aftermarket stuff onto mine. All the bolt on stuff, no motor parts. And the stock parts off my 06 onto the 01, then im going to sell the 01

Let the fun begin
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/008.jpg

http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/013.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/014.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/016.jpg

Im no expert, but im pretty sure this is why the head gasket wouldnt seal.... That and one of the studs was replaced with a bolt

One more shot for fun
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/015.jpg

Parts going on my 06
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/017.jpg


So now you know what im doing, here are my ?s
1) Do I need to replace the headstuds with new ones, I know I need at least 1 (essentially are they a torque to yeild type deal?)
2)Can i measure the bore of the cylinder to see if it is really a 416 kit (from what I read is should be 86mm?)
3)Are the clutchs interchangealbe for 01 to 06 (idk becouse the 06 has reverse)

[IMSROLL450R]

for the price, GT Thunder head studs will go in every 400 I build. Blown head gaskets are common when adding compression so id just put em I'm...

I think the 416 is 87mm.

Clutch's are same for all years.

GREAT buys by the way. Cool project. Where are you at in illinois? I'm just outside springfield.

[CJM]

Looks like they tried to seal it with some rtv?

x2 on the GT Thunder head studs!

[ridehonda400ex]

Did you buy that 400ex off a guy in lincoln illinois? if so, i was gonna buy that and am so glad i didnt!!

[dukedrummer89]

Originally posted by IMSROLL450R
for the price, GT Thunder head studs will go in every 400 I build. Blown head gaskets are common when adding compression so id just put em I'm...

I think the 416 is 87mm.

Clutch's are same for all years.

GREAT buys by the way. Cool project. Where are you at in illinois? I'm just outside springfield.

Ive read you have to drill and tap the block for those aftermarket studs? May be overkill for something im just goin to resell... IDK what compression it has tho


I went back thru my notes ive been jottin down about these things, I read 87mm is a 416... Now Im assuming a stock gasket (85mm?) wont work?

Where is a good place to get a 87mm gasket? It looks like the cometic gasket is a MLS peice, so id like to go with it for the few extra dollars

Im just outside peoria, so bout an hour away... I got the 06 in granite city (just outside st louis), and the 01 in lincoln...

[dukedrummer89]

Originally posted by CJM
Looks like they tried to seal it with some rtv?

x2 on the GT Thunder head studs!

Everything was sealed with RTV, seemed like...

[dukedrummer89]

Originally posted by ridehonda400ex
Did you buy that 400ex off a guy in lincoln illinois? if so, i was gonna buy that and am so glad i didnt!!

Yea, some kid had it, he bought it with all the stuff on it... then blew out the gasket, and TRIED to fix it himself

Im glad u didnt buy it lol

[CJM]

Originally posted by dukedrummer89
Everything was sealed with RTV, seemed like...

Ive seen worse, nice deal you found tho!

[IMSROLL450R]

I buy about 60% of my parts on ebay, 30% here on this site, and 10% from specialized dealers for more rare stuff.

Where are you gonna ride it? I am runnin a 440 with long travel elkas and lonestars.

You should look into an fcr carb for the one you're gonna keep. I keep a lot of parts around so if you need somethin pm me and I may have it....

[CJM]

Piston doesnt go high enough to worry about gasket size, a stock size gasket will work just fine.

[dukedrummer89]

Originally posted by IMSROLL450R
I buy about 60% of my parts on ebay, 30% here on this site, and 10% from specialized dealers for more rare stuff.

Where are you gonna ride it? I am runnin a 440 with long travel elkas and lonestars.

You should look into an fcr carb for the one you're gonna keep. I keep a lot of parts around so if you need somethin pm me and I may have it....

Ive been buying parts thru rocky mountain atv, 3day ship and its free if over $100....

We ride at the badlands, astoria, and around our property and friends property... id like to try that smurfwood trails out too

[dukedrummer89]

Originally posted by CJM
Piston doesnt go high enough to worry about gasket size, a stock size gasket will work just fine.

Ok, thats what i needed to know

[chronicsmoke]

Nice finds man!

Why does nothing like that ever come up around me.. :ermm:

Looks like you're going to have a nice handleing quad by the time youre done.. Maybe make a few $$ too

[dukedrummer89]

Shots from today, no class, it is a good friday

http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/001.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/002.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/007.jpg
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/008-1.jpg

This is the ID of the sleeve... 87mm, so i would assume it does have a 416 kit in it.
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/005-1.jpg

[supertrooper90]

not sure if you mentioned it, but that swingarm doesnt look stock either. I'd yank that too.

[HondaRacing83]

He said lonestar +3 swinger^
Put on the red plastics! Way better than the black IMHO! the red plastics would complete it. and get them ****ty tires off and throw them razrs on there.

[finsteratv]

im not a huge fanof blackplastics either. they show imperfecions more then any other color IMO. depending on what you ride those tires might not be to bad but better ones in the future would be a plus.

[dukedrummer89]

Im not gonna put the razors on, they are getting pretty low on tread. Id like to keep the holeshots on the front tho, and I plan on keeping the ITP wheels also.

My 06, with all the parts from the 01 on it. And the maxxis' on the rear. I put the pro-circut exhaust on until my HMF comes. I didnt want to run my stage 2 dynojet kit with the factory exhaust
http://i206.photobucket.com/albums/bb10/dukedrummer89/2006%20400ex/001-1.jpg

[HondaRacing83]

What about the nerfs? I'm not a huge fan of that +3 swinger. Maybe a +1 would be good.

[dukedrummer89]

Originally posted by HondaRacing83
What about the nerfs? I'm not a huge fan of that +3 swinger. Maybe a +1 would be good.

Im not going to run them, they wont work with the heal guards. Im prob going to order the Tusk nerfs with the healgaurds built it, I just wish they were in black.

I like the swingarm, its a hill climbin machine.

[dukedrummer89]

I put the 01 back together today, or at least tried too. The stud on the passanger side is stripped out, and has been heli-coiled before. the front stud (the one I replaced) threaded in hard, so I think those threads are junk also.

I read on the gt-thunder site that their head studs cant be used if the old studs are heli-coiled in. So essentially the 01 has a junk cylinder.

I cant decide if I want to sell the 01 as it sits, or... I was thinking about buying a 440 big bore kit w a new cylinder for my 06(im keeping the 06) installing oversized studs in it, probably a cam also. Then I would use the stock piston/cylinder/cam out of my 06 to get the 01 running

any thoughts?

[CJM]

I wouldnt do a 440 kit, a much better option is a 416 or 426 kit. 440 means you need those GT headstuds and will need to jet it right or you risk blowing up (many have before).

Id suggest:
-416 or 426
-10:1, 10.5:1 or 11:1 high compression piston
-Hotcam stage 2
-CRF450 2002 timing chain, new chain tensioner.
-Cometic brand gaskets

That will build one nice powerhouse of a quad, it will out rev a 440 easy.

You could find a cylinder on ebay, alot of the time they are decently priced and if your bore is beat you could bore it or you can put it in your cyl itself pretty easy.

[2001400exrida]

yeah the 440 requires to much extra stuff.

I just finished a 426 11:1 high comp wiseco piston with stage 1 hotcam.

piston $130 bucks
bore $100 (i paid too much)
gaskets $35 (tusk set came with valve seals)
stage 1 cam (was already in it)
cam tensioner, chain, and guides $100

if your 01 was ridden anything like my 01 had been, i would check on the cam chain guides and the chain.

[dukedrummer89]

Yea, i think im just ogoing to put the 01 up for sale as a rebuilder or even a parts quad. I just dont want to tear into my 06, It has lots of power in stock form and Id like to keep the reliablity of a stock machine. Plus riding season just started and I dont want to ride my scrambler this year :(

I think i should be able to get my 1300 back out of the 01 as it sits. In case anyone here is interested, if not ill put it up on craigslist.
http://images.craigslist.org/3na3m83p55V25W65R6b4r6d620f261d34103c.jpg
http://images.craigslist.org/3nf3m73oc5Z25U55P2b4rec450ccc15d7191f.jpg
http://images.craigslist.org/3m53oc3l45Z45W65S0b4rb42e9398649a1274.jpg

[01boneless]

or you could part it out

[dukedrummer89]

Originally posted by 01boneless
or you could part it out

Crossed my mind, but id just end up keep 75% of it for spare parts

[IMSROLL450R]

The only difference in a 440 and smaller bores is a sleeve, they all require a bore and in my opinion hd studs if you up the compression. A 440 is easy to build reliable if its put together right and WILL overpower smaller bores of any kind with all other mods being equal....

[dukedrummer89]

Ive decided to put it back together and keep it around as a spare... I had it on craigslist for a week, and im sick of dealing with low-ballers trying to tell me its worth 500 bucks, and then people not showing up... if youve never used craigslist, its frustrating

So, im going to order a new 87mm cylinder (found one on ebay) they cost 180 bucks. Im going to get gt thunder head studs to be safe, and a new gasket. Along with a new battery and chain. Roughly 350 bucks in parts.

Hopefully with finals coming up I can get it put back together before the weather turns and its riding season again. That and ive been busy getting my official quad hauler back together (its gets better mileage than my 5.4 superduty lol)

I put a 12v cummins in it
http://i206.photobucket.com/albums/bb10/dukedrummer89/002-19.jpg

[CJM]

Me likey your truck :)

[dukedrummer89]

I read on GT thunders website that they dont recommend drilling and taping the head, rather having it done on a mill.

Has anyone done it with a hand drill and a tap set?

[IMSROLL450R]

[QUOTE]Originally posted by dukedrummer89
I read on GT thunders website that they dont recommend drilling and taping the head, rather having it done on a mill.

Has anyone done it with a hand drill and a tap set? [/QUOTE

I know it requires a special tap that you cant just get anywhere. I recommend having it done. They showed me the 7/16" tap they used and its far different from a normal one.

Also, NICE Ford man! Dont see the cummins conversion often but man thats nice. Bet it moves too. You can see my Ford in my build thread.....

[dukedrummer89]

Originally posted by IMSROLL450R
[QUOTE]Originally posted by dukedrummer89
I read on GT thunders website that they dont recommend drilling and taping the head, rather having it done on a mill.

Has anyone done it with a hand drill and a tap set? [/QUOTE

I know it requires a special tap that you cant just get anywhere. I recommend having it done. They showed me the 7/16" tap they used and its far different from a normal one.

Also, NICE Ford man! Dont see the cummins conversion often but man thats nice. Bet it moves too. You can see my Ford in my build thread.....

Where did you have it done @?

[IMSROLL450R]

Capital city machine shop in spfld but they are crazy expensive and slow. Id use andy **** at ****techatv in jacksonville.

[dukedrummer89]

Thats an hour and a half away, too far for me...

I wouldnt think it would take more than an hour to drill 4 holes and tap them... i think i could handle it myself

[IMSROLL450R]

Well make sure you get the right tap, its taperless so the threads go full depth. Im confident you can do it i was just saying machine shops are already set up to do the job. Hope it works for ya. If so, im tryin it on my next one....

[dukedrummer89]

I will get a bottoming tap.

Does anyone know the tpi on the on the studs, there website just says 7/16ths course thread.

[IMSROLL450R]

Huh?

[trxPOWER]

threads per inch?

[IMSROLL450R]

Duh. Jesus, im an idiot. I wish i could remember....

[hocman123]

u can use a cutting tape on the head studs if u dont have a roll forming one it is not as string but it is still stonger then stock because it is a course thread instead of fine and u have to drill it deeper giving the bolt a lot more to grab.

also people that are not used to roll form taps can often get them stuck and snap them and then ur introuble

it is what i have done and i have a 406 11:1 with no problems

[dukedrummer89]

Originally posted by hocman123
u can use a cutting tape on the head studs if u dont have a roll forming one it is not as string but it is still stonger then stock because it is a course thread instead of fine and u have to drill it deeper giving the bolt a lot more to grab.

also people that are not used to roll form taps can often get them stuck and snap them and then ur introuble

it is what i have done and i have a 406 11:1 with no problems

Ive never used a roll form tap, ive only done some lathe/mill work in class

Im just going to get a regular tap from fastenal 7/16th 14tpi is what i believe they are

I did get the head studs today, talk about fast shipping

[dukedrummer89]

Its all back together now... and I must say it runs well. It has so much more power compared to my 06.

We went riding last weekend, after I got the carb tuned in it did awesome. I put at least 2 hours on it with no problems

Im going to be putting it up for sale now that its all fixed and running (i had to put in a new battery, chain, and bars) to get it all cherried out.

Think 2k is a good starting price? Im going to be putting it up on craigslist...