2001 426 Rebuild!

[chronicsmoke]

I'm doing my 426ex this time, going to try not to spend a fortune..

I plan on using 'rocker guard' on the frame. That money can be used on other more important things.

what I'm putting into it this time around,

-Stage 2 Cam
-CRF Timing Chain
-New springs
-New Clutch
-+3 Key (Thanks Wheelie!)
-Port&Polish
-Steering stem bearings
-Other odds & Ends
-Nerfs
-MX Wheels/tires
-Bar risers

That's hopefully it..

anyway, this is what I'm workin with:

[chronicsmoke]

should of also added, I wanna ditch the crappy nerfs.. got a set of ACs on the way

[chronicsmoke]

A little bit of progress, got my subframe off tonight.

Anybody know id there is enough length in the brake line to add 1 1/2" risers??

[chronicsmoke]

a little bit of progress..

rocker guard looks like it's going to be pretty tough..

http://imageshack.us/photo/my-images/703/250r028.jpg/
http://imageshack.us/photo/my-images/202/250r029.jpg/

starting to put it back together

http://imageshack.us/photo/my-images/196/250r032.jpg/

[Budweiserebel07]

Nice ! Just cleaning up the frame makes it look sweet.

[finsteratv]

just undo your handle bars and see how far you can pull them up till everythings taught. that will show how much you can raise

[chronicsmoke]

Originally posted by finsteratv
just undo your handle bars and see how far you can pull them up till everythings taught. that will show how much you can raise

Yah I'm pretty sure they'll fit, I tried that method when I was stripping it.. I'll figure something out if they are too tight afterward.

The AADS is starting to get ahold of me as well.. once you have it apart it's hard to stop adding stuff!

new to the list is;
20" front tires, 18" Rears
AC Nerfs
possibly 2005-2007 front fenders <--- If anyone has some for sale, let me know!!

and I'll probably add more stuff down the road..

[chronicsmoke]

Little update.. starting to come together..

Swinger/air box/seat are back on..

[chronicsmoke]

got it on the ground now, everything is lubed and tight.. waiting for the engine mostly.. a couple of other odds and ends.. going to powder coat the nerfs black and get red mesh too

[chronicsmoke]

uno más

[chronicsmoke]

Ok so I'm looking into a 4" spal fan to help with cooling, and an XR's only dipstick.

And, if anyone want to make a ball-park guess on what kind of HP i'll be making, i'd love some input! :macho

This is what the engine has into it;

-88mm 10:1 Wiseco
-Stage 2 Cam
-Wiseco Timing Chain
-Kibblewhite springs
-+3 Key
-Port&Polish
-Choke Removed
-Big Gun Full Exhaust
-Uni Filter

Anyone want to make a prediction?

Also, Do you think the dipstick will hold up to the abuse on a MX track?

[chronicsmoke]

I messed around with the airbox last night. I wanted to move the Battery inside the airbox, but need the clearence over the caliper.

I spent a bit of time while I'm waiting for parts/the motor to be finished.

I'll post some pics of it if anyone is interested in doing something similar.

[chronicsmoke]

again

[chronicsmoke]

painted, ready to reinstall

[CJM]

I wanted the XR dipstick, sadly I kept reading how they freaking leak. I was thinking of getting someone to tig weld me a bung and Id install a thermometer in the oil tank itself or maybe find some kinda adapter to put it inline with the oil tank lines.

Id say your gonna make around 37hp, if you can drop the airbox lid and use an outwears lid or pre filter-sure gives mine a nice bit of power-Ive got the lid with the ehs outwears cover.

As for making the caliper clear-try spacing the exhaust out if you can with some AL or steel spacers from lowes/home depot.

[chronicsmoke]

Originally posted by CJM
I wanted the XR dipstick, sadly I kept reading how they freaking leak. I was thinking of getting someone to tig weld me a bung and Id install a thermometer in the oil tank itself or maybe find some kinda adapter to put it inline with the oil tank lines.

Id say your gonna make around 37hp, if you can drop the airbox lid and use an outwears lid or pre filter-sure gives mine a nice bit of power-Ive got the lid with the ehs outwears cover.


I'd be content with 37hp, 36-38 is my guess..

I've got the Outerwears from my old K&N that I'm going to use to cover a hole in the airbox lid.. the original 400ex airbox had holes in it, but I have no idea where it went.. (fell off while riding WITH the seat on?!) lol. That's actually a 450r aibox lid that's on it (doesnt fit that great) but you get the idea..

I've been hearing the same about the XR dipsticks too, you've got a good idea on putting your own thermometer. I'd be interested in doing something like that. but I really liked the idea of having that gauge right on top of the oil tank.. I wish they got better feedback..

My intentions with this bike aren't to win against built up 450's. Im hoping my little brothers can use it to get more experience at the MX track, these 400s are easy enough to ride even a beginner can throw a leg over it and have some fun.

[CJM]

Sounds like a good plan. I think the hp estimate is pretty close. What would really help is a 450r carb, much better power. I have one myself but just dont have the time to mess with it right now.

[jgar]

Nice bong lol.

[JR3]

Originally posted by jgar
Nice bong lol.

+1:bandit:

[chronicsmoke]

Originally posted by jgar
Nice bong lol.

haha I was waiting for someone to comment on that. I forgot it was on the bench.

It's where I get all of my inspiration from :chinese:

[jgar]

It works pretty good for you. That is a crazy a air box. Nice work.

[chronicsmoke]

got the engine back from the installation of;

Cam Chain,
Stage 2 Cam,
CSR P&P,
Valve springs,
3 degree Key,
and some valve work..

Now I'm really getting pumped to take this thing for a rip.. Last time i rode it, I noted how SLOW it revved (well, slow compared to my 450).. but I found out the cam chain was stretched so much it was retarding the timing 1/2-3/4 of a tooth!

So new cam chain, stage II cam, 3 degree key, and a P&P, I'm hoping this thing will revv up a little quicker anyway haha..

the only thing I am missing is fuse assembly.. Don't have a clue where I put it :( but I hope it turns up tonight.. if so I'll fire it up and give you guys a ride report..

[chronicsmoke]

a pic with the motor in.. exhaust/carb are also installed but not pictured..

[chronicsmoke]

Well last night I finished putting the ol' girl back together.. Still waiting on a few things (Rear master cylinder, new nets for the nerfs, SPAL fan, and a new battery) But here is what she looks like after a winter of rebuilding..

BEFORE::

[chronicsmoke]

AFTER:

[chronicsmoke]

one more:

[PhatDave]

looks good!!

What kind of hood is that? I've never seen anything like it before on an 400?

I like those graphics too, where did you get them?

[chronicsmoke]

Originally posted by PhatDave
looks good!!

What kind of hood is that? I've never seen anything like it before on an 400?

I like those graphics too, where did you get them?


The hood is a QT hood made for the 450r, it took a bit of work to get it on, but it was worth it.. one of my favorite hoods for sure..

the graphics are by 'One Industries' and i beleive they are the "Contra" model.. i got them back in 03-04 so I'm not sure haha..

Thanks for the feedback!

[chronicsmoke]

Finally got it out to try out the new cam, cam chain, 3 degree key, and P&P.. as well as the 450r swinger, +2 arms and 450r shocks..

All I can say is what a difference! It revs faster for longer..

We had my 450 out too, the 426 is obviously not as fast in a straight line, but whoever was riding it could keep up to the 450, especislly in the tight corners.

I havent installed the fan yet, but it really didnt seem THAT hot..

All in all, I'm pretty happy with the way it turned out.. I really like the TQ in the low rpms, I was surprised it pulled that hard all the way to the top end too.

Heres a pic of us cleaning off the bikes after a track session:

[chronicsmoke]

Well I was going to start a new thread, but I can just keep this one going.

I've been biten with the XC Bug so rather than log all the hours on my MX bike (and being influenced by Ben300 & 400man), I'm going to build the 426 into a woods bike but still be able to hit the MX track when a friend wants to try that dicipline.

Since the last build not too much has changed.. It got TCS Front shocks, 450r LSR +1 andti-vibe stem & 1 1/8" pro taper bars, new front fenders, the Alba nerfs off my 450r.. I think that's it.

In the cards/what's new;

450r Carb (190 main, 4th clip, 48? pilot.. still fine tuning)
450r +1 Anti-Vibe stem
1 1/8" bars
TCS Front triple rate shocks
Fenders
Nerf bars
CCP Stabilizer
Oil Tank
CBR1100 oil cooler
New Clutch
New 250X Clutch cable
Tether kill switch
Stock key way
Rev Box
Elka LT shock and link from my 450r

I'll keep this list going as it progresses.. It'll take me the majority of the winter to get it completely finished

I've been tinkering with this the last week or two between riding and prepping my 450 for this weekend.

As it sat
http://imageshack.us/a/img43/5043/qjmh.jpg
Tinkering begins
http://imageshack.us/a/img818/1926/fm94.jpg
http://imageshack.us/a/img191/4816/vc8v.jpg
http://imageshack.us/a/img194/9441/e1hv.jpg

[chronicsmoke]

Started getting the rear shock measurements for the 450r Elka Dual linkage and spacing the exhaust away from the caliper.

Slammed (compressed length)
http://imageshack.us/a/img812/6921/mdtz.jpg
Elka 450 linkage on 450r swinger
http://imageshack.us/a/img826/8108/o6fj.jpg
Spacers for exhaust..
http://imageshack.us/a/img14/7734/xprs.jpg
http://imageshack.us/a/img202/4757/g5p2.jpg

What are you guys bending out on the subframe with a bottle jack? I remember CJM and Stickman talking about.. Any insight guys?

[ben300]

Started getting the rear shock measurements for the 450r Elka Dual linkage and spacing the exhaust away from the caliper.

Spacers for exhaust..
http://imageshack.us/a/img14/7734/xprs.jpg
http://imageshack.us/a/img202/4757/g5p2.jpg

What are you guys bending out on the subframe with a bottle jack? I remember CJM and Stickman talking about.. Any insight guys?



i didnt bend my subframe at all. i dont run a sprocket guard on mine. i use the GTT 400ex swing arm skid with the built in sprocket and rotor guards. i have my rear shock set fairly soft (compete rebuild)...its acutally to the point were im going to need to either have it revalved or keep the same valving and go up a spring because im getting fast enough that its almost always to soft now(5/8 of the way on max compression and preload all the way). anyways, the nuts on my sprocket bairly hit my subframe. and i when they do, its only enough to scrape paint. i deemed this not neccessary to mod the subframe.



asl for spacing my exhaust..my set up is pretty much similar to yours. i used a 1 inch (25.4mm) long bushing that had big washers on eihter side of it. ran ths for a good while untill back in the beginning of may, got rear ended at a race and it mangled my exhaust all to hell. after bending that back, i took an old 8 point socket and welded it to two washers. the socket worked better because it was a tighter firt around the stock exhaust bolt (8mm or 10mm botl...cant remember?)

if i had current pics, id update...but i dont...sorry

[ben300]

also, jsut as a suggestion, if you feel comfortable enough, i would buy a really good set of aftermarket foot pegs (sharp as you can) and heel guards and just run those. those tusk/rock/alba nerf bars may look good ( i have the tusk ones) and may be in expensive, but trust me..you will bend those thigns alllllllllllllllll to hell. mine are very mangled and i only ran them 6 races total. not to mention, when you caked in mud, the foot pegs, IMO, dont grip. my feed slide off them all the time. the "Gusher" GNCC a couple weeks back was rediculous, my feet were flying everwhere.

[chronicsmoke]

also, jsut as a suggestion, if you feel comfortable enough, i would buy a really good set of aftermarket foot pegs (sharp as you can) and heel guards and just run those. those tusk/rock/alba nerf bars may look good ( i have the tusk ones) and may be in expensive, but trust me..you will bend those thigns alllllllllllllllll to hell. mine are very mangled and i only ran them 6 races total. not to mention, when you caked in mud, the foot pegs, IMO, dont grip. my feed slide off them all the time. the "Gusher" GNCC a couple weeks back was rediculous, my feet were flying everwhere.

Haha funny you say that.. they are off of my 450r too.. I mangled them once already and fixed them then upgraded to pro armor on the 450r..

http://imageshack.us/a/img19/7137/udc2.jpg
http://imageshack.us/a/img29/3766/3zgs.jpg

My feet were all over the place once my pro armors packed with mud too haha.. the only spot that had grip was the kickups.

Are you going to full nerfs again or just pegs/heel guards?

[Stickman400]

I kinda went overkill when I did mine and used a press to bend it. Marc used a bottle jack which got the same results. I have no clearance issues with the sprocket bolts on my frame though, it doesn't scrape the powder coat or anything, which was what I wanted, otherwise I would have just barely bent it and left it. I did the same thing with my exhaust, spaced it using a steel spacer. Don't forget to raise your airbox either, I tried small spacers but it broke the box eventually, ended up using HUGE zip-ties wrapped underneath the airbox that my dad had for the farm equipment. Haven't had any issue yet.

[chronicsmoke]

Hmm, that's what you guys were spacing out..

I dont think I have contact there in that area, I will have to double check..

Rear end update; I found out my 450r LT Elka MX setup is almost the perfect setup for the 400ex with XC tires on, but with the MX tires on it would frame out slightly before the shock bottoms completly. I'll see how it acts as is with XC tires.. I do like being able to boot around on the MX track when friends come along with me so the shock will get modified for the extra travel when it needs serviced. Untill then it'ss stay loced with XC tires on it.