My 400ex 2003 rebuild

[Tloc]

For the ones who like rebuild thread, here is my. First of all, sorry for my english, I live in Quebec (Canada) so I speak french. I will do my best.

Last fall, I have bought a 400ex 2003 for my girlfriend. I bought it to tear it down and rebuild it. This is my first rebuild and while there is nothing fancy, I enjoy doing it. I decided to keep it mostly stock because my girlfriend will learn with it. She doesn't need race suspension because she will do trail riding. I don't need to tear down the motor because it is in very good shape. It doesn't burn oil and run strong.

Here is what I start with :

http://img194.imageshack.us/img194/8015/img16144286689.jpg (http://imageshack.us/photo/my-images/194/img16144286689.jpg/)

[IMG]http://img809.imageshack.us/img809/802/img00085302615.jpg (http://img809.imageshack.us/i/img00085302615.jpg/)

[finsteratv]

so what are you planning to do on this 400 just freshening it up i assume?? congrats on getting a lady who rides with ya too! haha

[Tloc]

Here is the tear down. Sorry for the blurry pictures. I use my IPod touch to take them.

http://img837.imageshack.us/img837/836/img00165554660.jpg (http://imageshack.us/photo/my-images/837/img00165554660.jpg/)

http://img802.imageshack.us/img802/2198/img00185563857.jpg (http://imageshack.us/photo/my-images/802/img00185563857.jpg/)

http://img62.imageshack.us/img62/6317/img00215540435.jpg (http://imageshack.us/photo/my-images/62/img00215540435.jpg/)

http://img26.imageshack.us/img26/5938/img00225545050.jpg (http://imageshack.us/photo/my-images/26/img00225545050.jpg/)

[Tloc]

I got the frame and the steering stem powdercoated and I painted the others parts myself. I also bought new OEM fender. I decided to put TRX450R front shocks.

I replaced front wheels bearings, front brakes pads and swingarm bearings.

Here is the performance mods I will put on it :

- FMF Q4 slip on (I need to keep db down because we will use it for trail riding)
- Uni filter
- EHS racing airbox lid
- Sparks X1 cam
- Sparks timing advance key

I am still waiting for the slip on exhaust and the EHS lid.

I am lucky because she like to ride. Now it's her who insist to go riding.

[Tloc]

I have never took the time to upload the pictures of my rebuild.

http://img406.imageshack.us/img406/1222/img1877km.jpg

http://img713.imageshack.us/img713/1582/img1880x.jpg

http://img94.imageshack.us/img94/8209/img1887f.jpg

http://img585.imageshack.us/img585/3708/img1890i.jpg

http://img857.imageshack.us/img857/2663/img1896b.jpg

[Drfat400ex]

Looks like a fun build, it's also nice to see some more Canadains getting on this site! When you have that header pipe off make sure you grind those welds off, might not seem like much but you get a little more kick from it. :)

[TheAwesomehonda]

I love threads like this cuz i'd rather watch other people do lots of work to make there quad awesome then do it myself. haha

[Tloc]

@Drfat400ex : Yes, I took the time to grind the welds on the header pipe!

That was a lot of cleaning and sanding, but the result worth it!

[Tloc]

Some more pictures :

http://img820.imageshack.us/img820/3528/img1897ki.jpg

http://img52.imageshack.us/img52/4880/img1898ca.jpg

http://img812.imageshack.us/img812/3787/img1903k.jpg

http://img715.imageshack.us/img715/597/img1906nh.jpg

http://img714.imageshack.us/img714/9080/img1917n.jpg

[Tloc]

The final result :

http://img710.imageshack.us/img710/913/img2072w.jpg

http://img217.imageshack.us/img217/3457/img2074oq.jpg

http://img825.imageshack.us/img825/7098/img2075v.jpg

http://img703.imageshack.us/img703/9301/img2076iz.jpg

[HondaRacing83]

Wow. Thats nice and very clean. Wanna send a brother down your old set of plastics? hahahaha. hey, just a little advice but to make your old lady feel a little safer, you should get the tusk nerf bars with built in heel guards. very sturdy and cheap. like $180. also, when tires start to wear i found this place where you can get gbc x rexs on all fours for $240. 20x11x9 and 21x7x10s and i got mine and rode them and love them. they are identical to razr 2's but half the price and they are 6ply. amazing trail tire. plus the 21 fronts handle better. plus wrap around hand guards or something would help protect her hands. and if you get an aftermarket clutch perch (msr one is like $50) it makes the clutch much easier to pull. just some beneficial mods for the old lady!

[Stickman400]

Damn, that thing looks brand new. Even the bolts were nice and shiny. Looks great, good job.

[ke26]

very very Nice!!! One day I will do this!

[Tloc]

Thanks for your comments guys! I've had a very good time doing this restoration.

@HondaRacing83 : thanks for your suggestions. I will take a look at the nerf bars and the tires. The front tires are quite worn. The only complaint for the moment is the stiffness of the thumb throttle. The throttle cable is brand new.

[chronicsmoke]

Looks clean! Where abouts are you in Quebec? I'm less than an hour east of Montreal

[Tloc]

@chronicsmoke : I am from Val-d'Or (Abtibi-Temiscamingue). It's about 5 hours from Ottawa.