**Revised** NEW GUY does 400ex Re-build

[DirtyBirdRacing]

Well I think that my original thred is a little unorganised Changed the plans with it a little to many times so im going to do a simple and clean start to how it sits as of now, I will still Post updates in both threds. (ORIGINAL THRED) (http://www.exriders.com/vbb/showthread.php?s=&threadid=455252)

List of what im doing to it Now. Not going in to the motor just yet I do have plans to do a Stage 1 HC soon.

Painted frame Met Red [DONE]
Changed all bearings with All Balls [DONE]
Battery box "Dirty bird design" (going to try and custom make)
Sparks +6 Timing key [HAVE]
Tuck Comp bumper
Bumper skull face plate [HAVE]
DG fat full skid plate Set
Two brother’s M7 exhaust
Power Bomb Header
Polished Stainless ATV Bolt Kit [HAVE]
Aftermarket Red Aluminum Gas Cap
Hand grips red skull grips
Moose Break and Clutch levers [HAVE]
Break rotor saw blade [HAVE]
New Plastic Fender clips [HAVE]
Throttle & Break Covers (say 400EX)
K&N Oil filter [HAVE]
K&N Airfilter [HAVE]
New front and Rear tires
ITP SS112 Chrome and black rims (Yes I am getting them)
New Front and Rear Breaks [HAVE]
New O-ring Chain [HAVE]
New Steel JT Sprocket Set (stock Gearing) [HAVE]
Aluminum Heal Guards
Red Chrome Lug Nuts (Possible not 100% right now)
Billet Oil Stick
Aluminum Air Box
Chain guard
Chain roller and slider
05 450R Shocks [HAVE]
Steel Braided Clutch Cable
Steel Braided Throttle Cable
Skull Graphic Kit
HID head lights
LegGlow Motorcycle Light kit
Smoke Kit
Working Rear Break Light
450R Carb
450R Carb adapter [HAVE]
*Random miscellaneous Parts I needed* [HAVE THEM ALL]

Collar, R. ENG HGR
Collar, FR. ENG HGR
Collar, L. ENG HGR
Collar, R. ENG HGR
Collar, L. ENG HGR
New Tie Rods
Left Crankcase Gasket
Right Crankcase Gasket
Throttle Case Gasket
2, O-Ring, Rotary case
2, O-Ring [81x3]
Slider Chain Guide
Swing arm Bolt
Nut, U [14mm]


Some pictures of It before take down and some being torn apart.

http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/1b56c563.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/0bb00b61.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/15a05347.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/be925299.jpg

http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/7e5e62ec.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/0a70c20d.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/1cb679e0.jpg

Swing arm bolt being removed By a guy that works at my friends place
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/23f0dc8a.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/4521baf3.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/b63326cb.jpg
Before SandBlasting
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/49988f91.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/bab73ad3.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/4bceeea1.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/57bbd0bf.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/87378557.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/63e7d308.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/76182894.jpg


http://i128.photobucket.com/albums/p185/lord-inuruku/e6f271ee.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/74476d1c.jpg
Before Clear coat
http://i128.photobucket.com/albums/p185/lord-inuruku/d6a522dc.jpg
After
http://i128.photobucket.com/albums/p185/lord-inuruku/1613fe7f.jpg



How it sat for a LONG time when I didnt have a job
http://i128.photobucket.com/albums/p185/lord-inuruku/Quad%20trip%202010/IMG_7585.jpg

Where it is now as of yesterday. Sorry for bad Pictures.
http://i128.photobucket.com/albums/p185/lord-inuruku/001.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/003.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/002.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/004.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/005.jpg

[01boneless]

nice bro did you paint the frame or powder coat if paint what was the step im getting ready to paint my 450r frame :D

[honda400ex2003]

looks good man! put any thought into those nerfs?

steve

[DirtyBirdRacing]

I used Automotive Paint. if I ever have to do this again I think I will go with PC the paint was free so I could argue with it this time.

I have thought about nerfs and have decided with the type of rideing I do I would likely Bend them to H#ll real fast, I often get held up on rocks and stuff right near my pegs, I just cant talk my self in to spending that much money on somehting I think I will 100% break lol. are you the one selling a set of 3 in the parts section? If so I was as close as the send button to asking what you wanted to for them yesterday, but again thought that I would kill them fast.

[honda400ex2003]

yeah i am the guy selling them. you actually asked about them in a pm, thats why i asked. I would like 125 for the set of them shipped in case you havent checked your pms lol.

steve

[Pipeless416]

looks good, but add some safety glasses to your list!

[DirtyBirdRacing]

Originally posted by honda400ex2003
yeah i am the guy selling them. you actually asked about them in a pm, thats why i asked. I would like 125 for the set of them shipped in case you havent checked your pms lol.

steve

HAHA I know I typed the message thought I deleted it before I sent it.... Hmm 125, Yeah I will def consider them.. Dont think it should be to hard to break even on them if I dont like them I guess.. ill talk to you about them in PM.

[DirtyBirdRacing]

Originally posted by Pipeless416
looks good, but add some safety glasses to your list!

If you talking about the guy cutting my swing arm bolt out, They dont ever use safety things there, the people that work at my friedns place are the stupidst, no common since people in the word, but when it comes to fixing a car and doing it fast they are amazeing for some reason lol.

[DirtyBirdRacing]

Yes I know there LOTS of information about jetting, and what the Main, Pilot, Needle clip and A/f screw does, but trying to take all of that in confuses me >.<

I'm I'm going to run the STOCK carb (for now)
with the fallowing set up for now things WILL change later and i know i will have to likely change the set up again

TwoBros M.7 Slip-On
Sparks +6 Key
Closed airbox
K&N Air Filter
To my understanding - Elevation 600FT-1500FT
(Wilkes barre, PA to in the hills of surrounding areas)

What Jets should I be looking at installing, I am buying a Dynojet kit that comes with Stage 1&2 Jet kits

Later on I will be trying to make a custom Open Airbox lid, and installing a Stage 1 HC

[honda400ex2003]

138 dj main, 3rd notch on the dj needle, and 3.5 turns out on the f/a screw.

that will get you right where you need to be. :D without an open lid. when you decide to do that go to a 142 and run er.

steve

[CJM]

Dont even bother with the junky crap dyno jets man. It just wont run right with them.

www.jetsrus.com sells every jet size under the sun and its WAY cheaper than buying a dj kit.

[DirtyBirdRacing]

Originally posted by CJM
Dont even bother with the junky crap dyno jets man. It just wont run right with them.

www.jetsrus.com sells every jet size under the sun and its WAY cheaper than buying a dj kit.

Oh I didnt think Jetsrus sold a KIT I thought they only sold single jets last I looked, Hmm so does there kit have every thing I need to jet it?

And what type of set up am I looking at running with the Jetsrus?

[Stickman400]

Originally posted by DirtyBirdRacing
Oh I didnt think Jetsrus sold a KIT I thought they only sold single jets last I looked, Hmm so does there kit have every thing I need to jet it?

And what type of set up am I looking at running with the Jetsrus? Here's the link right to the 400ex Jets-R-Us page: http://www.jetsrus.com/a_jet_kit_atv/honda_400_TRX400EX_1999-2008.htm

The jet kit is right at the top of the page. It's $30 and includes 152, 155, 158, 160, 162, 165, 170, 175, 180 main jets and 4 allen headed screws for the bowl.

[honda400ex2003]

which is unfortunate since he will need a 150 if he wants to keep his lid on.

you can add it for a few bucks along with a 42 pilot to put in it if you order from jets r us. then turn your f/a to 2.5 turns and you will be good to go.

steve

[DirtyBirdRacing]

Do i need to do anything with the needle?

[honda400ex2003]

not if you use the stock style jets. it will stay on the 3rd notch. i didnt check what year you had so it might not be adjustable if it is a newer 05+ carb.

steve

[DirtyBirdRacing]

Well this Friday I took a trip to PA to visit my quad, take some pictures of it, parts I have and to finally GET IT BACK TOGETHER.

First some Parts I had sitting waiting to go on..
http://i128.photobucket.com/albums/p185/lord-inuruku/782d30a3.jpg
(not happy with these! first ride and the grip started to peel!)

http://i128.photobucket.com/albums/p185/lord-inuruku/0bf9d4ef.jpg
(Sparks key I didn't get a chance to install I was on a short time line and was trying to ride it before I left when I go in after Christmas it will be installed)

http://i128.photobucket.com/albums/p185/lord-inuruku/c8e0708c.jpg
(My Break rotor I said I would get a better picture of.)

first night of working had the motor bolted in oil tank in and started to play around with installing a Two brothers racing pipe I had to buy one for a 03-07 400EX cause they didn't list one for my model a while back I checked the numbers for the sub frame, Headers, and Stock pipe from the 01-03 and I believe they all were the same, I also talked to people from Honda and asked if the exhaust systems were the same and then asked 2bros why they didn't list if for the 01 model they told me it was simply cause they didn't have one in the shop to check the measurements on so anyway, When me and my buddy started to install my pipe I was under the impression it would be a simple bolt on and go. I was wrong I dont know what if different but it was a little off in mounting
http://i128.photobucket.com/albums/p185/lord-inuruku/1a5e9a45.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/1399b9bb.jpg
With it bolted to the headers and not to the sub frame it was being pulled under the sub frame I dont know if possibly my headers are bent? there is no sign that they are, and as you can see the hole from the can doesn't line up with the sub frame,

To fix this problem I took a file and made the hole in the canister bigger and more over to the right to get a bolt straight trough.

After getting the bolt holes lined up I was faced with the problem of the pipe being pulled under the sub frame the spacer that came with the pipe was to small and didn't push the pipe far enough away, So after going over some extra parts I ordered for my swing arm on incident I noticed I had extra spacers We took one of them and measured how far out we could have the pipe pushed out with out any of it hitting the frame cut it to length and this is what we came up with.
http://i128.photobucket.com/albums/p185/lord-inuruku/96d328d0.jpg
I ended up using an extra motor mount bolt I had and cut it down to length and installed self locking nut.

Next day we Put about all of it back together except plastics and for small parts like new levers and grab bar, Most of the time spent the second day was installing the Stainless Bolt kit I bought... NEVER again will I buy one of these kits, They are good if you are NEVER planning on removing them, I broke so many of them it isn't even funny. half of them were to short, so I couldn't use them and others just wernt included.

Third and last day Working on it everything was bolted up, plastics on, levers installed, grab bar on..ect it was time to fire it up for the first time in a year! I was expecting it to give me some sort of problems and it didn't, Second time cranking it it fired right up and idled fine, Smoked alot at first, but I'm figuring that was the just from being apart for so long with the side case off and the new pipe being on. so after letting it run for a little we shut it down, checked the oil level. we then removed the oil filter cover, and re installed it with the stainless bolt kit we thought everything was fine then we re started it, with in seconds of it being started it literally blew the oil filter cover off the quad.. ( i was really surprised that it had that mush pressure in there :eek2: ) I'm guessing that we must of striped the threads when we put it back on, that is what I get for not using a tork wrench... the small bolt hole on the left side of the cover we were able to re tap, but the long one on the right side the tap wouldn't reach in there to get it, at first I didn't know what to do, or how to fix this problem, it was to late in the night to go to any store to look for a tap as long as i needed. I then compared the Stainless bolt to the Stock one and noticed the stock one was a little longer than the stainless one, I installed the stock one back in and it grabbed threads, I re placed the oil that had leaked out and re started it hopeing that it was fixed for now and it worked fine, ( I'm only doing this as a Temp fix) I am going to re tap the hole before I take it on any serious rides, i just couldn't help but take it out when i was there. When i go to re tap this Do they make a tap long enogh that i can leave the side case on or will i need to remove it?

I have more parts I want to buy for it, but im shipping out for Boot camp soon and just want to get it running strong and enjoy my time rideing before I leave.
I forgot to get pictures of it 100% back together so here it is with the plastics sitting on it and it close to done...
http://i128.photobucket.com/albums/p185/lord-inuruku/791c88cd.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/161514db.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/e03c9c69.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/e42485fb.jpg

[DirtyBirdRacing]

-Still waiting to be installed-

Graphic kit
450R shocks
Tuck Front bumper
Tusk Bumper face plate
Sparks Key
Throttle and break covers

-Parts still need to buy-

HID lights
450R carb
HC stage1
New tired
Skid plate all around
Stainless break, throttle, and clutch cables
ITP SS112 Rims
aluminum air box

[powerbomb400]

The spacer you had to install is the way it goes on. There should have been a couple of black spacers in the box. Anyway looking good. How did it sound and I'm asuming you have rode since you got it back together?

[DirtyBirdRacing]

Originally posted by powerbomb400
The spacer you had to install is the way it goes on. There should have been a couple of black spacers in the box. Anyway looking good. How did it sound and I'm asuming you have rode since you got it back together?

It came with 1 black spacer maybe about an inch or less long, I needed one about double its size. but it sounds AMAZEING I have herd a two bros pipe on 2 motorcycles (street and trail, and a sport bike) and a 350 warrior they all have a lower sound then the 400 but it still sounds great. Im glad I went with it and the little problems I had to take care of was well worth it.

I have ridded it about 3 times just for 30 min or less all together I didnt remember all the power it had im woundering how much more the sparks key and the cam can possibly give it lol, Im really intrested in installing the 450r shocks next cause it did seem a little more bouncey then what I remember it as well, I did buy replacement Stock 400 shocks that are on it as of now and think they might just not of been ridden as much as my old ones were possibly it felt great to be back on it after haveing it apart for a year.

[DirtyBirdRacing]

Update Pictures!

http://i128.photobucket.com/albums/p185/lord-inuruku/d3308b06.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/e6fdb153.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/f8d44436.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/978c6111.jpg


My 450R shocks installed
http://i128.photobucket.com/albums/p185/lord-inuruku/cdd62101.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/1bcc3baa.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/014cabdf.jpg

[DirtyBirdRacing]

after I got the thing running good, New battery starten up fine noting wrong with it, took it out at night with only 1 head light working, Mistake, I hit a rock the size of a small dog couldnt see it till I was right up on it tood a direct hit to the A-Arm bent it, and cracked it buy the ball joint welds.

http://i128.photobucket.com/albums/p185/lord-inuruku/ce3ec5cc.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/12ad0566.jpg

Hard to see but this is the crack
http://i128.photobucket.com/albums/p185/lord-inuruku/0f3c70cf.jpg

Showing the bend again
http://i128.photobucket.com/albums/p185/lord-inuruku/6e15b732.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/82a652f6.jpg

I didnt do anything to the shocks I just installed thankfuly, I only have 2 weeks till i ship for Navy boot camp so I just welded the A-Arm for now till i get back and buy new ones, The welds are holding great jumped it a few times as soon as I got done welding it to see if it was strong :) But becayse of thins I did decided that night I was getting HID's $110

[DirtyBirdRacing]

After crashing I wanted better lighting so that never happends again due to me not being able to see. so here they are

http://i128.photobucket.com/albums/p185/lord-inuruku/4140a5f7.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/101921c0.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/a74462c6.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/653c7571.jpg

Looking up hill
http://i128.photobucket.com/albums/p185/lord-inuruku/91c682a8.jpg

[throttle_out14]

Bike looks great! Turned out awesome! Sucks about the a-arm :(

[DirtyBirdRacing]

Originally posted by throttle_out14
Bike looks great! Turned out awesome! Sucks about the a-arm :(

Yeah im happy with how it turned out im still wanting to do a few more things to it. Thanks for youre FB on it :P and When i hit my A-Arm I was so :mad: I couldnt belive that the 1st time i was rideing with my buddy I killed my quad

[DirtyBirdRacing]

Started installing my graphics (wish I had a heat gun!! )

http://i128.photobucket.com/albums/p185/lord-inuruku/e0885b75.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/f359e837.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/02644555.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/1caa5f55.jpg
Not done yet, Still have to install the 2 side pices that go on the black part. then ill post more pics of it with a head on view.

SPARKS KEY being installed tomorrow. :) :P

[throttle_out14]

Yeah no problem, it always nice to see a nice, taken care of 400ex!

[throttle_out14]

Graphics are badass, where did you get them from?????

[throttle_out14]

O! and where did you get the headlights from??? Look like they work well. Are they HID??

[DirtyBirdRacing]

Originally posted by throttle_out14
Graphics are badass, where did you get them from?????

http://amrracing.com/

I love the graphics from them

[DirtyBirdRacing]

These will be the last pictures for a while, Im done working on this as of now, Im shipping out to bootcamp on Feb 7th so I dont know when ill see my baby again lol my friend is going to ride it for me everynow and then to keep fresh gas in it and all the parts moveing im still going to be buying parts online when i get the chance :P

THANK YOU CJM! for the smooth side pannels made installing my graphics ALOT easyier!

http://i128.photobucket.com/albums/p185/lord-inuruku/cecb5d00.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/0fc63f9e.jpg

http://i128.photobucket.com/albums/p185/lord-inuruku/4935bd0f.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/ba1f9dfb.jpg

Backing plate to my Bumper I made to have most the light come out the front
http://i128.photobucket.com/albums/p185/lord-inuruku/358d0b04.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/3278f626.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/ecbbf812.jpg


the plastic pice over the handdle bars didnt have a sticker but this kit came with the newer style front pice (in front of the headlights) I figured I payed 140$ for the kit i was useing all that i could lol so...
http://i128.photobucket.com/albums/p185/lord-inuruku/91dfa63a.jpg
http://i128.photobucket.com/albums/p185/lord-inuruku/05e13975.jpg


My 400 and my buddies 350 warrior
http://i128.photobucket.com/albums/p185/lord-inuruku/47aa0e52.jpg

[TheAwesomehonda]

WOW that ex is awesome love the build.

[Stickman400]

I love how you painted the "eye lids" on the headlights, it looks badass man, nice quad.

[01boneless]

dude so sickk!!! great job!

[CJM]

Very nice! Glad the side panels were well worth it Dirty!

Your quite welcome. Make me a thread in the feedback forum if you can please!

[throttle_out14]

Where did cjm find those smooth side panels???

[Stickman400]

'05 and up have them stock

[throttle_out14]

O nice!!

[powerbomb400]

Your build turned out great. Looks awesome Dirty Bird.

[DirtyBirdRacing]

Thanks for all the comments guys im glad you all like it sucks that I have to put it away in a shed for X amount of months after getting it looking this good :(

CJM - I will leave feedback for you now.

Sorry it took me so long to get back on here I have been trying to get ready to ship out 4 more days!!

[CJM]

Thanks Dirty. GL with boot!

[beastlywarrior]

Wow 140 for a kit thats spendy

[gixer2000]

Sweet ride bro! Good luck in boot camp and thanks for serving our country!

[DirtyBirdRacing]

Originally posted by beastlywarrior
Wow 140 for a kit thats spendy

Yeah at first i wasnt happy about the price they were asking 160 but On ebay it was OBO so I just offered 140 and they took it, Honestly I couldn't find a diffrent company that had ones in a better style and the quality of these are amazing not cheaply made at all. if I had to I would pay that price again.

[beastlywarrior]

Wow i got mine for 100 and its great quality

[Drfat400ex]

Man the light through the bumper looks so awesome! What did you use for a light?

[DirtyBirdRacing]

Originally posted by Drfat400ex
Man the light through the bumper looks so awesome! What did you use for a light?

I went to Advanced auto parts and they sell light kits Packs of 2 I forget the brand name the kits are a little over priced but they have large strips that you can cut to the size you need. I used the med size and used the whole strips. I installed a toggle switch on the plastic part that goes on the handle bars so I could have easy access to them when I'm ridding and so they can be the only thing on and not tied in to the main Leds

[Drfat400ex]

I might have to buy a tusk bumper just to do that eh! Looks sweet I'm gonna look into doing that.