My 400ex rebuild thread

[Fix29]

Ok, so I was planning on tearing my ex down this winter and rebuilding it. Blew my headgasket the other weekend so I figured I might as well get started.

What's in the plans:

- New top end gaskets, already a 426 and has a race built head, not sure what all it has done but it's quick lol
- New zest orange fenders
- 450r front shocks converted to dual rates
- Elka rear dual rate shock
- New graphics
- New handlebars, grips, steering stem, bearings
- Frame sandblasted and painted black
- Upper arms and swingarm painted orange
- Aluminum air box with lid
- Installing rear brake since its not there
- New swingarm pivot bolt and bushings
- Upgrading from my AC nerfs to AC pro peg nerfs
- Replace old cracked Dr. D with a new slip on, possibly an HMF
- HD head studs from GT Thunder

Here's a few pics before the tear down.

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/ex.jpg

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2035.jpgWhat's in the plans:

[Fix29]

Tearing her down:

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2056.jpg

Down to the bare frame. I was going to paint it but I think I'm going to look into getting the frame, a-arms, and swingarm powder coated now.

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2066.jpg

Here's the 426, going to replace the top end gaskets and most likely install some HD head studs from GT Thunder.

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2069.jpg

[Fix29]

I picked up a set of 450r fronts revalved and sprung and converted to dual rates by Dirtworks Motorsports. Should be a much nicer ride

http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2067.jpg

[Fix29]

DirtyBirdRacing


Whats all are you planning on doing to it?

I'm also planning on installing new swingarm bushings, new plastic, aftermarket heel guards, new handlebars since mine are bent and bent again lol, maybe a new exhaust since my Dr. D slip on is cracked in multiple places, and a bunch of other little things.

[Fix29]

Making some more progress. Sand blasted the frame and a-arms. The cylinder is at GT Thunder getting HD studs installed.

http://i171.photobucket.com/albums/u320/ltrain30/100_2070.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2071.jpg

[Fix29]

A couple fresh coats of epoxy

http://i171.photobucket.com/albums/u320/ltrain30/100_2072.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2073.jpg

[01boneless]

nice bro but it looks like the sterring stem is tweaked a little :ermm: and why did you cut the swingarm? lol paint looks asome tho nice shocks two!!!

[Fix29]

I had some serious issues removing the swing arm pivot bolt as it was siezed to one of the bushing sleeves between the swing arm and frame rail. I figured I really needed a new swingarm anyway, since the holes for the pivot bolt were wobbled out from the bushings and bearings being bad for a long time, I would just cut it off and pull it with the motor. Once I pulled the motor it came right out with a little convincing lol.

[Speed37]

is it me, or does the shaft of the right shock in the picture look bent? haha but yeah good luck with the build dude

[DirtyBirdRacing]

Originally posted by 01boneless
why did you cut the swingarm?

when I saw that I was like :eek: I figured he couldnt get the bolt out.. but im glad theres more of a reason that than just the bolt that made him do that :P

[dxcody]

Originally posted by Speed37
is it me, or does the shaft of the right shock in the picture look bent?

You are right it does, but i dont think it is, i think its just the angle, idk deff does from that angle tho. :confused:

[Speed37]

i hope its not bent for his sake! haha

[Fix29]

Shock is not bent, steering stem is though lol

[dxcody]

Originally posted by Fix29
Shock is not bent, steering stem is though lol

If i hadnt ever seen a new steering stem, i would think they are made with that bend in them, i had 4 of them that i bought used and they all looked just like that

[Pipeless416]

subscribing.. looks like it'll turn out really nice :cool:

[CJM]

Im on number 3 stem and its bent, been bent for eons now. If you put the quad down on its side the bars usually donty bend, the stem bends sideways and twists.

This winter im spending for a better one lol.

I really liek this rebuild btw, Id go to 407cc and 11:1 piston I were you. By now the bores probably wore out a bit.

[cutty2fast]

i got lucky and bent my stem back straight with a pry bar and a little heat.. subscribed! thinkin about building my 400 eventually

[Stickman400]

I went through 3 stock stems also before I decided to bite the bullet and drop the cash on a new one. And I couldn't have been happier with what I bought. Everyone looking for a new stem should look at a Houser stem, they are VERY strong, look good and have anti-vibe mounts.

[Fix29]

I really liek this rebuild btw, Id go to 407cc and 11:1 piston I were you. By now the bores probably wore out a bit.

Thanks, it's already a 426 though, I probably forgot to mention that.

[jkosakowski]

How much did it cost to have the 450r front shocks redone?

[Fix29]

My CeramiClear came in yesterday so I got to do some painting last night. The whole frame and lower a-arms are done. I'm really happy how it turned out, pics don't do it justice. I am probably going to paint the upper arms today.

http://i171.photobucket.com/albums/u320/ltrain30/100_2074.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2076.jpg

[TORO1968]

Looks like you have a really nice build going! :)

[Stickman400]

So is that paint or powdercoat? It looks nice btw, hope mine comes out that good this winter. Mines dirty and got pieces chipping off because I never clear coated my frame after I powdercoated it.

[Fix29]

So is that paint or powdercoat?

It is painted. I used basecoat - clearcoat and the clear is PPG's Ceramiclear. It's supposed to be very durable so we will see how it holds up over time.

Update: Got my cylinder back from GT Thunder and the upper arms have paint on them.

http://i171.photobucket.com/albums/u320/ltrain30/100_2078.jpg

[Fix29]

Finally starting to put things back together :D

http://i171.photobucket.com/albums/u320/ltrain30/100_2081.jpg

[Fix29]

Ok, a little update. Making a little progress and got the motor put back together and put back in the frame.

http://i171.photobucket.com/albums/u320/ltrain30/100_2088.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2090.jpg

I ordered an air box from CFM performance and an oem steering stem and bearings today. Also picked up a used set of AC pro peg nerfs. Here's a pic of my new bars and hand grips:

http://i171.photobucket.com/albums/u320/ltrain30/100_2085.jpg

[Fix29]

Not much progress yet this week but I did get my new steering stem and my new plastic. My air box should be in tomorrow and I plan on making some progress this weekend since I don't have much going on.

Just to get an idea:

http://i171.photobucket.com/albums/u320/ltrain30/100_2094.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2096.jpg

[OgerWA]

Build is looking great. Subscribed!

[Thumpin440ex]

Nice looking man.. I remember when I had my bike going all back together, I was like a kid on xmas, waiting for parts to get here.. LOL


John

[wolfe 21]

wouldn't have originally thought so without seeing it, but I like the color scheme you went with. Looks like your gonna have a really nice bike when you're finished. Good luck on the rest of the build.

james.

[Fix29]

Update: New steering stem and bearings installed as well as the bars, carb, CFM air box, gas tank, and all the controls. Also got the wiring ran along the frame, etc.

http://i171.photobucket.com/albums/u320/ltrain30/100_2099.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2101.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2100.jpg

[Fix29]

Thanks for the kind words everybody. I got my fenders all mounted up, hung the rear shock on the frame, tightened up some bolts, and mocked one of the nerfs up. I am getting to the point where I really need to get my new swingarm so I can paint it lol. I'm supposed to get that from my brother but he is really busy right now so I may end up just buying another one.

http://i171.photobucket.com/albums/u320/ltrain30/100_2103.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2104.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2109.jpg

[Fix29]

http://i171.photobucket.com/albums/u320/ltrain30/100_2110.jpg

[OgerWA]

So with your air box you can still run the factory snorkel? Oh and the build is looking great.

[Fix29]

So with your air box you can still run the factory snorkel? Oh and the build is looking great

Yeah, uses all the factory stuff, just moves all the wiring and battery inside the box. Thank you!

[Fix29]

Nerf bars installed, rear shock cover installed, and painted the shift lever and throttle cover.

http://i171.photobucket.com/albums/u320/ltrain30/100_2120.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2118.jpg

[Fix29]

Update: Haven't made too much progress lately with the holidays and just waiting on a bunch of parts but it's picking back up now. I got my HMF exhaust installed. Also got my shock linkage bearings installed.

Now, I painted my new swingarm only to realize it's not even an EX swinger like it was supposed to be. Looks to me to be off an 04/05 450R. From my research I think it should be the same as length as what my stock 01 400EX swinger was? Hopefully this is the case as I don't want a longer swingarm and I already painted it and I'm ready to put the new bearings in the pivot holes.

http://i171.photobucket.com/albums/u320/ltrain30/100_2123.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2126.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2125.jpg

[honda400ex2003]

looks killer man!

congrats on the build,
steve

[Reece616]

looks nice!

it also looks like you're doing a inverted color scheme that i'm doing.

I'm gonna have my frame orange, swinger black, the bottom arms orange, top black, and I have black plastic haha

you can check out my build (http://www.hondaatvforums.net/forums/builds-projects-diy/17938-400ex-winter-overhaul.html)

but I haven't gotten my stuff back from the shop yet haha

[Fix29]

Looks good Reece, nice to see another orange/black build but different. I'll have to keep an eye on your thread to see how it turns out.

[Reece616]

Originally posted by Fix29
Looks good Reece, nice to see another orange/black build but different. I'll have to keep an eye on your thread to see how it turns out.

Thanks.
I'll definitely be checking this build out as well.

[Fix29]

Got my swingarm mounted up and installed the axle. Have a few other small parts ordered to finish up the build.

http://i171.photobucket.com/albums/u320/ltrain30/100_2135.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2139.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2142.jpg

[Drfat400ex]

Lookin good man! I love the color scheme on the frame and the shock covers look real good with it too. I always wondered what is the benifit of an aluminum air box anyways?

[Fix29]

My main reason for doing the air box is that it moves the battery and other wiring into the box. I just think it cleans up that area of the subframe without all that hanging there.

[Drfat400ex]

Ok that clears it up thanks

[Fix29]

Making progress, just a bunch of little loose ends to tie up at this point.

My heat shield I made up from the factory heat shield of my 600rr haha.
http://i171.photobucket.com/albums/u320/ltrain30/100_2152.jpg

Rear end coming together
http://i171.photobucket.com/albums/u320/ltrain30/100_2157.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2150.jpg

[Fix29]

http://i171.photobucket.com/albums/u320/ltrain30/100_2158.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2155.jpg

http://i171.photobucket.com/albums/u320/ltrain30/100_2160.jpg

[Fix29]

http://i171.photobucket.com/albums/u320/ltrain30/100_2159.jpg

Thats all I have for now. Parking brake block off, drive chain, etc. to come soon.

[Reece616]

Looks good.
I really like the orange plastic.
Wish I had some extra cash for a set.

[honda400ex2003]

pretty sick looking with the orange and black!

steve

[Fix29]

Thanks. This thing is finally off the jackstands and resting on the wheels/tires. I am going to try and pull it out of the garage at some point this weekend to snap a few pictures.

Here is what's left to be done;
- Parking brake block off
- Install swingarm skid plate
- Put gas in it
- Install the battery
- Graphics

[TheAwesomehonda]

Awesome build man jw why didn't u paint your axle? I subed

[staakej]

good lookin ex what part of il do you hail from ?

[Fix29]

Southern part of Illinois, about half an hour southeast of St. Louis, MO

[Fix29]

Help! Tried to fire her up tonight to no avail. After some checking it isn't getting spark. I made sure I cleaned the paint off to bare metal on the battery ground and the coil wire ground. I am going to check and make sure the coil wire didn't come out of the boot and try a new plug. Any other suggestions would be appreciated.

[01boneless]

check all plug ins connections and grounds. new plug..check kill switch also

[TheAwesomehonda]

Originally posted by Fix29
Help! Tried to fire her up tonight to no avail. After some checking it isn't getting spark. I made sure I cleaned the paint off to bare metal on the battery ground and the coil wire ground. I am going to check and make sure the coil wire didn't come out of the boot and try a new plug. Any other suggestions would be appreciated. See when i had these problems i owned two 400ex's so i would just switch parts until i found the problem.. So get another ex haha jk

[staakej]

Originally posted by Fix29
Help! Tried to fire her up tonight to no avail. After some checking it isn't getting spark. I made sure I cleaned the paint off to bare metal on the battery ground and the coil wire ground. I am going to check and make sure the coil wire didn't come out of the boot and try a new plug. Any other suggestions would be appreciated.

make sure your subframe is making ground to the main frame your batter grounds to the sub frame but u need a connection to the frame if you have a fresh paint frame and sub frame they might not be making a ground

[Fix29]

make sure your subframe is making ground to the main frame your batter grounds to the sub frame but u need a connection to the frame if you have a fresh paint frame and sub frame they might not be making a ground

Ok, thanks. Not sure if this makes a difference but I never seperated the frame and subframe. I painted them together.

[01boneless]

if you never seperated them then paint shouldent have made its way between but check it just incase...

[Fix29]

Well it has spark now. The CFM airbox I put on has a little wall type piece that covers some of the wiring inside of it. I was looking around and pulled that off and what a ya know, the plug was not connected that has the wires going to the stator lol.

Battery is on the charger now so hopefully it starts now. Thanks for the input fellas.

[Fix29]

I know it's been a while but just figured I'd update. I ending up taking my EX to my local Honda dealer because I could not get the thing to start. (Had spark, fuel, and timing was right). Turns out the decompression spring apparently fell out at some point along the way during the rebuild. I'm just happy to finally have the bike back and running great. Will get some better pics up when I get a chance to do some riding.

http://sphotos-a.xx.fbcdn.net/hphotos-ash4/483289_4253611536780_1512110851_n.jpg

[HondaRacing83]

i realized i have the same shocks as you, and 450r shocks will look sexy as **** with them. lol

[HondaRacing83]

shock covers i ment

[on the rocks]

the decompression plunger is always a pain. you shout just get a hot cam then you wouldn't need it.

[Fix29]

Yeah, I didn't even know it was there honestly. It has a TC National head and cam in it.

[Fix29]

I know it's been a while but I never really posted up a picture after I installed my graphics and finished the build up completely. I had some graphics custom made by AMR Racing. I decided to set the bike up for XC so I sold my ITP SS wheels and got a set of ITP prolock beadlocks. Also installed the hand guards and upgraded to a Houser +1 steering stem.

<a href="http://s171.beta.photobucket.com/user/ltrain30/media/400ex%20build/100_2539_zpsa83fad30.jpg.html" target="_blank"><img src="http://i171.photobucket.com/albums/u320/ltrain30/400ex%20build/100_2539_zpsa83fad30.jpg" border="0" alt=" photo 100_2539_zpsa83fad30.jpg"/></a>

[JOHNDOE83]

That is one bad az graphics kit, for sure.

Awesome build!!!

[Fix29]

Thank you!