Winter Rebuld 2004 416ex

[quadmanw]

Well since CJM and Stickman are pretty much done with their builds I decided to throw mine up that is getting put back together.
Well I was on a budget so I ended up going with an 11:1 wiseco piston, crf timing chain, 416 bore, Port and Polish, new kw valves, Sparks racing rev limiter, eventually a stg 2 cam.

I powdercoated it black and red and it has a few red painted parts on it.

Decided to go with GTT +2 XC a arms.
Uni Filter
ODI Rogue lock on grips

made my own case breather

and its getting jetted

Its on its way to getting rebuilt.. Hopefully I'm happy with the results..
also soon to come a GTT link and resprung shocks

[quadmanw]

getting torn apart..

[quadmanw]

the crappy fullflights +2 that I sold for $300!

[quadmanw]

fresh GTT +2 a arms.. Tie rods are now PC red

[quadmanw]

Redneck Breather Hose.. gonna see how it works lol

[quadmanw]

PC frame, swinger, motor mounts and tie rods.. you can see parts everywhere in the background lol

[quadmanw]

painted steering stem

[quadmanw]

As it sits right now in my basement

[quadmanw]

Last one for now until I pick the motor up. sorry the pics are so spread out I dno how to make multiples in one post.. More to come soon.. Hope you guys like!

[quadmanw]

Come on, is it that bad lol? Any opinions, advice, or something good that I don't have is useful

[TheAwesomehonda]

Its awesome man!!!! keep uploading the pics.

[CJM]

Least you took pics, Im too lazy. Ill snap one tomorrow or thursday of it done tho. Not much to see really imho lol.

btw did you ever measure the frontend with the arms?

[Stickman400]

What color is that? Flat black? Looks pretty good from the pics. And you can get it out of the basement that you are building it in right???:D

[ke26]

yeah the building it in your basement is pretty funny lol. Keep up the pics. helps pass time at work. I love pictures haha

[Reece616]

Looks sweet so far!
I wanted to build mine in the basement but I have no way of getting it out. I did most of the cleaning and minor stuff in the basement and assembled in the shed.

[quadmanw]

CJM I haven't measure them yet because I can't assemble the front end completely in my basement. I should have the measurement by next week sometime, sorry about the wait.

And yes guys the quad will for out of the basement it I tilt it sideways out the door.. HOPEFULLY lol. I can't put any more parts on or it deff won't fit.. its going to my garage down the street tonight.

And the black powdercoat is called matted. It doesn't have nearly the shine of the gloss PC but this stuff looks good and its really tough. I figured I'd go with whatever was going to last the longest and I believe this should be it.

More pictures to come! Let me know if you want a picture of anything specific

[J51S]

Looks good man I like the color scheme. I too built it in the basement and had to go through 2 doors. It was harder than I thought getting it out, my doors are a little scraped up:devil:

[quadmanw]

Lol mine will be tonight.. It has to go out sideways

[J51S]

Ya i had mine sideways too, just loosen the bar clamp and collapse the handle bars. And if you don't have any gas in the tank remove the gas cap. Those were my 2 problem spots

[quadmanw]

I don't have the tank or the bars on haha. It's just the frame and the and a arms pretty much

[quadmanw]

Well, I had no trouble fitting it out the two doors to get outside.. Took it to my garage down the street and put it up on a crate.
The motor should be back tomorrow and I have to take the sparks key out and put stock in and I'm also thinking about doing the Tusk clutch kit while the motor is out.. Any opinions? $50 is pretty cheap and it shouldn't be too hard to install

More pictures next week probably. Steve

[Reece616]

Yea, if ur planning on doing the clutch, I'd say do it.
Since the motor's out, the oil should be drained so that'll make it easier.

[quadmanw]

With all the bikes Ive had I've never changed the clutch.. Is it difficult?

[Reece616]

Not at all.
pull the right side cover (it's like 12 or so 8mm socket bolts (I made a cardboard diagram to keep track of where each goes, and stuck them in the cardboard)
After the cover is off its 5 bolts for the clutch pressure plate.
You gotta soak the new plates in oil for a while, then just alternate fiber and steel plates.

The hardest part for me was taking off the old gasket material.
Don't forget a new gasket.

Do you have a manual?

[quadmanw]

No but I can grab my buddies lol. How long do I soak em?

[Reece616]

It doesn't say in the manual and I don't want to give you wrong info.
I would think a few hours would be fine, but I'd go overnight if you can.

You can download the manual here
http://www.hondaatvforums.net/forums/honda-atv-schematics-manual-help/10914-service-manual-downloads-all-years.html

[quadmanw]

Thanks man that will be useful.. But the dam gaskets are expensive! And I can't even find the one for the clutch side and the side for the key.. I can only find the full gasket kits.

[Reece616]

Are you looking oem?

Left
http://www.motosport.com/atv/oem-parts/HONDA/2006/TRX400EX/LEFT-CRANKCASE-COVER

Right
http://www.motosport.com/atv/oem-parts/HONDA/2006/TRX400EX/RIGHT-CRANKCASE-COVER

[quadmanw]

Yeah lol. The tusk kit is only on rocky mountain.. Thinking about using some permatex gasket maker..

[400exBRAAP]

if you use that gasket goop, make sure you dont plug the oil ports.. which can be difficult because when the cover goes on the stuff squeezes in all directions. IMO just chock up and buy a gasket. plugged oil ports means set up pistons.

[quadmanw]

Makes sense.. Lol. Ill buy the gaskets. I went over my budget but I really need the clutch so I mays well do it right

[CJM]

Originally posted by quadmanw
CJM I haven't measure them yet because I can't assemble the front end completely in my basement. I should have the measurement by next week sometime, sorry about the wait.



No worries, just was wondering.

[quadmanw]

Yeah I'll do it soon.. Work is killin me. Now I'm going to buy the tusk clutch kit and some gaskets :ermm:

[quadmanw]

well since my mechanic decided to takes 3 months with my motor and never finish and not answer his phone, I'm kind of in a bind.. hopefully I will have more pics and specs soon.. :rolleyes:

[CJM]

That sucks..

[quadmanw]

man am I POed. its ridiculous. I've pounded on his door and no answer.. wont answer his phone.. I have even looked on craigslist for a freshly rebuilt 400ex engine to make sure he didn't sell it or something!

[TheAwesomehonda]

WOW sorry to hear about the motor i hope u can get it soon... I guess thats why i like bringing mine to the big dealer i may pay more but i get it back in at most 2 weeks.

[quadmanw]

I was trying to keep the cost low. It'll be real low now when I'm done with him lol. But he's been my mechanic for years and he builds great engines and tunes them right for me so hopefully it will be done soon...

[TheAwesomehonda]

Originally posted by quadmanw
I was trying to keep the cost low. It'll be real low now when I'm done with him lol. But he's been my mechanic for years and he builds great engines and tunes them right for me so hopefully it will be done soon... I hope so but if he wont answer his phone or anythink i'd be woried.

[quadmanw]

Im pretty worried.. Hahah. Especially since race season already started..

[quadmanw]

Well I talked to my mechanic tonight and FINALLY my 416 is done. I should be picking it up tomorrow. The rebuild took ridiculously long and pretty much ruined my spring riding/racing. I should have pictures up tomorrow and pics of the rest of the rebuild.

[dxcody]

Sweet!

[quadmanw]

Man I have been waiting way to long for this lol. Hopefully it will look like Stickman's when its done lol. I took the same route without THAT much detail

[Stickman400]

Lol:D

[Zeb400EX]

That's suck about the motor man. You have those arms for while too. You'll love those arms over the fullflights. Their built so much better. I'll be looking for the pics.

[quadmanw]

hopefully Ill have some pics tomorrow!

[TheAwesomehonda]

I can't wait to see some pics!!!

[400ex_alldayy]

nice man, im in the process of doing my ex to similar specs. 10.8:1 JE piston, stage 2 cam, etc. id recommend getting a aluminum airbox that can hold all your electrical, makes for a real clean look....just a thought. Ive also head that aftermarket clutches wear out real fast compared to OEM plates
i went gloss black on my frame and im kinda feelin ur flat black more :mad: lol
and if u really wanted to save cash, shoulda done ur top end yourself lol one of the easiest engines to work on
post pics!!

[quadmanw]

Got some pictures from yesterday. Gonna go out and do some more right now. Here is the painted headers with the welds ground out

[quadmanw]

Polished welds

[quadmanw]

IMS tank I picked up for $60 and painted it black

[quadmanw]

Some of the rear end and PCd swinger

[quadmanw]

starting to look good

[quadmanw]

Last one for right now

[quadmanw]

rear end

[quadmanw]

GTT Arms

[quadmanw]

I think All the red looks sick. You can see the breather I made that is circled. I have to cut the hose but I would like to see how it works first

[Stickman400]

Looks almost identical to mine other than the pegs, stem, hubs and oil tank. Did you re-wrap your wiring harness in red tape? It looks good. Looking forward to seeing it sitting on the ground, outta look sick, just like mine, almost.:p

[Zeb400EX]

NICE! The red looks awesome! That's gonna look sweet man! Is that crank case breather one of those from the auto stores?

[quadmanw]

Yeah I rewrapped the harness, made it kind of stiff but it looks sweet. And yeah the breather is from PEP boys. I made it. Thanks for the compliments guys! Should be done soon

[quadmanw]

heres the GTT Arms that I bolted up tonight. Gonna get them all set up and in spec tomorrow

[quadmanw]

Probably the last one until the finished product but heres the awesome motoworks exhaust that I have had for awhile now. I finally got to start it today and man did it sound sick! may need to play with the jetting a little more.. or maybe it just needs to idle more and be riden. I dno yet. Almost done I'll keep you guys posted. Let me know what ya think!

[Stickman400]

Looks sick man. Is that a Galfer rotor on the back of there? I was thinking of getting one of those over my streamline but I couldn't take the price seriously on the galfer. Plus the streamline looks like a saw blade, lol:devil:

[quadmanw]

Yeah thats a Galfer lol. When I was younger I bent the stock one and obviously did not care about the price and loved the look.. I have no complaints though lol. Its always protected by a pro armor skid. I just havent made it that far yet!

[TheAwesomehonda]

Looks great except that weird tank but thats what you need for dessert races i guess but i was never a fan of aftermarket tanks. Also are those gtt arms camber and caster adjustable?

[quadmanw]

They're only camber which is perfect and they're easy to set up. I love the tank. I've always like them and I will love being able to ride forever without filling up or worrying. If I don't like it I'll take it off

[TheAwesomehonda]

Originally posted by quadmanw
They're only camber which is perfect and they're easy to set up. I love the tank. I've always like them and I will love being able to ride forever without filling up or worrying. If I don't like it I'll take it off No man i know that you don't care if i like your tank or not but like you say you can run for along time with those huge tanks.

[quadmanw]

Exactly haha. For $60 I couldn't pass it up

[TheAwesomehonda]

Originally posted by quadmanw
Exactly haha. For $60 I couldn't pass it up Dang man for that price i may even buy one and see how it works. but there ALOT more then that new.

[quadmanw]

$250 new.. Like 175 used.. So I got a great deal lol

[HondaRacing83]

Are you gonna pick up new front plastics?

[quadmanw]

nah I dont feel like spending the money on new ones. Plus with the abuse my bike takes from racing and hard trail riding it doesn't really bother me. I'd rather have a great engine and great suspension then looks lol

[quadmanw]

Alright well I got the a arms pretty dialed in today but im not sure how to adjust the toe. I just eyeballed it.. Can someone please explain because I tried everything I could. Any help would be appreciated.

I also took some measurements. Especially for you, CJM lol.
Right now with the small spacer in the axle it sits at 49 inches. The front sits at about 45 with GTT +2 arms. The back of the wheels meaures about 46 and a quarter.
The rear may have to be completely reduced for XC racing. I'm pretty wide.

Last thing is I can't tell is this gap in between my headers and exhaust is causing a leak or not. Heres a pic of it

[quadmanw]

here's a shot with the plastics just sitting on it.. Don't know How I feel about the tank..

[quadmanw]

Here it is done without the plastics.. Just have to tighten some things up and bleed the breaks, which takes forever for some reason. then figure out the toe and maybe adjust the camber a lil more.. seems off to me

[Stickman400]

I used this article to adjust my toe and it makes it very easy and fast: http://www.atvrideronline.com/tech/0706_atvp_toe_camber_adjustment/index.html

Quad looks sick btw.

[quadmanw]

thanks man! and thats a great article

[CJM]

quadmanw,thanks for the measurements. Your quad looks awesome.

Could have an exhaust leak-did you seal it with anything or maybe you should put a clamp on it?

I just measured my frontend and can confirm-with no preload on 450r shocks and stock arms Im at 43.5 inches. So with +2 arms I would be around 46.25-46.5 and thats just not gonna work in the trails I ride. I was barely squeezing thru last sunday in some spots so +1 arms would work better I think. +1 would put me right about 45.25-45.5 which is better. An inch might not seem like alot but when your squeezing thru trees pinned in 3rd-4th gear it makes a hell of a difference.

I spose I could get some 4:1 wheels but the front stockers are just so tough I havent managed to really break one-bent but not broke.well not yet anyways lol

[Zeb400EX]

Just went out and measured mine. I'm sitting about 46 1/4in. Thats with 4x1's. I got the preload adjusted down so the quads sitting about 7 1/2in at the front motor mount. The back measures 47 3/4. I'm using one spacer on the axle.

[quadmanw]

CJM, what would you recommend sealing it with? Motoworks says it isnt supposed to leak but I'm not too sure.. lol

[CJM]

Copper high heat RTV.

[quadmanw]

well I just found a clamp so I'm gonna throw that on and see how it works. I just need to bleed the breaks and throw the plastics on. I've been driving around with it in the back of the pick up lol

[quadmanw]

so I got the quad out today for the first time.. Man is it a whole new machine. The throttle response is ridiculous and first gear is just a wheelie. Gonna need to change the gearing a bit and mess with the front end a lil more and it should be ready to go. I'm gonna take it out tomorrow and saturday and ride it. I should have some real good pics by saturday. Couldn't be happier with the build

[quadmanw]

A few pics of the final built quad. Still missing the skids and killswitch in this

[quadmanw]

action shot lol

[quadmanw]

Favorite pipe ever

[TheAwesomehonda]

Nice looking ex man... I love those wheels!!!

[quadmanw]

Thanks man, and yeah i like em too. Still look good after a few years and alot of abuse

[Stickman400]

Man, that looks like a 99-04 version of mine except for the color of the nerfs, rims, plastic and a different bumper. Looks sick man, great build.

[quadmanw]

Thanks man! I'm happy with the outcome

[Zeb400EX]

Looks great! U should paint those rim black. It looks good either way tho. I'm just a big fan of black rims.

Does your front end feel better?

[quadmanw]

yeah the front end is fine. Needs adjusted more just never got to it. Went riding today and my freaking thumb throttle lever fell out lol. Ruined a day of riding

[quadmanw]

Well, It ended up that the IMS Tank did not grow on me so here's a pic without it. What do you guys think? I Also have the front end almost perfect and backed the preload all the way off of the front shocks

[TheAwesomehonda]

Looks awesome man!! I Love the rims and the black header.

[Stickman400]

Lookin' good. Now you just need a good graphics kit and a seat cover and she'll be bangin' lol

[Reece616]

Originally posted by Stickman400
Lookin' good. Now you just need a good graphics kit and a seat cover and she'll be bangin' lol

HT moto makes some pretty nice seat covers. If you're interested, I'd check out their website.

[quadmanw]

I am gonna get graphics and seat cover eventually lol. Any suggestions on graphics and cover?

[Stickman400]

I'd honestly just put a Factory Effex cover like mine on it and then buy some large stickers from some of the company's that you have parts from and lay them out really well. That would look just as good as any graphics kit if you do it right.

[quadmanw]

Just what I was thinking. I cant really do a kit becase I have my plastic stitched all along the tank. I just hate to pay $50 for a seat cover lol

[on the rocks]

nice build, wheeler looks good. wondering why the tube for the crank case breather? why not just put the filter right on the crank case port? looks like the filter in its place now will get cover in dirt/mud/dust the typical stuff. :confused:

[quadmanw]

I cut it and put it right over top of the engine. It's out of the way now lol. Hadn't seemed to be catching mud or anything haha. Thanks for the compliments man

[trailrider91]

Looks awesome man!!!!

[quadmanw]

Thanks dude!