2012 GNCC Sport class build - 2007 400EX

[matt400ex]

I'm getting close to being done with my race bike for this year and wanted to share my progress. I wouldn't be as far as I am without all of the help here on the forums, so thank you to those that post and share!

This fall I picked up a 2000 400ex as a way to get back to racing and start putting together parts for this year's season.

http://img.photobucket.com/albums/v420/2004YFZ/2000ex1strace.jpg

I was lucky enough to have a few universal parts like bars, beadlocks, and tires sitting around that fit. I also had a "vintage" set of Works triple rate front shocks that were built for a 250R at one point and swapped them out for the stockers. I modded a skid plate from my YFZ to fit and a buddy loaned me a set of IMS pegs to get me going!

[matt400ex]

One race and I had a better idea of what I needed to do to the quad to get it ready. I sent off the rear shock and the Works to GTThunder for some help!

http://img.photobucket.com/albums/v420/2004YFZ/400exsuspension.jpg

I was blown away by the difference in how well everything worked after the service. I lucked into finding someone wanting to trade Yamaha DWT beadlocks for Honda pattern DWT's and made an even trade.

My son's Kasea 70 with the 2000EX..
http://img.photobucket.com/albums/v420/2004YFZ/2000exkasea.jpg

[matt400ex]

After doing some reading here in the 400EX section I learned that YFZ450 calipers would work with the stock spindles and I had to try it.

http://img.photobucket.com/albums/v420/2004YFZ/brakefrt2.jpg
http://img.photobucket.com/albums/v420/2004YFZ/brakesfrt.jpg


Luckily I was able to use the Yamaha's master cylinder also which translated into a great set of front brakes. I was tempted to change the rear to 450R parts but so far I haven't had any complaints from the stock 400 setup and their pads are cheap! lol

[matt400ex]

A good friend of mine decided to part out his 450R XC racer which worked out great for me. I was able to pick up his Precision stabilizer, Burgurd anti-vibe stem and Durablue axle.

http://img.photobucket.com/albums/v420/2004YFZ/burguardstem.jpg
http://img.photobucket.com/albums/v420/2004YFZ/precision.jpg

[matt400ex]

I eBayed a set of Lonestar +2 Sport a-arms and that put me just over 47inches wide in the front. I knew the Works shocks would not be the ticket for a full season of XC racing but couldn't find any standard travel shocks that I like. I played with putting my YFZ's EXIT shocks on the quad.

http://img.photobucket.com/albums/v420/2004YFZ/2007exwithEXITS-1.jpg

I probably should have pursued that more. The EXITS were 17in long compared to the 16.25 that the 400EX needed so I moved them out and stuck with the Works for a little while longer. :D

By this time I had picked up my '07 and started making the switch of parts off the 2000.

http://img.photobucket.com/albums/v420/2004YFZ/bothquads.jpg

[matt400ex]

I started to realize that I was going to be needing some more power.....and lots of it! I talked to Todd Demaree at Demaree Motorsports (http://www.facebook.com/#!/pages/SICC-Racing/193869490637308) about putting together a package close to that of Garon Davis' 2011 Sport class bike and ordered a few things off of Garon's list while Todd works on the rest!

http://img.photobucket.com/albums/v420/2004YFZ/sparkstimingkey.jpg
http://img.photobucket.com/albums/v420/2004YFZ/hotcamex-1.jpg

[matt400ex]

Again, I looked through the forums and found more of my Yamaha parts that would work great with my XC 400 this time being the FCR carburetor. I've had it on and off about 50 times getting the adapters right and jetting it, but with the stock piston/head its firing fast and running good with a 162 main, NCVQ needle 2 clips from the top, and a 48 pilot.

http://img.photobucket.com/albums/v420/2004YFZ/fcr.jpg

Now unlike 99% of quad riders, I actually prefer my Yamaha throttle over the Honda. My hand cramped almost every race with the stock EX throttle and so I went back with old faithful.

http://img.photobucket.com/albums/v420/2004YFZ/yfzthrottle.jpg

This one in particular is off an '07 YFZ, but any '06+ will do!

[matt400ex]

As the season really started to get closer I was getting worried about not finding a good solution for the front suspension. I just happened to luck into another good eBay find with a set of long travel Axis shocks already setup for my weight and riding style. I had a Mr. Demaree order me a set of Houser Racing (http://www.houser-racing.com/Home.jsp?refresh=true) +1 LT a-arms to match and had them to my door in no time!

+2 Lonestars next to the +1 Housers
http://img.photobucket.com/albums/v420/2004YFZ/lonestarhouseraarms-1.jpg

Both setups on the quad...
http://img.photobucket.com/albums/v420/2004YFZ/workslonestarwithhouseraxis.jpg

[matt400ex]

Houser's Slicast Pro-Series arms go together quick and are easy to adjust. As she sits right now right @ 46inches wide...

http://img.photobucket.com/albums/v420/2004YFZ/axishouser.jpg

I hope to have my new hood and graphics installed this week and the quad will be pretty much ready for Florida. It's been a lot of fun putting both bikes together and with all of the upgrades I've made to the '07, I now have a decent quad in the 2000 model. Once I get it a little more finalized I'll make sure I get some good photos of it before I tear it apart again. :D

[dxcody]

All i have to say... is Bravo my friend. Bravo.. :D

You have one amazing quad setting there!

[426kidz]

looks good man!!:D

[HondaRacing83]

amazing..

[400man]

Hey are you gonna do the race in April in Kentucky? its called "the mammoth" and its literally in my backyard. the track will be 2 or 3 miles down the road from me. Its a completely new track and im not sure if they have even started making the trails on it yet. I'd say its gonna be a hell of a track with some good WFO field sections on the old golf course and its got several big hills and ridge lines in the area.

[dxcody]

Originally posted by 400man
Hey are you gonna do the race in April in Kentucky? its called "the mammoth" and its literally in my backyard. the track will be 2 or 3 miles down the road from me. Its a completely new track and im not sure if they have even started making the trails on it yet. I'd say its gonna be a hell of a track with some good WFO field sections on the old golf course and its got several big hills and ridge lines in the area.

I will be... Not racing just going to watch. Sounds like an awesome spot!

[matt400ex]

Originally posted by 400man
Hey are you gonna do the race in April in Kentucky? its called "the mammoth" and its literally in my backyard. the track will be 2 or 3 miles down the road from me. Its a completely new track and im not sure if they have even started making the trails on it yet. I'd say its gonna be a hell of a track with some good WFO field sections on the old golf course and its got several big hills and ridge lines in the area.

I'll definitely be at that race! I'm glad Kentucky got another race.

Thanks for the kind words guys!

[matt400ex]

Well I got a little more work done today on the quad. My Sparks X6 exhaust that came on the '07 was in bad need of some attention!

http://img.photobucket.com/albums/v420/2004YFZ/Sparksbefore.jpg


I picked up some 2000* header paint and primer at Autozone and went to it. The painting process wasn't that big of a deal but the curing afterwards took awhile. 30 minutes in the oven at 250* and then 30 minutes to cool. Then 30 more at 400 and then one more cycle at 600*. It actually turned out well but we'll see how it holds up to being caked with mud every weekend. lol

http://img.photobucket.com/albums/v420/2004YFZ/Sparksafter.jpg

[Stickman400]

Great job man, quad looks really good. I got a question about those Houser a-arms. I'm getting a set of +1 RTs just like those this coming week and was wondering if it was difficult to set the camber angle on them at all. Was it pretty straight forward with them?

[matt400ex]

Originally posted by Stickman400
Great job man, quad looks really good. I got a question about those Houser a-arms. I'm getting a set of +1 RTs just like those this coming week and was wondering if it was difficult to set the camber angle on them at all. Was it pretty straight forward with them?

These are actually the easiest a-arms I've ever put on. The Slicast makes setting the caster and camber very simple. I set this one at 0 on the caster and will let you know how I like it after I race it this weekend.

The camber is just as easy because the lower ball joint is fixed in the arm and the upper isn't threaded into the a-arm. So its as straightforward as loosening 2 nuts to tilt the wheel in or out.

[quadmanw]

Looks awesome man! What kind of oversized tank is that?

[matt400ex]

Originally posted by quadmanw
Looks awesome man! What kind of oversized tank is that?

It's an IMS. I have not had a chance to race with it yet but I'm liking the extra fuel capacity. I'm hoping I won't have to stop for fuel!

http://img.photobucket.com/albums/v420/2004YFZ/imstank.jpg

[dxcody]

Originally posted by matt400ex
It's an IMS. I have not had a chance to race with it yet but I'm liking the extra fuel capacity. I'm hoping I won't have to stop for fuel!

I was always scared i would bust my face off of that type of tank if I used it...

[quadmanw]

I'm getting a really good deal on one.. $50 bucks.. I think it may be the newer model though.. I like the ims better than the Clarke. Looks great for gncc racing.