Teixeira TRX 400EX Build

[X-tech]

This is going to be a build on a 2000 Honda TRX 400EX for my 16 year old daughter who has decided that she wants to race our new local XC series www.sorra.org. She will be racing whatever we can get our hands on for the first three rounds and will pick up the rest of the season after the break on this build. I'm excited to have her want to get into racing.

I should have started taking pictures sooner before I took it apart, but didn't. So here is what I have so far and will keep you posted as the progression develops. This quad was bought for $600.00, but should have cost about 1/2 of that because of the condition it was in. Just about every bolt is lost or stripped and the swing-arm pivot bolt had to be torched out of the swing-arm to get it out of the frame and then drilled out of the cases.

[X-tech]

Here is the motor.

[dxcody]

I have been wanting teixeira tech a arms ever since i saw them on Ockermans quad, but i never could find any that were standard travel.

[HondaRacing83]

i am so stoked on this build. subbed

[400man]

was the bike running when you got it?

[X-tech]

Yes, but it need about 1/2 a quart of oil after every 2 hour ride.

[400man]

oh ok, so its in need of a rebuild ;) . you gonna go through the bottom end too or just the topend?

[X-tech]

I'm going through the whole thing. Top to bottom.

[X-tech]

The 1st thing I did was tear this quad down to the frame. I have developed a gusset kit for the frame. It should be up on the website in the next couple of days for anyone that is interested in it. You can also see more detail if you like our Fan Page on Facebook. The website will have detailed directions under the installation guide page. Here are a few pics of the gusset kit.

[X-tech]

Close up of front end.

[X-tech]

Close up of rear end.

[X-tech]

Here is a pic of the motor in pieces.

[X-tech]

Here is a start to cleaning up the cases.

[finsteratv]

good to see some updates!

[MtnEX]

So I came over here to this site and this section to see what the options for XC suspension and arms would be for the 400EX/X if a person was wanting to build a SERIOUS XC RACER.

Talking aftermarket shocks and arms, the works...

I didn't know if 450R aftermarket arms and shocks would bolt right up and work perfect or what?

Anyways, so I saw this thread and I have always eyeballed Teixeira Tech products for my 400EX and KFX450R... but there is not an XC width offering for either. I race tight woods XC where the quads can't be much wider than stock. LTR guys have to narrow theirs to fit.

So will some XC width stuff be born for the 400
EX now or is the XC stuff there real wide?

[X-tech]

There will be XC width that will work for you and any XC rider and there will be MX width also available as we progress through this build. I will keep you posted.

I am working on a rear end that will use a lot of TRX450R components. I am trying to finalize some things before I give too much away that might not work. It needs to be figured out before I go ahead and do it.

[MtnEX]

I totally understand that.

This is great news!

I'll stay tuned.

[MtnEX]

How has the progress been coming on this one?

[X-tech]

I'll try and get some updated photos this week.

[X-tech]

Sorry, guys I've been super busy and haven't had much time to post. I will try and post as much as possible over the next couple of days.

Here is a new coating that I am working on with W2G Powder Coating. This is a type of ceramic coating, but it is engineered to dissipate heat and not hold it in.

[300exBorg]

wow this build is going to be awesome. can't wait to see the progression of it over time.

[Stickman400]

WOW, that coating looks sick az ****. I wish I had the time to break my motor all the way apart and do that to it. Looking good man, can't wait to see more.

[X-tech]

Here are some parts with the Candy Blue over Sparkle Silver Metallic Powder Coat.

[X-tech]

The next step with the top end was to send it off to CT Racing for some hop up goodies. Since the cylinder is known for having week studs that pull out, I ordered some heavy duty cylinder studs from GT Thunder.

[Resq]

Congrats on your daughter wanting to race.. keep us updated on how she does.



Originally posted by Stickman400
WOW, that coating looks sick az ****.


+2,

like to see more as you move forward, thanks for the pics

[X-tech]

I know this is a little backwards, but here is a picture before anything got started.

[X-tech]

The rear of the sub-frame was pretty chewed up from someone doing wheelies. I didn't want to replace the whole subframe and figured I would cut off the stock grab bar. I then welded on some new mounts so that I can use the TRX450R stock grab bar off of the 04' 05' versions or any other company's for that matter. This will also allow me to replace the grab bar anytime I want or need to.

[Stickman400]

That looks legit, very nice.

[X-tech]

I got the cylinder and head back from CT Racing. We went with their 440cc Midrange Complete Package. Once the cyclinder and head were in my hands it got the full coating treament and then some blinging with the fins getting some accents. The side covers all got clear powder coat over sparkle silver base. The accessories received candy blue over silver powder coat base. Once bolted together, it was installed in the frame. Then it was time to get some treatement on the oil cooler as well. The fins were coated with the gray version of the Cool Kote and the rest of the oil cooler got the Black Cool Kote. All coatings are from Way 2 Go Powder Coating. You will also notice a larger oil tank from X-Factor Motorsports.

[X-tech]

Even took the starter apart to clean insides and coat the outsides.

[X-tech]

Pic 2

[hondaREX]

I just tried your website to get a better idea of what areas your gusset kit covers and there is no detailed instructions for the TRX400ex kit. When will you be putting instructions up for the 400? I plan to do my frame this winter and want to see where your kit covers. Thanks

Edit: just found your page on facebook with some more pictures, but let us know when your website has detailed instructions for the 400ex. Also, did you re-weld some of the factory welds?

[X-tech]

I should have something up this week.

[X-tech]

Some more goodies for the 400. The rest of the package from CT Racing is here. Some of the gears that I had to replace are also in this picture along with the steering stem bearing and seals. I also got the UPP or Moose Racing case saver. The K&N lid and my stock '04 '05 carburetor will also find its way onto the 400.

[hondaREX]

Man i wanted the CT slip-on in the worst way then they discontinued them. BOOOO. Let us know how loud and how the full CT performs. Id consider the full system just for the noise level adjustability as long as power isnt sacrificed too noticeably. And it looks awesome too. Always liked the old Supertrapp with discs. Post a video if you can of the bike running with the CT on and how many discs. Thanks.

[dxcody]

That things going to be soo amazing!

[X-tech]

Originally posted by dxcody
That things going to be soo amazing!

Thanks! I'm also working on swapping lots of parts out for TRX450R parts, but need to finalize somethings before I post them. I want to make sure I'm not forgetting anything before doing them.

[D Bergstrom]

Dang Ed, your daughter is going to have a nicer quad then you! haha Quad looks awesome so far, can't wait to see it finished.

Doug

[X-tech]

Originally posted by D Bergstrom
Dang Ed, your daughter is going to have a nicer quad then you! haha Quad looks awesome so far, can't wait to see it finished.

Doug

Ya, I've told her that already and she laughs at me.

[X-tech]

I went ahead and picked up a heavy duty cam chain since the motor was apart. There is an updated picture further down the posts.

[xtreme762]

Whats the part number on the HD cam chain?

Or, can I just use a 450R chain since they have the same amount of links?

[Stickman400]

14401-MEB-671

http://www.motosport.com/dirtbike/oem-parts/HONDA/2002/CRF450R/CAM-CHAIN-%2B-TENSIONER

[X-tech]

Originally posted by Stickman400
14401-MEB-671

http://www.motosport.com/dirtbike/oem-parts/HONDA/2002/CRF450R/CAM-CHAIN-%2B-TENSIONER

Thanks for that. Yes, it is a CRF450R Cam Chain.

[X-tech]

Here is a picture with the stock on the left and the heavy duty on the right.

[russellsroost31]

is this a mx or xc build

[dxcody]

Originally posted by X-tech
This is going to be a build on a 2000 Honda TRX 400EX for my 16 year old daughter who has decided that she wants to race our new local XC series

[xtreme762]

Originally posted by Stickman400
14401-MEB-671

http://www.motosport.com/dirtbike/oem-parts/HONDA/2002/CRF450R/CAM-CHAIN-%2B-TENSIONER

Awesome, thanks.

I asked because when I looked up the other number, before the updated pic, all google returned was an o-ring seal something or other. Number 91204-HN1-003, on the other pic.

Nothing close to a cam chain. LOL :)

I'm glad you said CFR450R too. I was looking at the TRX450R cam chain.

[X-tech]

I wasn't happy with how all the old discolored bolts were making the quad look so I took them to the chromer and had them do their least expensive chrome. It was a quick sandblast and a chrome dip. I've done zinc plating, but wanted to see how this would look and hold up.

[Stickman400]

Looks good. Hope you know where they all go now, lol

[dxcody]

Any updates??

[X-tech]

I will try and get some time to post some more pictures and updates by this weekend.

[X-tech]

I still have all of my stock Honda TRX450R parts that I took off when I built my WORCS and Dezert quads. I wanted to see what I could make work on this 400EX so I did some measuring and came up with a few things. I will be using a TRX450R swing-arm with the complete bearing carrier, axle, and brakes off of the TRX450R. The only thing I am using on the rear off of the 400EX are the wheel hubs and sprocket hub. The chain alignment is off so I will be swapping to the TRX400EX sprocket hub on the TRX450R axle in the near future. The axle was a little beat up so I had it chromed when I did the bolts.

Swing-Arm on 2006 and newer TRX450R is 7/8" longer than 400EX
Axle on TRX450R is 3/4" wider than on 400EX when using 400EX wheel hubs
TRX450R Rear Brake Disc gains over 1/2" of extra ground clearance

[X-tech]

The front end will also be using a lot of TRX 450R parts. We will also be doing a similar build with a TRX250R in the future that will us some of the same concepts.

[ben300]

Originally posted by X-tech
I wasn't happy with how all the old discolored bolts were making the quad look so I took them to the chromer and had them do their least expensive chrome. It was a quick sandblast and a chrome dip. I've done zinc plating, but wanted to see how this would look and hold up.


how much does something like this cost? roughly....and the axle too?

ive just always wondered the cost of chroming something vs PC

[X-tech]

It cost me $150.00 for all the nuts, bolts, and the axle. There were also some miscellaneous parts in there like the clutch cable holder and some other stuff that is in the picture.

[Stickman400]

I think it deff. depends on where you get it done. Some guys prices are set and others are willing to go down. It also makes a difference if you go to a dedicated coater for custom parts or some company that does industrial parts mainly and then custom on the side. I went to a dedicated coater and did my entire frame in the black with clear over that for $125, then I did a bunch of misc. stuff (motor mounts, pegs, cable holders, etc.) for $30.

[X-tech]

Change of plans on the front end. I will be staying withe 400EX spindles and hubs, but will be swapping to the YFZ450 brake calipers.

[ceballos400]

What is the difference? Is it a direct bolt on?

[X-tech]

Originally posted by ceballos400
What is the difference? Is it a direct bolt on?

I was told it was a direct bolt on. I will know in a few days once the brake calipers get here.

[Threewits]

Curious..... Is the 2006 and later swingarm a direct bolt on for the 400ex or does it require shims or grinding?

[hondaREX]

x-tech. YFZ450 calipers are direct, bolt and go parts on the EX spindles!! Great improvement and damn near the price of replacemant pads for the stock EX's.

[X-tech]

Originally posted by Threewits
Curious..... Is the 2006 and later swingarm a direct bolt on for the 400ex or does it require shims or grinding?

Any 450R swing-arm will bolt on with the change of the pivot tubes. The rear of the swing-arm requires some more work. You can do the swap easy in the rear if you use all the trx 450r stuff.

[MtnEX]

Originally posted by X-tech
I still have all of my stock Honda TRX450R parts that I took off when I built my WORCS and Dezert quads. I wanted to see what I could make work on this 400EX so I did some measuring and came up with a few things. I will be using a TRX450R swing-arm with the complete bearing carrier, axle, and brakes off of the TRX450R. The only thing I am using on the rear off of the 400EX are the wheel hubs. The axle was a little beat up so I had it chromed when I did the bolts.

Swing-Arm on 2006 and newer TRX450R is 7/8" longer than 400EX
Axle on TRX450R is 1" wider than on 400EX when using 400EX wheel hubs
TRX450R Rear Brake Disc gains over 1/2" of extra ground clearance

That's awesome!

Lots of benefits to be had there I think.

DO let us know what the SHOCK and LINKAGE requirements turn out to be on this.

[chronicsmoke]

Originally posted by MtnEX

DO let us know what the SHOCK and LINKAGE requirements turn out to be on this.

x2 I have an 06+ setup just sitting in my garage that I'd like to replace the 04/05 rear end with.. I haven't had the greatest luck finding what linkage works the best.

[2001400exrida]

I put the 450 rear end on my 426 and it bolted right up.

My old swingarm bolt on the 400 was stuck so i ended up using a plasma cutter to get it off. Once i trashed the swinger i decided to just replace the entire rear with 450 stuff.

450r swinger
450r linkage
400ex shock
400ex hubs
450r axle
450r brake caliper
450r rotor
450r carrier

cutting the old one off
http://i102.photobucket.com/albums/m93/rschaef83/IMG_0647.jpg

new 450 rear end
http://i102.photobucket.com/albums/m93/rschaef83/20101219172644.jpg

here's how it sits with 450r front shocks and 450r rear end
http://i102.photobucket.com/albums/m93/rschaef83/2011-04-17_15-56-25_730.jpg
http://i102.photobucket.com/albums/m93/rschaef83/2011-04-17_15-56-04_455.jpg

[Threewits]

Wish I had done that with mine. When mine was stuck I used a pneumatic cutting tool with carbide disc and cut the bolt out. Did not do any damage, but the bearing races were so stuck in swinger I messed the swinger up a bit and now looking for another swinger.

[Stickman400]

I was also going to do the '06+ 450 swinger on my 400 but I think I'm just gunna get a +1 Houser swinger for a '04-'05 450 and re-use all my 400 stuff that I have and just get a spacer from **** Tech to take up the gap in the left side of the carrier. Might not be as cheap but it'll match my front end and everything else wasn't cheap on it so why stop now??:blah:

[ansimation]

Spacer from where? I'm wanting the 450 houser swinger also. I thought I would need a new carrier and everything else from the 450 rear to make it work. If not that's flippin awesome news.

[Stickman400]

Wow, I didn't even notice it censored that. It's M@ul Tech atv, but replace the @ with a normal a. For some reason that word is bad, lol. Here's there site, for some reason it's down: http://****techatv.com/ But just give them a call and they should have a spacer that takes up the gap on the left side of the carrier for a 450 swinger. Here's a thread I found from awhile back that I got the info from: http://www.exriders.com/vbb/showthread.php?s=&threadid=486832&perpage=10&highlight=450R swingarm&pagenumber=1

EDIT: GRRRRRR, it censored the damn link, so that won't work. Just bing "M@ul Tech ATV" and it should be the first link and it'll have their number on it.

[X-tech]

Alright! So I finally have some time to get back on this project and hopefully finish it up soon. I finally got the YFZ450 front brake calipers to mount up to this thing. I can't believe how they seem like they were made for Honda TRX 400 front end.

[X-tech]

Mounted up!!

[X-tech]

I took the intake manifold and ported the cylinder side to match in head and slightly bored the carburetor side to fit the larger 04-05 TRX 450R carb.

[X-tech]

I also took the hot start cable off and siliconed the hot start nub closed, since this is an electric start.

[X-tech]

I took the lid off the carb and welded the breather hole closed and drilled the side of the same breather so that the hose would clear the fuel tank. I also made a crude block off plate to cover where the TPS used to be.

[X-tech]

With the new TRX 450R Carb, I could not use the choke lever. I bought a petcock off of a Honda CR250R and now it clears. I had to use the stock TRX 450R fuel line and will do a slight extension with some copper tubing.

[X-tech]

Here is another shot. I don't know how to load more than one picture into a post.

[Blodg]

Nice work x-tech and nice pics to share with us. I am sure you know this but the choke isn't really needed with the 450R carb. I was a little skeptical myself but have had no problems starting mine below freezing after I installed a 450R carb this winter. Just turn the idle knob up some and pump the throttle 3 to 5 times and it fires right up and idles nicely. I would imagine that maybe the choke would be nice if someone rode a lot when it was closer to zero degrees F. but that is too damn cold for me.

[X-tech]

Thanks for the info! Any info to make this a better build is greatly appreciated. If I wind up not using it, then I'll probably take it off. At least this way if someone wants to use it, now they know what they can do.

[MtnEX]

Originally posted by X-tech
Mounted up!!

Dang! Very impressive.

[Shawthy33]

I'm tuned in now, this thing is shaping up nicely.

[QuadJunkies]

I done the 450 carb on my 440 years ago and its an EXCELLENT upgrade to have !!
Nice Ed !
I want that front end for MINE ! :D :macho :cool:

[X-tech]

The swing-arm is mounted using the Teixeira Tech TRX 450R Linkage. Initial measurements show a low progression linkage that eliminates any buck and should have no problem getting 10" to 10.5" of travel for XC and possibly even more for MX racing if needed.

The stock TRX450R swing-arm adds just short of 1" to the wheelbase.

[X-tech]

This allowed the use of the rest of the TRX450R components, which widened the rear end by 1" using the stock TRX450R axle along with the 400EX hubs. If you don't want the added width, you can use the TRX450R hubs to narrow the rear end slightly. I went ahead and also used the TRX450R bearing carrier, TRX450R rear brake stay, brake caliper, and brake disc. All this gains over 1/2 inch of ground clearance and the TRX450R bearing carrier has the dual bearing on the chain side. Everything was laying around in the shop from my previous TRX450R builds.

[MtnEX]

Dang, very nice....


Thanks for the info on the hubs. I may need to hit you later for some of the actual math on the 400 and 450 hubs.

I may put some Honda hubs on the back of my KFX.

[RNL]

Count me in on wanting to now how the CT exhaust does. I too love the older style disc type systems.

[MtnEX]

The exhaust will do awesome.


Worked awesome back in the day, no reason it won't now.

[RNL]

Originally posted by MtnEX
The exhaust will do awesome.


Worked awesome back in the day, no reason it won't now.

Sweet. Gains everywhere, or just down low?

[X-tech]

I had one of Precision-RP's steering stabilizers from testing so I called up George at Precision and ordered a mounting kit to fit the TRX400EX.

[X-tech]

I wanted a stronger yet light stem. This can be accomplished by going to a larger diameter steering shaft. To do this, I bought two front mounting clamps off of the TRX 450R and sandwiched them together to accept our TRX 450R stem and bushing. The bonus was that it also reduced the bumpsteer by a lot.

[X-tech]

Since I was this far into the clamps, I also drilled and tapped a hole so that I could grease the bushing.

[Blodg]

Did you say somewhere that the linkage and /or the spacers for using the 450R axle on the 400EX would be available for purchase as a kit?

[X-tech]

Originally posted by Blodg
Did you say somewhere that the linkage and /or the spacers for using the 450R axle on the 400EX would be available for purchase as a kit?

The linkage is available to purchase. We are currently working with ELKA to get the shock dialed in. We will offer others shocks as time progresses.

The rear end on this build is all TRX450R parts. We can look into making a conversion kit to use the TRX450R axle in the 400EX if this is what you are asking about.

[Blodg]

I should have said I would be interested in a kit to install a 450 R swing arm on a 400EX. several people have done it on their own but I have read the sprocket may not line up properly and getting the rear linkage and shock to work properly can be difficult. If a kit was available it would be great.

The one inch longer swing arm, the one inch longer axle, and the additional ground clearance would be perfect for many 400ex set ups.

[Stickman400]

I think the only thing you need to install a 450R swinger on a 400 using all 400 parts except the 450 swinger is a spacer for the carrier, because the carrier on a 450 is slightly narrower than a 400ex. I was wanting to do the conversion also and found THIS (http://www.exriders.com/vbb/showthread.php?s=&threadid=486832&perpage=10&highlight=450R swingarm&pagenumber=1) thread saying all you needed was a small spacer for the carrier. M@UL Tech ATV supposedly sold them awhile back when that thread was going.

[X-tech]

Going to try and use the TRX 450R axle with the TRX400EX sprocket hub to get the correct chain alignment. TRX 450R axle is 3/4" wider and 1/2 lbs. lighter without the sprocket hub on.

[X-tech]

I ended up pressing the sprocket hub off of the 400EX axle and pressing it on to the 450R axle. The chain lines up now and I am ready to move on to the next obstacle. Here is a shot of the 450R axle with the 400EX sprocket hub mounted up. The wheel hubs are 400EX and everything else is TRX 450R.

[X-tech]

I finally got this thing to the point that I could put it on the dyno. I took it to CT Racing to check and see where it would be at with the CT Racing TRX400EX 440 Midrange package with a 11/1 compression piston and my stock 04-05 TRX450R Carburetor. I only wanted to run pump gas in this beast and not have to spend on race gas. I squeeked out a little over 43 ponies. I'm plenty satisfied with that for this project and it will be plenty reliable.

[Blodg]

43 HP is great! Do you have the actual dyno graph that could be shared?

[X-tech]

Originally posted by Blodg
43 HP is great! Do you have the actual dyno graph that could be shared?

I don't have the graph. I should have asked CT for it or taken a picture.

[X-tech]

I finally got all the protection mounted up for the underside of everything.

[X-tech]

Here are the YFZ 450 brake calipers mounted up with Streamline Brake lines. Spindles are powder coated black.

[X-tech]

ASV levers as usual. I prefer the shortys and my favorite Oury Grips.

[X-tech]

I wanted this project to really stand out and going to the 2013 style plastics was one way of getting there. I called up Maier Plastics and got a set coming from them. I had to make a few brackets, but it was well worth it. While I was at it, I shortened up the front plastics a little bit. They hung down a bit more than what I like.

[X-tech]

The fenders came with the stock 2013 reverse knob hole on the right fender so I made a small plate and pop rivetted it on so I could mount the key and make it look factory. On the opposite side, I mounted the neutral light. The handlebars were also cluttered looking with the stock start button and light switches so I found this motorcycle kill botton on ebay and made it my start button and mounted to the clutch perch.

[X-tech]

I also mounted some Teixeira foot pegs that are down 1" and back ".

[Stickman400]

I like that linkage skid plate, looks really heavy duty. Also like the custom fender brackets, that's the way they need to come from the factory, much more solid looking. And I was looking at buying one of those kill switch buttons to replace my kx kill switch I have wired for a starter button to free up some space on the bars but most of the reviews said they were junk and fell apart after a couple hours of use. Let me know how it holds up or if you have any issues with it.

EDIT: Here's a link to it on Motosport, look at the reviews. $50 and reviews like that made it a little to iffy for me. http://www.motosport.com/atv/RIDE-ENG-BILLET-KILL-SWITCH

[X-tech]

I like that linkage skid plate, looks really heavy duty. Also like the custom fender brackets, that's the way they need to come from the factory, much more solid looking. And I was looking at buying one of those kill switch buttons to replace my kx kill switch I have wired for a starter button to free up some space on the bars but most of the reviews said they were junk and fell apart after a couple hours of use. Let me know how it holds up or if you have any issues with it.

EDIT: Here's a link to it on Motosport, look at the reviews. $50 and reviews like that made it a little to iffy for me. http://www.motosport.com/atv/RIDE-ENG-BILLET-KILL-SWITCH

Thanks for the completments. I did not see this review. The one I got off of ebay is actually a different company. I called them and talked to them ahead of buying it. The reason I went with this one is because it had longer wires than the Ride Engineering one. I will keep you posted on its durability.

[dwight420]

I've been watching this build for a couple years now.. It's getting really exciting! Great thread!! :D

[wfo4rv]

Post some pics if it done! I saw your daughter racing it at sorra

[jmarkel]

i've got an 08 and i'm in need of rear fender brackets bad! Would you fab me a set of those and how much? I currently have rear maier plastic. Thank you.

[X-tech]

i've got an 08 and i'm in need of rear fender brackets bad! Would you fab me a set of those and how much? I currently have rear maier plastic. Thank you.

These were based off of the 2000 frame to the 2012 fenders. I don't know if your frame would have the exact same location mounts. I would need the quad here to do it right.

[X-tech]

Here are some pics we took at Pismo Dunes for the photo shoot going into Sand Sports Magazine.

[MtnEX]

Very very very impressive.

Let us see it sometime with the XC tires....

[Speed37]

^ what he said. But are you gonna run the dwt's for xc also?

[X-tech]

Ready for XC racing.

[Speed37]

Thumbs up for a sweet looking 400! Good luck with the quad and your daughters season

[chronicsmoke]

VERY nice job! One of the nicest I've seen for sure :muscle:

[2001400exrida]

Beautiful looking 400ex!

[MtnEX]

Looks like an excellent XC quad. It should do very very well.