My 440ex Duner Build... Take #2

[Dubs_Tech]

Well I've owned this Honda 400ex for roughly 6 yrs. I rode it stock for a very long time, two years ago i decided to do a rebuild and mod it a bit. Here is how it sits now and the mods currently.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0013.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0014.jpg

Mods:
2001 Honda 440ex.
Wiseco 12.5:1
Hotcams stg. 3 cam
Mild Port & Polish
Large polished aluminum air box
K&N air filter with OuterWears
CRF450 cam chain
GT thunder head studs
GT thunder 8 plate clutch kit
Wiseco Billet Clutch Basket
MSR easy pull clutch lever
TRX250x clutch cable
Large oil tank with cooling holes
Spal fan - thermostatically switched
Additional oil cooler
Polished Air Scoops
White Bros modded E series exhaust
Brand Unknown big bore header
Dial-a-jet
Dual H7 6000k HIDs in headlights
Yamaha R6 LED brake light
TRX450r Rear Brake light switch
Hayabusa Battery
i5500 Complete Front Suspension System - w/NEW F8 iShocks
G-Force rear extended axle
Renthal 14t front sprocket
Renthal 39t rear sprocket
Renthal non o-ring chain
T.M. Designworks Chain Slider
T.M. Designworks Powerlip Chain Roller
Yamaha YFZ dual piston front brake calipers.

Just some videos from Glamis last season, messing around on China Wall
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_chinawallwheelie.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=chinawallwheelie.mp4)

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_chinawallwheelie2.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=chinawallwheelie2.mp4)

Whooping on an LTZ400
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_asswhoop.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=asswhoop.mp4)

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_armpump-1.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=armpump-1.mp4)

Pulled it out to take some more detailed pictures before i start the tear down. I'll update with all the new goodies later once i get more pictures loaded.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0456.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0457.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0459.jpg

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http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0469.jpg

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http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0475.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0482.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0483.jpg:devil: :devil:

[dxcody]

Lol you have alot of work into your cooling system it looks like!

Cant wait to see it finished!

[sand_blaster]

Yes this is going to be good! What are your plans as far as build goes? Do you plan on 450r carb for more power or keep stocker?

[Jayskee]

Sharp looking bike especially the first pic of it in the sand. Almost like how mine is gonna be. But im doing the matte black powder coat frame and engine cases. And gonna polish the other parts. But you really need to get rid of that stock carb! If you can afford the FCR 39 Id put that on there! And those rear red hubs spray paint them black to match the front arms and bumper. Otherwise good job man! And whats with the hose going to the head? Can you give me details on what you did there? I assume its for more cooling.

[Dubs_Tech]

Wait till you see my new cooling system set up ;) The 440 runs HOT in the dunes, once i added the external cooler it feels stock again. Im unhappy with the crap wiring and unhappy with the way the cooling system looks so this second time around everything is being done legit. As far as the 450 carb goes if its still in my budget and i still have time before dune season rolls around again i really want to swap to it. Right now im running the stock carb with choke removed. My plan for this second time around build it efficiency and simplicity. Here is a link to my car build to give you an idea of how i build: Project Jetta (http://forums.vwvortex.com/showthread.php?5317406-My-Budget-Build-Daily-Driver-(-pic-intensive-))

[Jayskee]

Glad im not on dial up with all those pics! lol. Thats awesome you took all those step by step pics though! Do we have anything like that on here? Maybe we should do a Step by step build on here. I have my frame down to bare frame now getting ready for powdercoat. I just don't think I have the patience or time to take all those pics. Ill try. Except I dont want you guys seeing my garage with the parts lmao. Parts all over the place.

[Dubs_Tech]

I love the 400, all my buddies are on 450s and they're great and all but i love how the 400 is easy to manage power wise. After this project i'll be jumping into my 250r and that will be my dune drag bike.... im shooting for 75-80horse with that one.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0476.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0478.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0479.jpg

My helper
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0477.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0480.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0481.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN0484.jpg

[Dubs_Tech]

Took some pictures of the items i've already purchased.

Dual Slim HID Ballasts
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0485.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0486.jpg

B&M Super cooler
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0487.jpg

Miscellaneous AN fittings both 6 & 8AN
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0488.jpg

5 Row CX racing cooler to replace the stock one.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0489.jpg

LED air stem caps for night riding at the Dunes :D
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0490.jpg

Red El Wire for my whip
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0491.jpg

Ozuim waterproof illuminated ( white ) button for my headlights.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0492.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0493.jpg

Thermostatic switch for my Spal fan, 6AN it'll screw right into the B&M cooler, this sucker was expensive.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0495.jpg

OMF 8" rear beadlocks, they need some prettying up but i got a great deal. Did a quick polish on one of the rings, it'll need much more though before im happy with it.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0497.jpg

Also picked up a new set of Douglas Blue Labels for the front.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0496.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN0498.jpg

I still have a laundry list of things to buy and have done by October but i have time. :P

[on the rocks]

build looks sweet, once i get my 4 wheeler up and running HID's and cooling system is on the to do list.

where did you find your Thermostatic switch. i have been looking all over ebay with no luck.

[Dubs_Tech]

Type 6AN thermostat in ebay. Kicks on at 190 and shuts off at 170.

[on the rocks]

with that being a fluid style do you think it would still work if it was screwed in do a block of aluminum bolted on motor? its still getting heated up. so far its not in the plans to cut open the oil lines so im looking to mount the switch on the motor.

[finsteratv]

I'm liking this build! Always wanted to build my old 400 into a duner but picked up a 450 for a good price so I cant complain..I cant wait to see the 250r too!

[Dubs_Tech]

Originally posted by on the rocks
with that being a fluid style do you think it would still work if it was screwed in do a block of aluminum bolted on motor? its still getting heated up. so far its not in the plans to cut open the oil lines so im looking to mount the switch on the motor.

No its an in-line thermo switch so fluid has to run through it. If thats the set up you want to run you can save a ton of money and just buy a generic GM 2-pin fan switch. Cost paybe $5

[on the rocks]

ended up changing my mind. im goint to stick the temp switch in a welded bung in my oil tank.

i thing the switch provides ground for the coil of the relay when it reaches temp. gotta gee is my oil tank needs a ground strap or its its already grounded.

here is the kit i went with for my fan

http://www.ebay.com/itm/185-DEGREE-FAN-THERMOSTAT-TEMPERATURE-SWITCH-RELAY-KIT-/400214167002?pt=Motors_Car_Truck_Parts_Accessories&hash=item5d2e9f8dda&vxp=mtr#ht_2842wt_1037

[Dubs_Tech]

Well you know the saying, theres more than one way to skin a cat. This was my choice of route :blah:

[400exshop]

I see your in AZ and you go to glamis....

you must have heard of Racers Edge over that way.

Or HDD out of cal. If you you have heard of them you need to take your head to Racers Edge to get it p&p and tell john to make you a custom cam for the bike....

He is bad A** with bikes. tell him Eric aka EJRacing out of south carolina sent you....

He will hook it up for you... I sent him my dyno sheets for my 440ex and my 804 700 raptor....

We make big power with th 440ex 68hp and 90+ with my raptor.

[Dubs_Tech]

Thats pretty cool but im just keeping it simple with this, im only looking to currently make it more durable and efficient. Like i said a few posts back im not trying to squeeze every pony out of this i just want it rock sold..... my 250r will be my drag bike when i get to it.

[Jayskee]

How are you getting 68ho out of the 400ex? turbo? nitrous? naturally aspirated?

[b0rn c0nfused]

Love the bumper! Looks like rhino line?

[Dubs_Tech]

Yep bumper has LineX on it

[Dubs_Tech]

sorry guys its been a while but im still working on this thing.

CX racing cooler mounted, roughly same size as stock just more efficient.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1047_zps765f90d9.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1049_zpsbb749bd9.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1050_zps67996c76.jpg

B&G cooler mounted in the front. Still have to attach the SPAL puller.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1051_zps02aa9ae8.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1052_zps660d543c.jpg

Made up the brackets to hold both coolers.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1053_zps51518c62.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1054_zpsc0873116.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1055_zps114516ba.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1056_zpsab180e78.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1057_zps86ff44b2.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1058_zpsf2a02992.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1059_zpse4a94311.jpg

Fan switch for activating my SPAL fan.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1060_zpsa959698b.jpg

Clutch cable bracket bent to clean oil fitting & head pipe. Using 250x clutch cable as well.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1064_zps92999441.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1065_zps79e2fe14.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1066_zpse866ac9d.jpg

Full custom harness starts now.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1071_zps03e96ecd.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1072_zps93c0328e.jpg

New airbox too :)
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1074_zps0159acb1.jpg

If you cant tell this is where i eliminate any crap i can from the factory harness.... this job sucked.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1075_zps99f46389.jpg

Getting there, eliminated a bunch of crap and replaced it with 10 gauge wiring for power to SPAl fan as well as HID ballasts.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1076_zps22768f3e.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1078_zps302ca46d.jpg

Hooked up everything temporarily to test everything.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1080_zps96f7b914.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1081_zpsd96bc1fe.jpg

Great success!
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1083_zps57e15c5f.jpg

My temporary power source until my GEL Hayabusa battery arrives.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1084_zps3f5891ff.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1085_zps85425e02.jpg

[finsteratv]

What's up with the 250x/300ex frame in the background??mlookin good!

[Dubs_Tech]

Thats a 300ex im building for my girlfriend, Hers is going to be built similar to mine. Ive already completed the motor i'll get a picture up of it tonight.

300ex motor:
bored .20 over
Weisco 11:1 piston
ported, rebuilt head
Hotcam Stg. 1 cam

[JOHNDOE83]

Have you tested the oil flow at all?

The only reason I ask is because Im not sure you can get any oil flow with any kind of pressure from where you tapped it.

Im sure I could be wrong, just wondering if you tested it at all?

Other then that it looks really cool, I would say use that instead of the stock oil cooler but its already been drilled and tapped on the motor.

[Dubs_Tech]

Originally posted by JOHNDOE83
Have you tested the oil flow at all?

The only reason I ask is because Im not sure you can get any oil flow with any kind of pressure from where you tapped it.

Im sure I could be wrong, just wondering if you tested it at all?

Other then that it looks really cool, I would say use that instead of the stock oil cooler but its already been drilled and tapped on the motor.

Yeah ive been running that set up for 2 years ( please see pictures on first page ), its tapped in at the oil filter ( where theres oil pressure ) which flows through the cooler and back into the head. The oil feed port inside the cylinder head is plugged which maintains pressure. This modification has been done since 1999.

[JOHNDOE83]

I meant tested as have you physically disconnected the inlet line to see if its pushing a flow of oil out to the cooler?

I know people have done it in the past but I never saw any flow videos or anything describing if it actually flowed oil.

Im not trying to be like "oh thatll never work" , Im looking into using something like that for a new 400ex based build, I just dont want to drill and tap to find out its not full flow.

Since yours in in the build process could you possibly post some video on the flow output?

[Dubs_Tech]

Im not trying to be a dick but... your drilling into the pressure side of the oil filter where ALL the pressure from the oil pump is, this is forced into the cooler. I have had this set up on my quad for 2 years and many many dune trips. My previous cooler i removed which if you look back you can see i already had this. The previous cooler was full of oil so to answer your question yes..... there is oil pressure. My motor hasn't blown after shooting hills 100 times so id say its rock solid. Do some research there's TONS of information on this modification.

[Dubs_Tech]

Anyway moving onward....:confused:

Harness is complete, going to fill her with oil tomorrow and hopefully get her started.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1102_zps7fc127bd.jpg

ASV lever on
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1100_zps1b288b8a.jpg

Exhaust back on
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1097_zpsdcf76337.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1096_zps465c214c.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1093_zpsadadd5ae.jpg

Im completely happy with how the harness turned out.
http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1091_zps61a3d032.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1090_zpse78d926a.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1089_zps8bb248f5.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1088_zps23d312f7.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1087_zps758c1c34.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1108_zpsd541807c.jpg

[Dubs_Tech]

Well got her running leak free and cooling system is working just as intended. Made my SPAL fan mounting bracket & hooked it up last night.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1109_zps8a51844c.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1110_zps63343d77.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1112_zpsfee5be70.jpg

Used a bunch of VW hose separators to secure my lines.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1114_zps98e04240.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1116_zps93c6f2e3.jpg

Scoops mounted & modified to clear lines.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1117_zps8674f650.jpg

Im not liking the IMS oversized thank AT ALL, fenders fit like crap and it looks like a giant tumor... im going to pull it off tonight and just keep this tank for my 250r project.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1118_zpsa3a5d281.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1119_zps65e3fa16.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/DSCN1120_zpsd5752eda.jpg

[jman7290]

Awesome job, I been wanting to do the secondary cooler for years and been doing a lot of research on it. Cant ever get in touch with Four Stroke Tech (FST) to order the kit. I want to built the kit myself, but I can't find any info on what size bearing and exackly where to put it to block the stock oil flow off to the head. I also want to put a spal fan on the stock cooler with a temp switch. Maybe even an oil pressure gauge on there somewhere! Also a dip stick from XR's Only with a tempature gauge built in. One day!

[Dubs_Tech]

Took it for a nice 15 minute ride today, fan never came on once meaning the oil temp never went over 180. I didnt really get on it or anything but thats great. My upcoming dune trip will be the real test.

[on the rocks]

i have a 180 temp sensor in mine and i have yet to hear my fan turn on. haven't been doing anything too difficult yet where the air flow stops though.

[Dubs_Tech]

Thats exactly how i want it, id rather the coolers do their work and the fan only comes on under extreme conditions. Anyway already ran into a problem, the cheapo slim ballasts i bought off ebay are crap. The bulbs will only ignite sometimes even though i have the system relayed straight to battery power. So i bought some better ones last night, at least i can still ride though!

[DnB_racing]

Originally posted by Dubs_Tech
Thats exactly how i want it, id rather the coolers do their work and the fan only comes on under extreme conditions. Anyway already ran into a problem, the cheapo slim ballasts i bought off ebay are crap. The bulbs will only ignite sometimes even though i have the system relayed straight to battery power. So i bought some better ones last night, at least i can still ride though! is directly off the battery how its recommended??

I would think it would be better of the fused regulated wire,

this way your not using battery then relying on the regulator to charge the battery,
but instead the regulator will allow for the load from ballast and wires plus the charge for the battery...

the long wires you used for the ballast will have a significant voltage drop.. if drawing directly off the battery your probably not getting a full 12 volts..

the added gauge will help reduce voltage drop, but the additional length plus resistance in all the connections will drop it down

if you wire them into the regulated wire it will get the full output

check your running voltage at the bulb. it should be over 13v ...EDIT... sorry I just remembered its a ballast... check as close to the ballast on the line side of the ballast as possible, this way as many splices and wires are measured in you voltage reading

after looking at the ex schematic.. if I was installing this i would power it off the black wire after the key, to allow no battery drainage when key is off... but thats just one of many ways

[jman7290]

Do you have any pics of your secondary oil cooler install, such as where to drill the holes and what size bearing that you used or what ever you used to block the stock oil flow port to the head? Or some good instructions on how to do it? Like I said I have been researching it for awhile, but mainly just found pics of after the install and not really any good directions. There is a sticky on a secondary cooler intall, but its just inline with the stock cooler. It would be awesome if you or someone else with the secondary oil cooler going from the filter straight to the head would make a step by step sticky on this install.

[Dubs_Tech]

Originally posted by DnB_racing
is directly off the battery how its recommended??

I would think it would be better of the fused regulated wire,

this way your not using battery then relying on the regulator to charge the battery,
but instead the regulator will allow for the load from ballast and wires plus the charge for the battery...

the long wires you used for the ballast will have a significant voltage drop.. if drawing directly off the battery your probably not getting a full 12 volts..

the added gauge will help reduce voltage drop, but the additional length plus resistance in all the connections will drop it down

if you wire them into the regulated wire it will get the full output

check your running voltage at the bulb. it should be over 13v ...EDIT... sorry I just remembered its a ballast... check as close to the ballast on the line side of the ballast as possible, this way as many splices and wires are measured in you voltage reading

after looking at the ex schematic.. if I was installing this i would power it off the black wire after the key, to allow no battery drainage when key is off... but thats just one of many ways

Funny you mention this because shortly after rethinking the set up i thought the same as you, so this is what i did.

I decided to change up the wiring in regards to the HID kit as well as replace the cheapo ballasts i had with some better quality ones.

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1131.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1132.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1135.jpg

Relay's new location in airbox as well as simplified wiring.
http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1136.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1137.jpg

This is how i wired the system:

1. Ballasts in front attached straight to bulbs.

2. Relay moved to airbox next to battery

3. 12 gauge power & ground to relay.

4. 14 gauge signal wire to relay from headlight switch/key power.

5. 10 gauge power wire run up to ballasts from relay.

6. 9 gauge high current power wire from battery to solenoid to starter.

7. 9 gauge high current ground wire from battery to frame.

I feel this is the optimum way to avoid any future issues. The lights ignite every time now with no issues whatsoever. I cannot WAIT for my dune trip in 2 weeks!

[Dubs_Tech]

Glamis trip planned for next weekend, took the bike out for a rip today. It ran GREAT and pulls HARD i cant wait to go against all my friends with 450s and banshees again this year. Last year i would BARELY loose to the modded ones every time..... though i greatly feel this year will be different.

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1138.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1139.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1140.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1141.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1142.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1143.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1144.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1145.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1146.jpg

[Dubs_Tech]

Also finally got to put my bead-locks to use, my Haulers arrived yesterday so i mounted them and set them in the sun with 20 psi in them so they regain they're shape before i use them. They're shipped collapsed ( flat ) so mounting is a pain and they're all deformed until aired up.

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1147.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1148.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1149.jpg

What do you guys think?

[Dubs_Tech]

Wanted to post mods to date:

Wiseco BigBore 440 kit
Wiseco 12.5:1 piston
Ported rebuilt head
GT Thunder HD head studs
Modded/Jetted carb ( choke removed )
175 main
42 pilot
3 clip on needle
Unknown brand BigBore header
Modded ( shortened/polished ) WhiteBros exhaust
PRM airbox
K&N airfilter w/ Outerwear skin
One step colder NGK spark plug
Dial-a-Jet leanest setting
Hotcams stg. 3 cam
CRF450 cam chain
GT thunder 8 plate clutch kit
Wiseco Billet Clutch Basket
ASV clutch lever
TRX250x clutch cable
Extra capacity oil tank with cooling holes
Spal fan - thermostatically switched
B&G additional oil cooler
CX racing factory oil cooler replacement
6AN & 8AN oil cooler fittings w/ Stainless hoses
Polished Air Scoops
Dual H7 6000k HIDs in headlights
Yamaha R6 LED brake light
TRX450r Rear Brake light switch
GEL Hayabusa Battery ( dry cell deep cycle )
i5500 Complete Front Suspension System - w/ the new F8 iShocks
PRM front bumper ( LineX coated )
ProTaper Fat bars
Kawasaki dirtbike kill switch wired in for starter.
Lucas Oil 15-40 Synthetic oil
G-Force rear extended axle
Renthal 14t front sprocket
Renthal 39t rear sprocket
Renthal non o-ring chain
T.M. Designworks Chain Slider
T.M. Designworks Powerlip Chain Roller
Yamaha YFZ dual piston front brake calipers.
OMF 8" rear bead-lock wheels
21x12x8 8 paddle haulers
Sandshark front sand tires
Red L-wire'd whip
Complete custom bike engine harness
Luminis super slim ballasts
HID relay w/ heavy duty wiring

[Dubs_Tech]

Wow this forum is slow...

[NacsMXer]

Wow the quad looks great, nice job on the build! I can't believe you went through all the wiring like that. Lots of attention to detail. The cooling system you put together is freaking impressive to say the least. It is so overkill and that is the best thing about it lol. I'm pretty sure you will have the coolest running 400 there ever was :cool:

[Dubs_Tech]

I agree its a bit excessive for a single cylinder motor, but being i live in AZ and ride the dunes in Cali often this thing sees tons of abuse as well as hot climates. I cant wait to try it out next weekend!

[quadmanw]

Do you have the button on the bars rigged to start or shut off? And I take it you have a switch for your lights to? lol. I am looking at doing that

[Dubs_Tech]

Originally posted by quadmanw
Do you have the button on the bars rigged to start or shut off? And I take it you have a switch for your lights to? lol. I am looking at doing that

Kill switch actually starts the bike, the key kills it. Yes look to the left of the neutral light, thats my Ozium illuminated white light switch.

http://i986.photobucket.com/albums/ae348/tonyinserra/DSCN1144-1.jpg

[quadmanw]

Whered you pick up that start switch? Im interested In doing that

[Dubs_Tech]

Originally posted by quadmanw
Whered you pick up that start switch? Im interested In doing that

I just typed Dirt Bike Kill Switch in ebay, I liked this style it was labeled "Kawasaki Kill Switch" my quad is literally an Ebay whore, most of whats on it i got from there.

[quadmanw]

Alright thanks man. Awesome quad by the way!

[Dubs_Tech]

Thanks!

[Dubs_Tech]

Back from Glamis

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0010.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0011.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0014-1.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0015.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0017.jpg

Took some more once the sun was going down.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0026.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0024.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0023.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0035.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0033.jpg

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/PICT0034.jpg

[Dubs_Tech]

Two short clips my girl took shes not very camera savvy.

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_PICT0030.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=PICT0030.mp4)

http://i986.photobucket.com/albums/ae348/tonyinserra/Quads/th_PICT0029.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/Quads/?action=view&current=PICT0029.mp4)

[Dubs_Tech]

***Updated pictures on previous page***

currently bidding on 450r carb on ebay, stand by for updates :)

[Dubs_Tech]

Ok so i need some help getting me to a starting point with the 450r carb. From the research ive been doing it seems like this is whats recommended:

180 main jet
4th clip down on needle
mixture screw 2-3 turns out
stock 48 pilot?

Does this seems right? Meaning for the set up im running? When i was at Glamis i was pulling on all my friends who had:

YFZ450 stock
Banshee with pipes only
Raptor700
YFZ450 pipe & filter

When we were at the drags i was BARELY loosing to others with the same bikes but more mods im assuming, i truly feel this carb will put me even with them but being the variables of the modifications i have im stuck on where to start. Any help would be greatly appreciated.

[Dubs_Tech]

Originally posted by Dubs_Tech
Ok so i need some help getting me to a starting point with the 450r carb. From the research ive been doing it seems like this is whats recommended:

180 main jet
4th clip down on needle
mixture screw 2-3 turns out
stock 48 pilot?

Does this seems right? Meaning for the set up im running? When i was at Glamis i was pulling on all my friends who had:

YFZ450 stock
Banshee with pipes only
Raptor700
YFZ450 pipe & filter

When we were at the drags i was BARELY loosing to others with the same bikes but more mods im assuming, i truly feel this carb will put me even with them but being the variables of the modifications i have im stuck on where to start. Any help would be greatly appreciated.

Anyone?

[CJM]

52 pilot, try a 190 main to start, 2.5 turns out the fuel/air screw. 4th clip might be ok if its cold, I went back to 3rd clip.

[Dubs_Tech]

Great thanks i'll try that out.

[Skeldaw]

Is that a white brother e-series exhaust?, If so, Did you notice a power lost when you removed all the disk and the spark arrestor. Is it much louder than 12 disk?

[Dubs_Tech]

[QUOTE]Originally posted by Skeldaw
Is that a white brother e-series exhaust?, If so, Did you notice a power lost when you removed all the disk and the spark arrestor. Is it much louder than 12 disk? [/QUOTE

Yes its an E-Series which i shortened. I packed it super tight with FMF exhaust packing so its not really too loud ( see the video clips on the last page ) I jetted up to accommodate the exhaust modification and i noticed a good increase in power.

http://i986.photobucket.com/albums/ae348/tonyinserra/th_PICT0030.jpg (http://s986.photobucket.com/albums/ae348/tonyinserra/?action=view&current=PICT0030.mp4)