My official build thread!

[Zakradu398]

I figure I'm a good way through it to start one of these. So here we go!

So it was my 17th birthday and my Dad told me he'd buy me tires and rims for my '99 Wrangler. That was sweet, but then I happened to look on a local Yamaha Dealer's website because I knew they were going out of business soon. They had an '04 400ex on there for $1400!! I thought it was a misprint or there was something wrong with it. So, I told my Dad and since rims and tires would cost the same, we went and took a look at it. Looked nice, rode fine, but needed tires. We talked them down $50 and got it for $1350.

Here's the pic they had on their website.
http://i148.photobucket.com/albums/s31/zakrad_u/400.jpg

I got it home and rode it for a while. I'd shut it off and then the fuse would be blown, so it wouldn't start. I then realized that was why it was so cheap.
Now, this is my second quad besides an old Arctic Cat 90. (I rode dirtbikes) So I tried diagnosing the problem. Turns out there was a bare wire grounding out on the frame and a 2" piece of electrical tape later I was set.

I then flipped it the same day doing wheelies and bent the bars. I went ahead and ordered Tusk bars and Polisport roost deflectors.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0020.jpg

[Zakradu398]

I started browsing craigslist for any aftermarkets and came across a Yoshimura Comp slip on listed for $150. I felt that was a damn fine deal so I went and picked that up. I also got anm Ebay PB block, 757 brand?

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0029.jpg

After that, my friend was selling a powerbomb header from his 400 but I was cracked by the "bomb". My GF's Dad is a welder, so he patched it up for me.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0238.jpg

Next came some 450r shocks, they don't look the best but work just fine for me. I'll be in the market for new shocks this next payday :devil:

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0240.jpg

[Zakradu398]

By now, I rode it for about 5-6 months and the tires were still horrible and I beat the living hell out of the stock rims. The clutch also started slipping so I got 4 gbc x rexs, black ITP BAJAs, uni filter, swingarm bearings, and a Tusk HD clutch. :cool:

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0258.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0259.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0263.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0270.jpg

[Zakradu398]

The swingarm bolt was a NIGHTMARE to get out. We had to cut it out, but it was still stuck in the motor bushing. MY friend who is an Arctic Cat dealer also has a shop so he drilled it out of there for me.

Here's how I ended up cutting it out.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/IMG_3263.jpg

During this time I also ordered GT thunder +2 A Arms.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/400.jpg


It was now summer and I started doing a lot of night riding, So I read the sticky and went ahead and bought the DDM Tuning HIDs.
http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0323.jpg

Here is a middle of the day shot.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/IMG_6572.jpg

[Zakradu398]

I broke off my back brake caliper mounts because a bolt had come out, I was drifting backwards, hit the back brake and it snapped. So I ordered a new one of those.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0439.jpg

I want to do a few harescrambles this year too in the AWRC Series, so I got a Tusk Tether.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0442.jpg

Here it is at that point, I got a moose case saver too because I had $50 free on RMATV

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0460.jpg

[Zakradu398]

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0463.jpg


My motor started leaking oil from the Rocker Arm Shaft washer on the head. So I was about to start tearing it down, but I went to ride one last time and it started blowing smoke pretty bad. I didn;t end up going out that day so I tore it all down.

I sent out my cylinder today to be bored and I ordered a Stage 2 Hot Cam along with a 11:1 Wiseco 86mm piston. ;)

This is my first time tearing down a 4 stroke motor. MY Dad says I'm gonna end up messing something up so I should take it to a shop. I had to tell him I don't believe in that and to sit back and let me prove him wrong.

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0486.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0511.jpg


Notice the blood by the dowl pin, I cut my finger on a piston ring :scary:


http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0493.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0501.jpg

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0500.jpg

My cylinder, cam and piston will be in on Saturday.

[AtvKid4Eva]

Bike looks awesome man! If theres one recommendation i can make thats to send the cylinder to GT Thunder and get the HD head Studs put in for around $100. That way when you reinstall it you dont blow head gaskets from the studs stretching. They dont like to be reused once you take them apart. If you have any other questions PM me and im sure i can help. Ive built many many 400ex motors. You can also text me 216-536-1500.

[Zakradu398]

Thanks for the idea man, I'll take your number down too if I have any questions or things. CJM has taken care of me so far :p

The stud thing though, I planned on doing that over winter because I will probably go up to a 12.5:1 piston on Avgas and get my head ported at the same time.

[AtvKid4Eva]

Sounds good. It just sucks to get the whole motor back together and then have to re tear it down because of the studs. Just text me anytime if you need any info.

[Zakradu398]

I just ordered a few bolts I was missing along with a Tusk Frame skid plate and 5 extra oil filters.

A guy on my local CL has AC blackline nerfs he is selling, it says $120. Is that reasonable or no?

[CJM]

One thing does perplex me: how are they boring your cylinder without the piston?

They need the piston to do it right, cant just tell them its 86mm or whatever and they measure and bore. Things like this need to be exact.

AC nerfs are ok, but they are made cheaply (least the ones Ive come across). For a few bucks more the tusk ones are the way to go imho.

[Zakradu398]

I gave it to my friend who has a Arctic Cat dealship, his names Kerrie. He's a wiseco dealer and gets them in, in 1 day so he ordered the piston and then is sending it.

[CJM]

Ah ok. Just wanted to make sure you werent gonna be SOL.

[HondaRacing83]

Originally posted by Zakradu398
I just ordered a few bolts I was missing along with a Tusk Frame skid plate and 5 extra oil filters.

A guy on my local CL has AC blackline nerfs he is selling, it says $120. Is that reasonable or no? I just seen them, good deal, if you can beat me to them ;)

[Zakradu398]

It's about 20 mins from my house so goodluck :p

[HondaRacing83]

Damn.. Haha i saw them and thought about picking them up but to be completely honest I like running just pegs. I had DG nerfs before and hated them

[CJM]

Originally posted by HondaRacing83
Damn.. Haha i saw them and thought about picking them up but to be completely honest I like running just pegs. I had DG nerfs before and hated them

When you run over your foot/leg you will curse the day you dont have nerfs.

[Zakradu398]

I don't like nerfs either. I mainly want some with heel guards so I feel better when the GF is with me.

[Zakradu398]

I also ordered the Tusk valve spring compressor.

[CJM]

Originally posted by Zakradu398
I also ordered the Tusk valve spring compressor.

Worth the money.

Did my post explain how to compress the valves? The compressor works like a large c-clamp, remove the keepers and bingo the valve springs come out.

[HondaRacing83]

I ride in fox comp 5s or alpinestars vectors so its nbd. Im prob gonna pick up a set of fatpegs and tusk heelguards or ims this winter though

[CJM]

Originally posted by HondaRacing83
I ride in fox comp 5s or alpinestars vectors so its nbd. Im prob gonna pick up a set of fatpegs and tusk heelguards or ims this winter though

Trust me when I say this: boots and heelguards wont stop you from running over yourself. BTDT and trust me it isnt fun. Thats why so many run nerfs.

[2003TrX400eX]

I came off a jump, foot slipped off the peg, and my leg got caught in the wheel and skin was ripped off. Nerfs were ordered the next day.

[Zakradu398]

Ya I think ill be able to figure it out. Thanks man. But the one day a root got caught on my boot and pulled me underneath the back tire. That hurt , I'm pretty sure my sg10s saved my ankle.

[Stickman400]

I was doing a no-handed no-footed can can one day a long time ago and landed from about 20' in the air with my feet about 6" above the peg and when I landed one foot caught the peg and the other didn't and I ended up breaking my leg. I ordered nerfs for it when my leg healed.

[Zakradu398]

Till my cylinder gets back I may be picking up an '05 Banshee on friday :D

[quadmanw]

Zakradu do the tie rods thats came with the GTT arms fit correctly? mine seem to be too long and I can never get the toe adjusted right because i cant get the tie rod to screw into the end anymore lol

[Zakradu398]

Yep, they worked perfect for me.

[Stickman400]

I don't think this will fix your length problem but I do know the tie rod ends are directional. If you put the inside end on the outside it will make it a PITA to adjust. If the flat spot in the rod is toward the inside they are on backwards.

[Zakradu398]

I didn't pay any special attention to my tie rods or ends when I put it together. :confused:

[quadmanw]

Maybe i put em on the wrong way or something lol. The L on the end should stand for lower right?

[Zakradu398]

Got that shee today and should have my cylinder back in 1 week.

http://i148.photobucket.com/albums/s31/zakrad_u/Shee/DSC_0577.jpg
http://i148.photobucket.com/albums/s31/zakrad_u/Shee/DSC_0576.jpg
http://i148.photobucket.com/albums/s31/zakrad_u/Shee/DSC_0575.jpg
http://i148.photobucket.com/albums/s31/zakrad_u/Shee/DSC_0574.jpg

[HondaRacing83]

i love banshees in the worst way. congrats dude sick quad

[Zakradu398]

just got back from a ride on it, pretty damn sick. :devil:

[HondaRacing83]

i wish we lived closer together :(

[Zakradu398]

Were about 2 hours away. I go up my girlfriends camp a good bit in oleopolis, we rode from there last time up to tionesta on my 400. Thats when it started leaking oil..

[HondaRacing83]

a buddy of mine has like 400acre camp in tidioute/tionesta and 99% of the time im out in tionesta ridin everywhere when im with them but for the most part i ride in conneaut lake or saegertown or cooperstown. maybe ill run into you oneday in tionesta

[Zakradu398]

Hell yea, I'll hit you up when I go up again

[HondaRacing83]

sweet **** man that banshees do clean though. if you dont mind me askin how much did you pick it up for?

[Zakradu398]

2700. I figure not too bad since its the only one around here with a title

[HondaRacing83]

thats a pretty good deal in general!

[Zakradu398]

I mean it doesn't add value, but it has decent stuff on it. I'm going to need new pipes when I build a 421 cub but they're good for now

[Zakradu398]

Got my full skid on yesterday. I'll get pics up in a few minutes. :D

[Zakradu398]

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0610.jpg
http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0609.jpg
http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0608.jpg


One of the banshee for good measure :devil:
http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0612.jpg

[Zakradu398]

I'm getting my cylinder piston and cam today. I'll put it back together tomorrow or the next day probably

[Zakradu398]

It's about time to get back on this. Should have it together tomorrow :D

http://i148.photobucket.com/albums/s31/zakrad_u/datFOhundy/DSC_0617.jpg

[Zakradu398]

Also, I know which side the longer stud goes in, but what direction do the threads go, each one has more threads on one side.

[finsteratv]

im lovin the shee!

[Zakradu398]

I got everything together but I have an oil leak. It's either the base gasket or cam chain tensioner gasket. I'm hoping it's the latter...

[AtvKid4Eva]

the cam chain tenioner gasket is probly the culprit. They leak pretty bad and till look like your base gasket is leaking.

[Stickman400]

Yea, I also had a small leak with my tensioner gasket after my rebuild. I just went back and tightened the 2 bolts and made sure the philips screw was snug and it stopped.

[Zakradu398]

I have a small leak now on my valve cover gasket. Its hardly putting out anything but I'm gonna take it off soon and fix that.

Runs really good though. Its starting to get in the 60 deg. range here so I'm going to bump up the main a little.

Also when starting cold now 60-70 deg. outside. I have to use half choke. Do I need a bigger pilot? or adjust the a/f screw?