Finally Made Decision to Mod the 400EX

[Blodg]

I have been back-and-forth many times over the last few months on buying a 450R. Even though I only trail ride now I raced MX for years and have owned several 250R’s and still have my old school 492cc 350X/250R hybrid that makes 45+ HP so the urge to try a modern 4 stroke was strong. But after asking for advice on this forum and doing countless research I decided that a 400EX fits my current needs the best. The 400EX may not be flashy and is slow by comparison in a drag race but they are fun to ride, ultra reliable and in the woods I know I can go just as fast as or faster than I would on a 450R.

After a couple months of looking at 450R’s and deciding against it I had a thought to look for a 400EX that was already modified to save some money and time. My thought was that I would keep my current 400EX near stock and my son could ride that and I would ride the newer modified 400EX when we went on riding trips (and maybe finally sell the old hybrid). I again scoured craigslist, eBay, and the forums for 400EX’s that already had some work done to them. After going to look at a few I then realized many of these were beat pretty good and there were hardly any modified bikes that I was interested in.

Riding season is fast approaching so I changed my plan again and finally made the decision to mod my current 400EX. I also am going to mod my 500RX hybrid from an MX setup to more of a stock motor and trail riding setup so I will have two quads for my son and me to ride. I figured that I might as well take the money I would have spent on buying another quad and spend it on modifying the two sport quads I already have so this thread will really be two builds.

[Blodg]

I want the 400EX similar to a XC racing setup because even though I don’t race that is pretty much the style of riding I do most of the time. My plans as of now:

400EX Motor
- 450R carb (completed this winter)
- 87mm bore with 10.8:1 JE piston for 416cc
- Stage 2 Hotcam
- CRF450R timing chain
- Cometic gasket kit
- Outerwears lid mod
- HD head studs???
400EX Chassis
- GT Thunder dual spring/revalve on 450R front shocks
- GT Thunder XC link for rear suspension
- GT Thunder revalve and spring on stock rear shock to work with XC link
- Lonestar +2 A-arms
- Tusk +2 steel braided front brake lines
- ITP Baja 4 + 1 offset front rims with reinforcing rings to bring width to about 46 1/2� with longer a-arms
- Holeshot XCR 21� front tires
- Holeshot XCR 20� rear tires
- Beadlock 3+5 rear rims, total width measures about 46 1/2� with stock axle
- Pro-Taper SE ATV High handlebars
- ODI Ruffian lock-on grips
- MSR AOF clutch lever & perch
- Precision shock & vibe bar clamps
- Tusk hand guards
- CCP steering stabilizer
- GT swing arm skid plate
- Maybe +1 swing arm?
- Maybe 450R rear brake caliper/rotor/hub?

RX Hybrid Motor
- Remove 492cc motor, repair stripped plug threads, sell on eBay
- Install my spare 355cc motor that already has 10.25:1 piston & midrange cam
- Try with my FCR 39mm carb but it may be too big for the 355cc motor. See how it starts and runs and may install stock 400EX carb if necessary.
RX Hybrid Chassis
- Pro-Taper SE ATV High handlebars (current Renthal bars are very low and not comfortable for trail riding)
- ODI Ruffian lock-on grips
- Replace twist throttle with thumb throttle
- HLS Front shocks setup for XC to replace PEP MX shocks that are too stiff for trail riding
- Replace 19� MX front tires with stock tires & rims from my 400EX (47� wide with Lonestar +2 a-arms already installed)
- Replace 18� MX rear tires with stock tires & rims from my 400EX
- +4 axle is bent and splines loose, replace with stock 400EX axle or with Tusk +2 axle
- Rear hubs to go with above axle
- 37T or 38T rear sprocket if smaller motor will not pull the current 14-35 well?
- Fab fender extensions for “race cut� Maier front fenders to give some splash protection (considered new plastic with full fenders but way too expensive for 250R)
- Install sprocket & rotor guards (current Laeger swing arm does not have any protection for sprocket/rotor and does not have mounts for a swing arm). I do not like any Bling products but may be my only option for the 250R swinger.
- Keep PEP stick style steering stabilizer at least for now

If the 355cc motor is too underpowered to keep up with the 416EX I have extra motor parts that I could buy/install an 89mm bore/piston that would be 423cc and sell 355cc motor? Maybe next year? Also plan to upgrade stock tires with GBC X-Rex tires at a later time.

Most people seem to think that spending a few thousand dollars to mod a 400EX is a waste of money when you can buy an already faster 450R but for me it is the right decision. I am hoping to get the quads ready by May 1st at the latest but I am the head coach of my younger son’s baseball team and practice is starting soon along with my daughters playing softball and my older son playing college rugby it is a challenge to make time. But as I said in other threads this is really the only hobby I still have and look forward to the wrenching and especially some of the riding trips planned with my son for this summer. I will try to get a few pics posted in the next couple days.

[quadmanw]

sounds like an awesome build man! make sure to add a lot of pictures! :devil:

[atvrider13]

Blodg!!!! I want to see this hybrid!! 492 out of a 350x engine?!!! WOW!!:eek2: Can I see some pictures of this beast?

[RNL]

Originally posted by Blodg
I want the 400EX similar to a XC racing setup because even though I don’t race that is pretty much the style of riding I do most of the time. My plans as of now:

400EX Motor
- 450R carb (completed this winter)
- 87mm bore with 10.8:1 JE piston for 416cc
- Stage 2 Hotcam
- CRF450R timing chain
- Cometic gasket kit
- Outerwears lid mod
- HD head studs???
400EX Chassis
- GT Thunder dual spring/revalve on 450R front shocks
- GT Thunder XC link for rear suspension
- GT Thunder revalve and spring on stock rear shock to work with XC link
- Lonestar +2 A-arms
- Tusk +2 steel braided front brake lines
- ITP Baja 4 + 1 offset front rims with reinforcing rings to bring width to about 46 1/2� with longer a-arms
- Holeshot XCR 21� front tires
- Holeshot XCR 20� rear tires
- Beadlock 3+5 rear rims, total width measures about 46 1/2� with stock axle
- Pro-Taper SE ATV High handlebars
- ODI Ruffian lock-on grips
- MSR AOF clutch lever & perch
- Precision shock & vibe bar clamps
- Tusk hand guards
- CCP steering stabilizer
- GT swing arm skid plate
- Maybe +1 swing arm?
- Maybe 450R rear brake caliper/rotor/hub?

RX Hybrid Motor
- Remove 492cc motor, repair stripped plug threads, sell on eBay
- Install my spare 355cc motor that already has 10.25:1 piston & midrange cam
- Try with my FCR 39mm carb but it may be too big for the 355cc motor. See how it starts and runs and may install stock 400EX carb if necessary.
RX Hybrid Chassis
- Pro-Taper SE ATV High handlebars (current Renthal bars are very low and not comfortable for trail riding)
- ODI Ruffian lock-on grips
- Replace twist throttle with thumb throttle
- HLS Front shocks setup for XC to replace PEP MX shocks that are too stiff for trail riding
- Replace 19� MX front tires with stock tires & rims from my 400EX (47� wide with Lonestar +2 a-arms already installed)
- Replace 18� MX rear tires with stock tires & rims from my 400EX
- +4 axle is bent and splines loose, replace with stock 400EX axle or with Tusk +2 axle
- Rear hubs to go with above axle
- 37T or 38T rear sprocket if smaller motor will not pull the current 14-35 well?
- Fab fender extensions for “race cut� Maier front fenders to give some splash protection (considered new plastic with full fenders but way too expensive for 250R)
- Install sprocket & rotor guards (current Laeger swing arm does not have any protection for sprocket/rotor and does not have mounts for a swing arm). I do not like any Bling products but may be my only option for the 250R swinger.
- Keep PEP stick style steering stabilizer at least for now

If the 355cc motor is too underpowered to keep up with the 416EX I have extra motor parts that I could buy/install an 89mm bore/piston that would be 423cc and sell 355cc motor? Maybe next year? Also plan to upgrade stock tires with GBC X-Rex tires at a later time.

Most people seem to think that spending a few thousand dollars to mod a 400EX is a waste of money when you can buy an already faster 450R but for me it is the right decision. I am hoping to get the quads ready by May 1st at the latest but I am the head coach of my younger son’s baseball team and practice is starting soon along with my daughters playing softball and my older son playing college rugby it is a challenge to make time. But as I said in other threads this is really the only hobby I still have and look forward to the wrenching and especially some of the riding trips planned with my son for this summer. I will try to get a few pics posted in the next couple days.

Most people are idiots. Lets face it, more people base their quad buying decision on whats faster in a drag race than the riding application the machine will be used for. IMO, there's nothing wrong with, actually it's a smart idea, to spend the money on a machine like the 400ex if your a woods/trail rider. Set the machine up for your intended use and rip away. Sounds like you have some great plans.

[suspension101]

I would do the HD head studs while you're there for sure. You may have to get a machine show or a really good ATV shop to install them though. You must have them drilled perfectly straight or it's hard to get the head back on. And you must use a special tap to cut the new threads

[Blodg]

Originally posted by atvrider13
Blodg!!!! I want to see this hybrid!! 492 out of a 350x engine?!!! WOW!!:eek2: Can I see some pictures of this beast?
Here ya go, in it's current MX setup:
<a href="http://www.flickr.com/photos/94196939@N02/8598364353/" title="500RX-1 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8090/8598364353_9740469e79_z.jpg" width="604" height="453" alt="500RX-1"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8599475546/" title="500RX-2 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8368/8599475546_71bfde012c_z.jpg" width="604" height="453" alt="500RX-2"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8572818699/" title="race-1 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8108/8572818699_fed9452dd0_z.jpg" width="429" height="604" alt="race-1"></a>

[Blodg]

RX Hybrid with motor pulled a few weeks ago to remove head and repair the spark plug threads:
<a href="http://www.flickr.com/photos/94196939@N02/8598361115/" title="RX hybrid teardown by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8099/8598361115_a28709a2f8_z.jpg" width="640" height="383" alt="RX hybrid teardown"></a>

[atvrider13]

Nice! What kind of bore / stroke makes up that 492? Does someone make a kit for this? And how is the power compared to a highly modified 400ex or 440ex?

[Blodg]

When I had the head off the 492cc 350X motor I took a few pics of the top end to include when I list it for sale.
92mm piston:
<a href="http://www.flickr.com/photos/94196939@N02/8598446307/" title="piston 92mm by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8508/8598446307_4fe4f07a11_z.jpg" width="640" height="480" alt="piston 92mm"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8598447639/" title="cylinder by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8525/8598447639_7bd805fccf_z.jpg" width="640" height="480" alt="cylinder"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8598448617/" title="head porting by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8245/8598448617_2657a45951_c.jpg" width="800" height="600" alt="head porting"></a>

[Blodg]

Originally posted by atvrider13
Nice! What kind of bore / stroke makes up that 492? Does someone make a kit for this? And how is the power compared to a highly modified 400ex or 440ex?
The bore is 92mm (+11mm) and stroke is 74mm (+6mm). Back in the day there were a few companies that offered this as a kit and this motor was done by Powroll. I have another 492cc motor that was built by GT Thunder and I know Fourstroketech built them as well. I am sure someone would still build one if anyone wanted to pay for it but the only kits I see being advertised are bore kits that bring the displacement up to 423cc (89mm) or 452cc (92mm) with the stock bottom end.

The 350X motor is amazing with its ability to be heavily modified and still be reliable. The gears, crank, rod etc... on the 350X are beefier than on the 400EX and these bored and stroked motors will run for years. The biggest issues with these motors is usually threads stripping out and oil leaks which are relatively minor but can still be a pain.

The fully built 492cc motor I have is probably not much faster than a fully built 440EX but it has more low end torque with the large stroke. The 350X motor has more low end torque than a 400EX and the stroked motors are absolute torque monsters but they do not rev as high as a 400EX, most of the power is in the low end and midrange. Once you are moving the motor will literally pull any gear without slipping the clutch but it does not rev out very well. I have not raced a 450 but have read that guys with a similar motor to mine can short shift and walk right past a slightly modded 450.

[Blodg]

Here is my 2006 400EX in the fall before this build. I have owned it since 2008 and it has low hours and is pretty much stock except for an HMF slip-on/Uni filter, AC nerfs & bumper, and 450R front shocks.

<a href="http://www.flickr.com/photos/94196939@N02/8573907820/" title="400EX at Wayne 2012 (Medium) by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8089/8573907820_7698a6cd83_c.jpg" width="800" height="478" alt="400EX at Wayne 2012 (Medium)"></a>

[Blodg]

A pic of my current quads together before the build:

<a href="http://www.flickr.com/photos/94196939@N02/8598369279/" title="stable by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8107/8598369279_c3cacbfcfa_z.jpg" width="604" height="453" alt="stable"></a>

[Blodg]

And the fun begins! Top end off 400EX for bore, piston, & cam. Cylinder is sent out to be bored...

<a href="http://www.flickr.com/photos/94196939@N02/8572826003/" title="IMAG0178 (Medium) by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8085/8572826003_efd73ee3a2_c.jpg" width="800" height="478" alt="IMAG0178 (Medium)"></a>

[Blodg]

I had pulled the 492cc motor and repaired the plug threads. This weekend I installed the motor back into the frame and filmed it starting and running to hopefully help sell it. Yesterday I got the 355cc motor installed in the 250R hybrid chassis. Need to finish the carb and gas tank install and see how if runs after the motor sat for 12 years in a plastic bin. Hope to try and start it tonight.

[Blodg]

A couple pics of the 492cc motor before I pulled it to sell. It started on first kick every time the last 2 days and was pulling real hard but it is not comfortable for trail riding so I want something more tame. Note: I do run an airbox but in the interest of time since I only rode it around the yard a few times I just put a filter on the end of the air boot.

<a href="http://www.flickr.com/photos/94196939@N02/8605957997/" title="492cc 350X (2) by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8116/8605957997_ca665ff509_c.jpg" width="800" height="478" alt="492cc 350X (2)"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8605947933/" title="492cc 350X by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8264/8605947933_c0398e4636_c.jpg" width="800" height="478" alt="492cc 350X"></a>

[Blodg]

I suppose this pic probably doesn't look any different than the previous ones to you guys but yesterday and today I got the 355cc motor installed and running. This motor is bored .5mm with a 10.25:1 piston making it 355cc instead of the stock 350cc. It has a midrange cam, and mild port job.

The FCR39 was jetted spot on for the big 492cc motor so I took some guesses on the jetting and went from 190 on the main to 152, moved the needle down 2 notches and turned the fuel screw from 2 1/2 turns out to 1 1/2 turns out since it has a 50 pilot and I didn't have a smaller one to install. This motor has sat in a plastic bin for 12 years since the last time I ran it and in a few minutes I had it started. The jetting, however, is way off especially in the midrange. It was stumbling right off idle and that was improved when I backed the fuel screw back out to about 2 1/2 turns. The off idle got better but it will just bog in the midrange unless I slowly roll on the throttle. When I did get to full throttle it was not bad but between 1/4 and full throttle it was struggling. I would guess maybe it is rich but don't know if it is lean or rich so tomorrow I am going to move the needle back up 2 notches where it was in the middle notch and see if it gets better or worse.

A FCR39 is too big of a carb for this motor but I am going to see if I can tune it to make due or if I can't get it running right I will stick the stock 400EX carb on which is a common mod for a 350X motor. I will say the motor felt pretty good except for the midrange bog, if I can get it tuned I think it will have similar power to a 400EX with a pipe which is about what I was looking for. It started easier than the fully built 492cc, definitely had less vibration, seemed to run cooler, and even the wife told me it was quiet in comparison when I was doing my jetting runs around the yard. I think I am on the right track with keeping this quad and modding it to trail ride versus buying another 400EX.

<a href="http://www.flickr.com/photos/94196939@N02/8607395545/" title="rps20130331_210552_950 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8106/8607395545_d8939513c1_c.jpg" width="800" height="478" alt="rps20130331_210552_950"></a>

[atvrider13]

I would suggest moving the needle back. Cool build. I wouldve loved to have taken that 492 for a ride before you took it out!

[quadmanw]

Awesome man, sounds like you're making progress

[Blodg]

400EX motor parts, cylinder is sent out to be bored for the 87mm piston and have HD head studs installed.

<a href="http://www.flickr.com/photos/94196939@N02/8572780177/" title="motor parts by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8108/8572780177_1f6ea5c8bc_c.jpg" width="800" height="600" alt="motor parts"></a>

[Blodg]

Front and rear shocks for 400EX sent out to be resprung and revalved. For some reason this one is blurry.

<a href="http://www.flickr.com/photos/94196939@N02/8573872748/" title="shocks ready to send out by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8508/8573872748_a683d92799_c.jpg" width="800" height="600" alt="shocks ready to send out"></a>

[Blodg]

400EX bars & components:

<a href="http://www.flickr.com/photos/94196939@N02/8573873130/" title="bars &amp; components by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8230/8573873130_e93293c06c_c.jpg" width="800" height="600" alt="bars &amp; components"></a>

[Blodg]

400EX Lonestar +2 a-arms. I am also going with 4+1 offset front rims so the overall width gained will only be 2" over my current setup with stock a-arms and 3+2 rims.

<a href="http://www.flickr.com/photos/94196939@N02/8572780449/" title="lonestar +2 a-arms by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8519/8572780449_bf47ac81db_c.jpg" width="800" height="600" alt="lonestar +2 a-arms"></a>

[Blodg]

+2 Steel braided brake lines to go with longer a-arms.

<a href="http://www.flickr.com/photos/94196939@N02/8573873206/" title="+2 braided brake lines by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8526/8573873206_43bac2e276_c.jpg" width="800" height="600" alt="+2 braided brake lines"></a>

[RNL]

Awesome!!!

[Blodg]

I worked on jetting the RX hybrid some more. I had assumed the 355cc motor would require much less fuel than the 492cc motor with big valves. So I had moved the needle down 2 notches and the midrange was poor. I guessed maybe it was still rich so moved the needle down 1 more notch to the leanest setting and it was worse. So I went back to the middle clip position on the needle and it was much better. I went from a 155 to a 165 main and it was better yet but still a bog at 3/4 throttle when transitioning from the needle to the main. My next step will be to move the needle up 1 more notch which would be richer than the 492 used. I have heard that a bigger or more built motor can sometimes require smaller jetting because the increased vacuum can pull more fuel but don't know if I ever believed it until now.

The RX hybrid mx setup used a custom aluminum airbox. There is no option for a lid and I want to be able to run an outerwears lid for trail riding so I am working on modifying a 250R airbox to accept a modified 400EX airboot to the FCR carb. The normal 250R airboot is not even close to working for the 350X motor/carb location.

On the 400EX I completed my own outerwears lid mod and will post pics tonight.

[Blodg]

I wanted to fabricate my own outerwears lid for the 400EX so I priced out some outerwears material for about $20. I also did some searches on the web and found several people were saying they found the exact same material called "black casa sheer" at JoAnn Fabrics. When I told my wife this material might work and be cheaper the next time she went to the store she bought a whole yard of the casa material for like $3. I will say that even though this material is somewhat similiar it is not the same as the outerwears material.

I didn't want to use the casa material so was going to order the outerwears material. When I was in the barn working on the quads I noticed I had an old Coleman tent that I was going to throw away anyways and then I realized this might be perfect! A tent is both waterproof and breathable and after comparing closely if the nylon tent material is not the same thing outerwears uses it is damn close!

So now I had the fabric for no cost so so I bought an aluminum plate to use for the frame.
<a href="http://www.flickr.com/photos/94196939@N02/8572779909/" title="lid mod by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8383/8572779909_a57a3040eb_c.jpg" width="800" height="600" alt="lid mod"></a>

I traced the shape I wanted for the frame on a thin piece of cardboard and cut it out to use as a template on the aluminum plate.
<a href="http://www.flickr.com/photos/94196939@N02/8599489592/" title="lid mod2 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8090/8599489592_ac54c1e24c_c.jpg" width="800" height="600" alt="lid mod2"></a>

I cut the plate with a jigsaw which took longer than I expected as the teeth on the blade kept clogging up with aluminum. I then used the actual aluminum frame to trace shape onto the tent fabric.
<a href="http://www.flickr.com/photos/94196939@N02/8607417657/" title="lid mod3 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8111/8607417657_353f564dfa_c.jpg" width="800" height="478" alt="lid mod3"></a>

I cut a trial sample out of the tent material and experimented with using a flame to burn the edges to keep the nylon threads from unravelling. The problem was that that the heat caused the material to deform and curl up a little so I decided not to do it. After cutting out the final material I marked the holes and poked them with a knife. It may not have been necessary but I applied some RTV silicone sealant between the frame and the material and bolted it down with stainless fasteners.
The final product:
<a href="http://www.flickr.com/photos/94196939@N02/8611241845/" title="lid mod4 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8118/8611241845_8547f3df57_c.jpg" width="800" height="478" alt="lid mod4"></a>

For this one lid I didn't save a ton of money as I have about $30 in the aluminum plate and about $10 in fasteners so I spent about $40 and could have bought an EHS outerwears lid mod for $55 and saved a couple hours of work. But now that I have the plate and material I can do the 250R lid for my hybrid also.

[atvrider13]

Sweet!!!!!

[quadmanw]

That lid is awesome. Looks better than the EHS lid too. I like the diamond plate

[Blodg]

The diamond plate looks cool but honestly I was looking for a smooth plate. The only aluminum I could find at the local hardware stores, however, was the diamond plate. Some of my fasteners needed to go right where the diamond tread was so I ground the tread off in those locations so the bolt heads would sit flush.

I am going to use this diamond plate when I cut out the front of the 250R airbox for my hybrid and mount the plate to the front and cut my own hole for the airboot. And as mentioned I will make another "outerwears" lid for the 250R hybrid but need to buy a lid off eBay. You can buy a brand new 400EX airbox lid from one of the OEM website's for $10 but a 250R lid goes for $50 to $65 on eBay. But that's the norm for parts they don't make anymore for a 25 yr-old classic quad like the 250R.

[Blodg]

Removed the valves on the 400EX head to clean the carbon from he valves and head and to install new valve stem seals.. Trying to decide if I should lap the valves or not. I have read that it is not recommended to lap the stock valves since they are coated and it will remove the coating. But have also read that a bunch of people have done it with no problems. After having the valves out I am worried they would not seal well if I didn't lap them.

<a href="http://www.flickr.com/photos/94196939@N02/8625688185/" title="rps20130406_230636 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8120/8625688185_5e5b467bfc_c.jpg" width="800" height="478" alt="rps20130406_230636"></a>

[Blodg]

Another thing I am thinking about - There is a distinct casting line running along the sides of both the intake and exhaust ports. For those of you who have had your head off, did you see this? I assume this common and am thinking of going in and filing or sanding to removing the casting flaw. But then again it is just a line running along the port so maybe it wouldn't have any benefit to removing it? Any thoughts?

[atvrider13]

I just looked at a stock head and yes there are the casting lines in it also. I believe my head that I had ported the lines were removed. Hope this helps!!

[Blodg]

I have been working on the RX hybrid trying to get it ready to ride this weekend. The 400EX is in waiting until the shocks and cylinder get back.

Believe it or not when I bought the 500RX hybrid the 492cc GT Thunder motor it had used dual carbs. Yes a single cylinder motor with two carbs which some bikes like the XL500 came with back in the day. I damaged the case and didn't run the GT motor very long so when I went to a normal 350X motor I just ran a hose to one of the filter intakes on the custom aluminum air box. I ran it like this for several years when racing MX.
<a href="http://www.flickr.com/photos/94196939@N02/8639308388/" title="rps20130410_210044_433 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8544/8639308388_e39fe5f1dd_c.jpg" width="800" height="478" alt="rps20130410_210044_433"></a>

Now that I am converting the quad to more of a XC/ trail riding setup I want to run a stock air box so I can run an outerwears lid. I had bought a 250R air box off ebay over 10 years ago back when I was still racing but never got around to rigging it up to work. Here is what a stock air box looks like with the airboot for the 250R.
<a href="http://www.flickr.com/photos/94196939@N02/8638218747/" title="250r airbox front (Medium) by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8099/8638218747_0b91623aeb_c.jpg" width="800" height="600" alt="250r airbox front (Medium)"></a>

The airboot is not even close to being in the proper location for the 4-stroke motor in my hybrid so I came up with a way to modify it. First I removed the small snorkel intake tube and ripped out the structure that holds the air boot. The air boot side still had a ridge molded around the lip of the hole.
<a href="http://www.flickr.com/photos/94196939@N02/8639310342/" title="rps20130410_210149 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8386/8639310342_2b030db971_c.jpg" width="800" height="478" alt="rps20130410_210149"></a>

I cut the lip off with a hack saw so the front of the airbox had a flush surface. I made a template and cut a piece from the diamond plate aluminum I had used for the outerwears lid mod I showed previously. I cut a smaller hole to fit a 400EX air boot that is more centered than the normal 250R boot location. I mounted the aluminum plate to the front of the airbox with RTV sealant and SS bolts. Getting the hole right to fit the air boot was a little tricky and I actually had to cut two plates until I got it right. The finished product other than a short hose from the end of the boot to the carb:
<a href="http://www.flickr.com/photos/94196939@N02/8639306866/" title="rps20130410_210001_796 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8520/8639306866_f26a819ca1_c.jpg" width="800" height="478" alt="rps20130410_210001_796"></a>

[Blodg]

I lose the "trick" feature of having a custom aluminum air box but the modified stock air box not only will allow me to run an outwears lid but using the 400EX air boot should provide better air flow as well. The boot is more straight than my old setup and having a larger diameter taper into a smaller diameter will flow a higher volume of air with maybe more velocity. Using only one side of the old dual air filter air box like I was doing was limiting the volume of air with the skinny 2 1/4" hose running all the way to the air box. The built 492cc Powroll motor still had monster power so I never worried about it but this should be a better setup.

The two air boxes together to show the difference:
<a href="http://www.flickr.com/photos/94196939@N02/8638202827/" title="rps20130410_205827 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8404/8638202827_e10c7a0f30_c.jpg" width="800" height="478" alt="rps20130410_205827"></a>

Now I am working on making my own "outerwears" lid using the tent fabric like I did for the 400EX lid.

[jos_19]

where the 92mm piston come out??
what is the sleeve you run??

[Blodg]

Originally posted by jos_19
where the 92mm piston come out??
what is the sleeve you run??
The 92mm 350X piston I showed a picture of earlier in this thread is still in the Powroll motor which I am planning to sell as a 492cc running engine.

I have another 492cc motor built by GT Thunder that is apart so I do have a 92mm piston from that engine.

I think both Powroll and GT Thunder used an 89mm XL 500R sleeve to install in the 350X cylinder and bore to 92mm. The bottom end cases must be machined for this sleeve and bore.

[Blodg]

I was working on trying to get the 355RX ready to ride this weekend but there was a ton of rain in Ohio this week and I am not into the mud thing. And then I got a box of parts from UPS yesterday so I switched gears and started working on the 400EX now that I have the stuff back.

<a href="http://www.flickr.com/photos/94196939@N02/8646077421/" title="rps20130413_200856_969 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8112/8646077421_b68e53ea44_c.jpg" width="478" height="800" alt="rps20130413_200856_969"></a>

Taking a break right now to eat and then heading back out to the barn.

[beastlywarrior]

Where are you in Ohio login the 350x

[Blodg]

I am about 40 min south of Sandusky, 15 min east of Tiffin.

[Blodg]

I bought a bottle jack mainly so I could spread the subframe to give clearance for the extra travel of the rear link and shock. I was surprised when I moved the swingarm through its travel the left side of the subframe doesn't hit anything. I still have the airbox off and the swingarm bottoms out when it hits the rear brake caliper. The sprocket bolts miss the subframe by maybe 1/8", I wonder should I bend the subframe a little anyways? Or just let it go?

[CJM]

I bent it a good 1/4" away from everything.

Did you space out the exhaust for the caliper?

[Stickman400]

I thought I was gunna get lucky and not have to do anything other than space the exhaust and raise the airbox, but after I got everything bolted on it hit bad, so I had to bend it out a good 1/4". Also you only need to get a certain amount of clearance so that the shock will work through it's full stroke. I can't remember what the number is but your shock builder can tell you, it's just the fully compressed length of the shock.

[Blodg]

Originally posted by Stickman400
I thought I was gunna get lucky and not have to do anything other than space the exhaust and raise the airbox, but after I got everything bolted on it hit bad, so I had to bend it out a good 1/4". Also you only need to get a certain amount of clearance so that the shock will work through it's full stroke. I can't remember what the number is but your shock builder can tell you, it's just the fully compressed length of the shock.
Yea I remember reading your thread and the issues you had with clearance and the carrier rotation position. I was impressed you did so much work and measuring, most people would have said the hell with it and just rode it.

[Blodg]

Well I did decide to clean up the ports a little. I would not recommend anyone do their own port job and I was careful to not enlarge or change the shape of any of the ports. What I did do was file the casting parting lines and flaws and I also gave the intake divider a sharp edge. I know none of this is going to add much power but it can only help the flow.

My intake ports before:
<a href="http://www.flickr.com/photos/94196939@N02/8653168448/" title="400ex intake port by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8401/8653168448_8aac74f0a9_c.jpg" width="478" height="800" alt="400ex intake port"></a>

My intake ports after my own clean-up job:
<a href="http://www.flickr.com/photos/94196939@N02/8652065341/" title="rps20130415_144128_806 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8389/8652065341_f881f20637_c.jpg" width="800" height="478" alt="rps20130415_144128_806"></a>

[Blodg]

I also did decide to lap the valves and they turned out good with a nice even seating surface. Of course I cleaned up the head before assembly.

My head before cleaning and valve grinding:
<a href="http://www.flickr.com/photos/94196939@N02/8625688185/" title="rps20130406_230636 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8120/8625688185_5e5b467bfc_c.jpg" width="800" height="478" alt="rps20130406_230636"></a>

My head ready to install:
<a href="http://www.flickr.com/photos/94196939@N02/8653160244/" title="rps20130415_143951 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8261/8653160244_5e78db25e2_c.jpg" width="800" height="478" alt="rps20130415_143951"></a>

[Blodg]

Working on two quads at once has been fun but it seems like it is taking forever. It brings me back 20 years to when I was racing because you are always wrenching and I enjoy it but now that the weather is getting warmer I am ready to ride. Wrenching to me is fun but after a while I get tired of it and just want to get it done.

I took a vacation day today to try and get the 400EX mostly ready to ride. After sitting on my wooden stand for a month I now have a roller. Camber and toe still need adjusted and I have ordered 4+1 wheels but they have not arrived yet. I did receive new HLS shocks for the RX but have not put them on yet.

I will have the HD cam chain installed today and hope to have the cylinder on and ready for the head before I have to leave to go run my little league team's baseball practice this afternoon.

<a href="http://www.flickr.com/photos/94196939@N02/8652062633/" title="rps20130415_144048 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8380/8652062633_a6578d48b2_c.jpg" width="800" height="478" alt="rps20130415_144048"></a>

[JOHNDOE83]

Oh man this is getting good!!!!!


I like the motor work it came out nice and clean and will deffinetly be noticeable when you ride it the first time!

[Stickman400]

Originally posted by Blodg
Yea I remember reading your thread and the issues you had with clearance and the carrier rotation position. I was impressed you did so much work and measuring, most people would have said the hell with it and just rode it. Yea, it was a gigantic PITA but I like to know everything is going to work the way it was intended and that I wouldn't have to buy more parts or re-buy the same parts because I installed it wrong and broke it because of that. Plus I didn't feel like tearing it all the way apart again to mess with it anymore during the summer. I had plenty of time to do it while it was cold and miserable out so why rush through it?

Anyway your build is coming along nicely, I'm liking the 400. Stance looks badass.

[Blodg]

My new HD cam chain for a CRF 450 next to the stock 400EX one I took out.

<a href="http://www.flickr.com/photos/94196939@N02/8658512969/" title="rps20130417_202219_542 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8110/8658512969_33467923e7_c.jpg" width="478" height="800" alt="rps20130417_202219_542"></a>

And the HD cam chain installed:
<a href="http://www.flickr.com/photos/94196939@N02/8659620980/" title="rps20130417_202428_644 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8104/8659620980_cd3dde2b39_c.jpg" width="800" height="478" alt="rps20130417_202428_644"></a>

That damn gasket on the case is a nightmare to scrape off. It is taking more time scraping on the gasket as it took to pull the whole clutch, oil pump, and drive gears out to get to the cam chain. Sometimes I have had gaskets that come off in large pieces and aren't too bad and this one is not coming off hardly at all. It is basically like sanding it off in layers with the gasket scraper. It looked good too, now I almost wish I would have just stuck the clutch cover back on and reused the gasket.

[Blodg]

The whole time I was working on pulling the clutch to get to the cam chain I was thinking maybe I should be replacing the clutch plates while I am in there. I was about to go in the house and order a clutch but didn't want to wait for it to be shipped. The stock friction plates didn't look very worn so I measured them and they are still in spec for a brand new plate and well above the service limit. So I decided to leave the clutch go for now. I will scuff the steel plates before re-installing but I probably have a frickin hour of scraping the gasket before I can put it back together...

Let me know if anyone has any tricks for getting the old gasket off. I have plastic scrapers made for removing gaskets and tried spraying brake cleaner but that didn't help at all.

[Blodg]

Ok I got the gasket off after an hour or so when I switched to a razor blade from a utility knife. If I would have stuck with the plastic gasket scraper it would have literally taken days.

[Stickman400]

I always have the same issue when I took off that clutch cover. I always think it's gunna stay in one piece and I won't have to mess with it and then a tiny piece rips off and I die a little inside. I've tried brake cleaner, carb. cleaner and gasket remover and it all works a little, but it's not worth the time really. I always end up spending about 2 hours with a gasket scrapper that uses a razor blade. Just gotta be careful not to gouge the gasket surface rushing through it.

[Blodg]

Getting ready to install the cylinder bored to 416cc with HD head studs installed by GT Thunder:

<a href="http://www.flickr.com/photos/94196939@N02/8661210506/" title="rps20130418_124549_994 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8124/8661210506_069c5e60ab_c.jpg" width="800" height="478" alt="rps20130418_124549_994"></a>

[Blodg]

Out with the old and in with the new:
<a href="http://www.flickr.com/photos/94196939@N02/8661971844/" title="rps20130418_184716 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8249/8661971844_4d3916bb7e_c.jpg" width="800" height="478" alt="rps20130418_184716"></a>

I find it easier to install the piston in the base of the cylinder first and then slide the piston pin through the rod while holding the cylinder and piston together. Most instructions tell you to install the piston to the rod and then slide the cylinder over the piston but doing it my way makes it easier to compress the rings with the cylinder sitting on the bench. I did not replace the o-ring around the bottom of the sleeve as the shop manual recommends. Hopefully it wasn't needed.
<a href="http://www.flickr.com/photos/94196939@N02/8661973008/" title="rps20130418_184757_705 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8256/8661973008_a96d7de2d8_c.jpg" width="800" height="478" alt="rps20130418_184757_705"></a>

And with new piston/cylinder installed onto bottom end:
<a href="http://www.flickr.com/photos/94196939@N02/8660873207/" title="rps20130418_184834_796 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8262/8660873207_57c849fa36_c.jpg" width="800" height="478" alt="rps20130418_184834_796"></a>

[Blodg]

I have only had a chance to work on the quad for a few hours over the last week so I still have not started it yet. But today is the day after I post a couple updates and set the camber and toe.

After getting the airbox on I removed the rear shock to check for how much clearance was needed for the increased travel of the XC link and reworked shock. What I came up with is I needed to spread the lower sub frame rail out 1/4", space the exhaust out 5/8" and raise the airbox up 5/8". I am a little concerned I still may have a clearance issue because with everything moved the amount described above it clears except the brake caliper hits the subframe very close to the full travel. Since there is no practical way to add clearance for the brake caliper I just hope it is OK because it looks like it could hit at full travel but then again full travel assumes the rubber shock bumper is fully compressed which really isn't possible.

Exhaust spaced out:
<a href="http://www.flickr.com/photos/94196939@N02/8680833026/" title="rps20130425_075007_905 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8399/8680833026_0cf15c806d_c.jpg" width="478" height="800" alt="rps20130425_075007_905"></a>

When I raised the airbox up with a spacer I couldn't latch the seat anymore. I knew I could buy another type of seat latch but didn't want to wait. I removed the bolt from the seat latch that was hitting the airbox bolt and kept grinding my spacer down until I could latch the seat. I ended up with just under 1/2":
<a href="http://www.flickr.com/photos/94196939@N02/8679725319/" title="rps20130425_075157_516 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8114/8679725319_3d3fd8f6e5_c.jpg" width="800" height="478" alt="rps20130425_075157_516"></a>

[Blodg]

I had read on this forum that a common mod was to grind the weld on the stock header pipes. I had pictured in my mind a common weld bead and figured it probably helped but not much. When I removed my header pipe I couldn't believe how large the actual weld was and realized why so many people are doing this. From my measurements I increased the inside diameter of each head pipe by 3.5mm which calculates to a 30% increase in area for both headers!

I could have probably went another mm or more but the diameter of each head pipe is now 2mm larger than each exhaust port (started 1mm smaller) so I didn't go any further.
<a href="http://www.flickr.com/photos/94196939@N02/8680833904/" title="rps20130425_075050_175 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8122/8680833904_d012116998_z.jpg" width="640" height="383" alt="rps20130425_075050_175"></a>

[Blodg]

One last pic is how my 450R carb setup looks. I cut some of the plastic heat shield away for clearance. Yes I kept the hot start cable intact, I know I won't need it on the 400EX but if I ever decided to swap this carb with the 39FCR on my 350X the hot start may come in handy as the 350X motor can be a bear to kick start when hot. For now I am just running the cable under the front hood and have it zip-tied.

Yes I also kept the snorkel. I know most people remove it when they remove the airbox lid or go to an outerwears lid. My thoughts are that if I keep it I can always re jet and use a solid lid if I ever felt the need in super muddy or wet conditions. And also the outerwears lid obviously increases flow over a stock lid but it is not the same as running no lid at all. I saw a pic someone had where they raised the airbox up for the shock link and had it almost touching the bottom of their seat pan. They had removed their snorkel because they had an outerwears lid but the clearance between the lid and seat was probably not flowing anymore air than the snorkel did. Anyways, by keeping the snorkel it can bring in air through the lid mesh and through the snorkel both.
<a href="http://www.flickr.com/photos/94196939@N02/8680834636/" title="rps20130425_075125_897 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8260/8680834636_b6d72a57fc_z.jpg" width="640" height="383" alt="rps20130425_075125_897"></a>

[Blodg]

These arrived yesterday, there was nothing wrong with my current front rims but they are 3+2 and I wanted 4+1 to bring my width back in with the +2 a-arms.
<a href="http://www.flickr.com/photos/94196939@N02/8686374764/" title="rps20130427_104607_378 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8397/8686374764_b27458c72a_z.jpg" width="640" height="383" alt="rps20130427_104607_378"></a>

I also received my CCP steering stabilizer the day before the rims but already took it down to the barn.

[Blodg]

I forgot to mention a couple problems I ran into.

When I was installing the clutch cover after swapping in the HD cam chain the Cometic clutch cover gasket had the upper right dowel hole sized wrong! The hole was on the gasket but it was sized the same as the bolt holes so it would not fit over the dowel. I used the dowel to trace on the gasket and very carefully cut a larger hole using a utility knife. I made it work but it was something else to dick with and could have been bad if a slip of the knife causing an oil leak or having to buy another gasket. I guess I should email them to let Cometic know but haven't done it yet.

Also when I stayed up to 1:30A one day this week trying to get this thing done I had removed the levers, bars, and clamps. I had to wrestle to remove the cross-bar on my new SE bars and when I slid them through the Precision shock-and-vibe clamps I realized the clamps were sized for 1 1/8" bars! I looked at the box and sure enough it said for 7/8" bars but that is not what was in there. The next day I called RMATV and they sent another clamp out right away and are paying for the shipping to send the other back. I thought about asking the lady on the phone to check the box before they sent but I didn't. The next day I get a voice mail saying they went through their inventory and all the boxes were labeled wrong so the new one they just sent is probably wrong too! I have not received it yet but sounds like I will be waiting a while to install my new bars and clamps.
<a href="http://www.flickr.com/photos/94196939@N02/8685255655/" title="IMAG0298 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8406/8685255655_401452cd41_z.jpg" width="640" height="383" alt="IMAG0298"></a>

[Blodg]

After setting the camber and toe I was finally ready to start this thing after working on it off and on for over a month. I used a wrench on the crankshaft and turned it over through a good 8 or 9 strokes. This was the same as you would do with a kick start bike where you slowly kick it over 4 or 5 times before starting to get everything moving and hopefully coated with oil. I gave the throttle 4 or 5 stabs and it started instantly when I hit the starter button! It didn't crank over for more than a split second so that was a good feeling after having everything apart.

I held the throttle at a very high idle for 4 or 5 minutes and then rode around the yard at medium throttle for 5 minutes or so and then I let her rip. It ran great and the jetting seems spot on. It pulled hard on bottom, mid, and full throttle with no hiccups or flat spots anywhere. It felt a lot faster than before but of course it should be going from just a pipe and uni filter to a 416cc 11:1, stage 2 HC, 450R carb, outerwears lid, and cleanup port job as well as lapping the valves.

I rode it hard for 30 min. and honestly I can't imagine anyone short of a pro level rider wanting any more power for riding in the woods. I never ride on the road and never ride in the dunes or in open fields so I wanted something more than a stock 400EX but didn't need the top end power of a 450 and this feels right in between which is perfect.

I stopped to check everything over and play with the kids and am getting ready to go romp on it for another half an hour and then change the oil and check the valves before putting the front fenders back on. I had guessed at a 185 main and almost want to leave the jetting alone as good as it felt but I should go up to a 195 or higher until it stutters at full throttle.

Another good thing is the Precision bar clamps arrived today and they were the right size so I spoke too soon when I thought they would be wrong again.

[Stickman400]

Sounds like you had the exact same problems that I had when I installed my XC link. I spaced everything out and then the caliper hit the sub-frame assuming the rear shock completely bottomed out. I ended up flipping the carrier and running it 180° from stock location. Then I ended up using really big zip ties looped underneath the airbox to hold it up and chopped off all the stock mounts.

That was probably me that you are talking about that had my airbox right against my seat pan with the EHS lid on. When I first did it I had it way to close and didn't need it. I've got about 4 or 5" between them now. And I also put a 230 main in the 450 carb. on mine and it runs like an animal. I don't know how it isn't cutting out on top end from being too rich but it runs perfect, it pulls so hard for a 400 it's ridiculous. And it's just a 407 with 11:1 compression, stage 2 cam, full HMF exhaust, UNI filter, EHS lid and the 450 carb.

And I also had similar problems with my cometic clutch cover gasket I put on mine awhile back. The dowel pin holes were too small and a couple of the oiling holes weren't even in the right spots. I had to cut new ones and enlarge the others. It was a joke.

[Blodg]

Thanks for the info. on the airbox and spacing stickman. I just left my brake caliper where it is at so hopefully I don't regret it. Wow, a 230 main, I rode mine again and left the 185 in but tomorrow I will go up to a 195 and see how it compares. But man it pulls nice and honestly I don't think I would want it any faster for my type of riding. I have a XC type course laid out on my property and I was ripping on some of the trails and it almost felt like a different course with the extra power. Some of the turns, hills, jumps felt different because I was going faster.

I said earlier that I never ride on the road because I have probably only done it a half dozen times in the last 25 years. Well this afternoon I ran about a half mile down the road and back to see if it was sputtering at all at full throttle and I turned my phone GPS speedometer on.

I honestly have no idea if this is fast or not because like I said I never top my quads out because I have mostly ridden on tracks or trails. But it was faster than I expected and it wasn't even fully topped out. I fully revved it out in 4th but only hit 5th for a couple seconds and this is what my GPS said:
<a href="http://www.flickr.com/photos/94196939@N02/8686806413/" title="2013-04-27_21-41-05 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8397/8686806413_e75e981b33_z.jpg" width="384" height="640" alt="2013-04-27_21-41-05"></a>

[Blodg]

One other thing, I don't know how people get away with running anything higher than an 11:1 compression piston because when I shut mine off for just a minute like when I got stuck on a log and then start it right back up it barely turns it over. Actually sometimes it doesn't turn it over. Sometimes it cranks for a split second until it comes up on the compression stroke and stops. I let off the starter button and hit it again and once it gets past the compression stroke it cranks faster and starts up but I hope this doesn't become an issue. I think I read somewhere about people buying a different battery that has more cranking amps, maybe for a Z400?

[Stickman400]

I actually just bumped a thread about different batteries if you wanna check it out. I always had a Hayabusa battery in mine since I put the 11:1 in it so I never noticed a difference at first. But after I drained it this last winter it does that constantly. I'll hit the starter and it cranks for just a second and then the motor locks up and you can hear it getting hung up and can't turn it over. I'd deff. say it's your battery getting weak or it doesn't have enough oomf (CCA) to turn it over. And I wouldn't doubt that speedo is too far off. My 400 has 15/36 gearing and 20s (and has the slightly different internal gearing the '05+s have) and I hit 65 topped out on flat pavement with no wind. I gurantee you could hit 75 with a set of 22s on the back, as long as your motor can pull them once it gets that high in the rpm.

[Blodg]

Stick, I will check out that battery thread, I have not read it yet.

That 70mph was with stock '05+ 14-38 gearing and 20" tires. And I wasn't holding it wide open for miles down the road, I was in 5th for maybe 5 or 6 seconds after fully winding out 4th. You can see the whole run down and back was only .7 miles. It was plenty fast for me and I will likely never have it going that fast again. Actually that may have been the fastest I have ever ridden a quad as I never took any of my 250R's or my 500RX on the road, only rode them on the track. When I showed my wife my phone she was not real happy lol.

[atvrider13]

I had this same problem when I went from stock to high compression. I got a new stock battery and worked great for years. I recently was in need of a new one and did some researching on a higher cranking amp one. I found that a battery for a GSXR1000 is the same size and has more cranking power. It is part# YTX 12BS. I got one of those orange gel ones on ebay and it works great.

[Blodg]

Originally posted by Blodg

That 70mph was with stock '05+ 14-38 gearing and 20" tires. And I wasn't holding it wide open for miles down the road, I was in 5th for maybe 5 or 6 seconds after fully winding out 4th. You can see the whole run down and back was only .7 miles.

I wanted to mention the GPS run above was slightly downhill. I had 67 MPH on the way out and 70 MPH on the way back.

I changed the oil and got the new clamps, bars, and grips installed. Still have to mount the steering stabilizer, GTT skid plate, touch up some rust spots on the frame, and mount the front plastic back on after I try a 195 main and finish the jetting adjustments. After all that I will finish the 350RX and I need to spend some time working on my trails clearing all the branches and trees that fell over the winter.

I am debating what to do with the fenders. With all the components I bought I have enough stickers to cover about every square inch of the plastic. I kind of like the plain look with no stickers but then again a bunch of stickers reminds me of my race days and kind of protects the plastic from scratches. What looks better to you guys? If I had new plastic I would probably put a graphics kit on to protect the plastic but I already have scratches and also I exhausted my budget for this year.

[Honda.rider5871]

Originally posted by Blodg
I wanted to mention the GPS run above was slightly downhill. I had 67 MPH on the way out and 70 MPH on the way back.

I changed the oil and got the new clamps, bars, and grips installed. Still have to mount the steering stabilizer, GTT skid plate, touch up some rust spots on the frame, and mount the front plastic back on after I try a 195 main and finish the jetting adjustments. After all that I will finish the 350RX and I need to spend some time working on my trails clearing all the branches and trees that fell over the winter.

I am debating what to do with the fenders. With all the components I bought I have enough stickers to cover about every square inch of the plastic. I kind of like the plain look with no stickers but then again a bunch of stickers reminds me of my race days and kind of protects the plastic from scratches. What looks better to you guys? If I had new plastic I would probably put a graphics kit on to protect the plastic but I already have scratches and also I exhausted my budget for this year. Sounds like a nice build, lets see some pics of it done. If your not going to get graphics I would leave it wthout stickers, a couple here and there are fine but when you cover everything it looks tacky IMO

[Blodg]

Early in this thread I showed how I made my own "outerwears" lid using material from an old tent. Here is a pic of it installed:
<a href="http://www.flickr.com/photos/94196939@N02/8704991977/" title="rps20130503_182412_435 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8259/8704991977_9b4ec9ecbd_z.jpg" width="640" height="383" alt="rps20130503_182412_435"></a>

[Blodg]

I am still evaluating the jetting, I started with a 185 main in the 450R carb and it ran absolutely great but I want to bump it up until I get a sputter so I installed a 190 and only rode around the yard for a few minutes but it almost seemed like it was not pulling quite as hard. I am going for my first trip to ride tomorrow morning so I will get a full 4 hours or so to evaluate the jetting. Most everything is done except I still need to install the GTT skid plate and swap the tires onto the 4+1 rims. Here is a pic of the quad from today about 95% done. I will get a few more when it is completely done and a before and after together.
<a href="http://www.flickr.com/photos/94196939@N02/8706118954/" title="rps20130503_182653_681 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8536/8706118954_55dd445e4f_c.jpg" width="800" height="478" alt="rps20130503_182653_681"></a>

[Blodg]

Went on the first real trail ride over the weekend with a buddy from work on a Z400. Everything felt great and the lower ride height with the suspension really make it ride nice. We climbed a couple fairly tough hills alongside a trestle on some abandon tracks and was happy with how it handles everything.

When we swapped quads the Z400 with a pipe and filter had much less power on the bottom end but pulled almost as hard as the 416 in the upper rpm's. The handling, brakes, and suspension, however, were not even close to mine which is no surprise since his chassis is all stock. Jumping on his after riding mine hard for a while I also felt a lot more vibration through the handlebars on the Z. He liked the handling of my XC setup and commented that on my 416EX he felt like he was riding "in" it and on his Z it feels more like you are riding "on" it.
<a href="http://www.flickr.com/photos/94196939@N02/8717531701/" title="rps20130507_152810 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7285/8717531701_0f0e16a1fc_c.jpg" width="800" height="478" alt="rps20130507_152810"></a>

Baseball/softball season is fully underway and my kids have games or practices 6 days a week and the one off day is usually spent mowing so I need to try and finish the 350RX in between some riding on the 416EX.

[Blodg]

Saturday I got the GTT swingarm skid plate installed and the tires swapped onto the new 4+1 Baja rims. If not for my chain slider I would not have had to use spacers on the skid plate like I have several others had to do. I did add 3 washers to the front chain side bolt to give more room for my TM chain slider which was putting quite a bit of upward pressure on the chain. It will wear in some.

Other than maybe a new battery I have completed everything I wanted to do to the 400EX this year. About the only other things that I may want to do next winter is maybe a +1 swing arm or a 450R swing arm conversion and maybe a Houser steering stem. I did buy this swing arm this winter:
<a href="http://www.flickr.com/photos/94196939@N02/8599459364/" title="houser swingarm by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8241/8599459364_8584cd892f_z.jpg" width="640" height="383" alt="houser swingarm"></a>
But after I received it I measured and realized it was stock length and not +1 1/4 as advertised so I sent it back and the seller was good about it. I will get some more pics of the finished 400EX this weekend.

On the 350RX hybrid I got the new 400EX air boot and 250R air box installed on Sat. I had to cut the filter end of the air boot and make an adapter for the filter to clamp to and it turned out great. On the hybrid I still need to install the sprocket and rotor guards and new front shocks and new bars/grips.

[Blodg]

Today my son and I went on our first trail ride using both the 400EX and the RX hybrid after all the mods that were completed this winter/spring and covered in this thread. Some pics of the quads below but here is a reminder of everything that was done:

2006 400EX
- Cylinder bored to 416cc (87mm) & JE 10.8:1 piston
- Stage 2 Hotcam
- HD head studs
- Cometic Gasket kit
- Lap valves & new valve stem seals
- My own “clean up” port job to remove casting flaws & add knife edge to intake port divider
- CRF450R HD timing chain
- 450R carb (190 main/48 pilot/2.5 turns)
- Fabricated my own custom “Outerwears” lid
- Grind header welds on pipe
- Lonestar +2 a-arms
- Tusk steel braided +2 front brake lines
- Front 450R shocks revalved & dual springs by GT Thunder
- Rear shock revalved & spring by GT Thunder
- GT XC rear shock link
- Pro Taper SE ATV Hi bars
- ODI Ruffian lock-on grips
- Precision shock & vibe bar clamps
- CCP Steering stabilizer
- MSR AOF Clutch perch/lever
- Tusk hand guards
- remove & grease swingarm pivot bolt
- Baja 4 + 1 front rims
- Beadlock 3 + 5 rear rims
- Holeshot XCR front & rear tires
- GT Thunder swing arm skid plate
- TM chain slider on skid plate

RX Hybrid conversion from MX to XC setup
- Remove 492cc motor & install 355cc motor with 10.25:1 piston & midrange cam that is more trail friendly
- Weld broken motor mounts on frame
- Fabricate my own custom intake using 400EX airboot on 250R air box
- Keep 39FCR carb (165 main/50 pilot/2.5 turns)
- Fabricated my own custom “Outerwears” lid
- Pro-Taper SE ATV High handlebars
- ODI Ruffian lock-on grips
- Replaced twist throttle with 450R thumb throttle
- HLS Front shocks setup for XC to replace PEP MX shocks that are too stiff for trail riding
- Install stock tires & rims from my 400EX to replace MX tires
- Moved extended axle to most narrow position & made shims using aluminum can to tighten hub splines
- 36T rear sprocket to replace 35T
- Texierra rear sprocket guard
- New brake pins front & rear

This was a ton of work on two quads while still spending time with my wife and kids. It took a few months to get it done but both quads ran great today. Our group had to stop a couple times to work on a bike and again to work on a quad so I was pleased that my 25 yr-old quad ran flawless.

The only thing I still have on my list to complete is to fab some front fender extensions to give the RX some splash protection with the Maier race cut plastic.

Here are the two quads after riding (yes my son snagged the left hand guard on the RX on a tree so it is missing):
<a href="http://www.flickr.com/photos/94196939@N02/8860003468/" title="rps20130527_181242 by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8279/8860003468_a072a64dcf_c.jpg" width="800" height="478" alt="rps20130527_181242"></a>

[Blodg]

And here are some pics after hosing them off:

<a href="http://www.flickr.com/photos/94196939@N02/8859410285/" title="rps20130527_181428_946 by Blodg15, on Flickr"><img src="http://farm6.staticflickr.com/5339/8859410285_cd0044b935_c.jpg" width="800" height="478" alt="rps20130527_181428_946"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8859416829/" title="rps20130527_181509_769 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7424/8859416829_e5ed95e7e4_c.jpg" width="800" height="478" alt="rps20130527_181509_769"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8859422463/" title="rps20130527_181545_780 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7384/8859422463_040ee2d9fe_c.jpg" width="800" height="478" alt="rps20130527_181545_780"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8860035968/" title="rps20130527_181623 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3699/8860035968_a0775bdfde_c.jpg" width="800" height="478" alt="rps20130527_181623"></a>

<a href="http://www.flickr.com/photos/94196939@N02/8859434845/" title="rps20130527_181659_290 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3665/8859434845_8f0814c561_c.jpg" width="800" height="478" alt="rps20130527_181659_290"></a>

[Blodg]

I wanted to add that the 355cc 350X motor feels like it is going to be just fine for trail riding. At first I was concerned that it may be too underpowered but with the 10.25:1 piston/midrange cam/ported head/and 39FCR carb in the low and midrange it felt similar to the modified 416EX. When you get to the upper RPM's it flattens out real fast, however, as the 350X motors make their power down low. With the trail riding and hill climbing we do the quad is in the low and midrange most of the time anyways.

[RNL]

Went on the first real trail ride over the weekend with a buddy from work on a Z400. Everything felt great and the lower ride height with the suspension really make it ride nice. We climbed a couple fairly tough hills alongside a trestle on some abandon tracks and was happy with how it handles everything.

When we swapped quads the Z400 with a pipe and filter had much less power on the bottom end but pulled almost as hard as the 416 in the upper rpm's. The handling, brakes, and suspension, however, were not even close to mine which is no surprise since his chassis is all stock. Jumping on his after riding mine hard for a while I also felt a lot more vibration through the handlebars on the Z. He liked the handling of my XC setup and commented that on my 416EX he felt like he was riding "in" it and on his Z it feels more like you are riding "on" it.
<a href="http://www.flickr.com/photos/94196939@N02/8717531701/" title="rps20130507_152810 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7285/8717531701_0f0e16a1fc_c.jpg" width="800" height="478" alt="rps20130507_152810"></a>

Baseball/softball season is fully underway and my kids have games or practices 6 days a week and the one off day is usually spent mowing so I need to try and finish the 350RX in between some riding on the 416EX.

So would you say the Z400 with a pipe and filter would have a lot more overall power than a 400ex with same setup?

[Blodg]

So would you say the Z400 with a pipe and filter would have a lot more overall power than a 400ex with same setup?

I have only ridden that Z400 so I do not have much seat time on them. But from what I felt and what I have read a Z400 compared to a 400EX with the same mods will have more top end power. The dyno charts I have seen show a Z400 to have 3-5 more peak HP than a 400EX with the same mods. But the 400EX will have more low end which makes more usable power and for woods or trail riding the top end advantage on the Z may not come into play much.

[Blodg]

I showed the work on my two sport quads over the winter/spring in this thread. Now that summer is over I thought I would come back and report on how they rode. This summer I went on 6 riding trips with 3 of those being overnight 2-day rides with my son (also several rides on our trails on my property). Both quads ran great and the XC setup on both of them allows me to absolutely rip over the rough stuff in the hills and woods where I do most of my riding. The setup gives great confidence to attack every section full speed and I always feel in control. I am not the fastest rider but I am experienced and on the 3 trips with 12 guys from work there was no one on a dirt bike or a 450 quad that could keep up with me on the trails on my 416EX. Half the guys are on dirt bikes and I really thought they would be faster but they were slow, especially in the turns. My son and I would switch quads every once in a while. He would usually start out on the 350RX but after a few hours he would be tired of kick starting it as he doesn't have the routine down as well as I do so he would ride the 416EX the rest of the day. From switching back and forth we both agreed that handling wise they are very similar although the stock tires on the 350RX are less predictable when sliding around the turns. The bottom and mid range power is also similar but the 416EX has more power in the upper RPM's. Anyways here are some pics from our trips to Wayne National Forest in Ohio:
<a href="http://www.flickr.com/photos/94196939@N02/9113186496/" title="rps20130622_213922 by Blodg15, on Flickr"><img src="http://farm3.staticflickr.com/2831/9113186496_3d78dce651_c.jpg" width="800" height="478" alt="rps20130622_213922"></a>

In this next one I tried crossing right on the other side of where my son is standing and got stuck! I got off and pulled it out myself but this was only 15 minutes into an all day ride so I rode with wet feet on the 2nd day! One reason I try to avoid water/mud when I can but in this case it was the only way to continue on the trail.
<a href="http://www.flickr.com/photos/94196939@N02/9113185454/" title="rps20130622_213837 by Blodg15, on Flickr"><img src="http://farm3.staticflickr.com/2879/9113185454_470227d90b_c.jpg" width="800" height="478" alt="rps20130622_213837"></a>

No, I am not in any of the photos because I was always the one getting off to take the pic.
<a href="http://www.flickr.com/photos/94196939@N02/9110964965/" title="rps20130622_214027_471 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3716/9110964965_5cd3cbb2a3_c.jpg" width="800" height="478" alt="rps20130622_214027_471"></a>

This next one is from our 3rd trip of the year to Wayne:
<a href="http://www.flickr.com/photos/94196939@N02/10476911524/" title="rps20131025_112241 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7319/10476911524_e075b90359_c.jpg" width="800" height="478" alt="rps20131025_112241"></a>

From being stuck on the previous trip we had found a shallower crossing (to the right in these pics) but the guy from work's son had to try the deep spot anyways. His dad getting ready to pull him out:
<a href="http://www.flickr.com/photos/94196939@N02/10477169136/" title="rps20131025_113903_804 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7426/10477169136_4ba9cc16f4_c.jpg" width="800" height="478" alt="rps20131025_113903_804"></a>

[Blodg]

These pics are all from Wellsville Ohio where there are some absolutely HUGE hills. The whole place is a hill climb of sorts as even the main trails that go around the huge ones are on hills. The pictures (and videos on youtube) do not do these hills justice. The group of 25 yr-old guys on dirt bikes from work had planned on trying some of the hills but only 1 of them climbed a single hill so this 45 yr-old guy on the quad had to show them how it's done. But I only did some of the easier hills which most newbie don't do but there are some monsters that the Wellsville vets climb.

Taking a break on one of the power lines:
<a href="http://www.flickr.com/photos/94196939@N02/9190653425/" title="rps20130702_095803 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3738/9190653425_d5bddf5847_c.jpg" width="800" height="478" alt="rps20130702_095803"></a>

A view the other direction on the power line:
<a href="http://www.flickr.com/photos/94196939@N02/9193448964/" title="rps20130702_095709 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7310/9193448964_f594c80d77_c.jpg" width="800" height="478" alt="rps20130702_095709"></a>

A good portion of the main trail rides right on a creek bed:
<a href="http://www.flickr.com/photos/94196939@N02/9351139751/" title="rps20130723_141231 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3734/9351139751_60a0a10b55_c.jpg" width="800" height="478" alt="rps20130723_141231"></a>

A view from the top of one of the hills called "lookout" for perspective of how big these hills are:
<a href="http://www.flickr.com/photos/94196939@N02/9364172683/" title="rps20130725_120129_615 by Blodg15, on Flickr"><img src="http://farm8.staticflickr.com/7454/9364172683_cd2f111856_c.jpg" width="800" height="478" alt="rps20130725_120129_615"></a>
There are a few guys who climb up that steep wall between the highway and this hill, friggin nuts! The climb we took to get up here is actually pretty gradual.

This is not my pic but one of the hills that my son and I climbed. If you look closely you can see a couple quads coming down on the right to get perspective of the hill.
<a href="http://www.flickr.com/photos/94196939@N02/9191680073/" title="scooby from top of shaggy by Blodg15, on Flickr"><img src="http://farm3.staticflickr.com/2880/9191680073_a88b056d3d_o.jpg" width="600" height="450" alt="scooby from top of shaggy"></a>
After I climbed it a few times my son who obviously is not as experienced wanted to try. I told him I wasn't sure about it so I reminded him to bail if he doesn't make it and the quad starts coming back down. I then asked if he realized my 416EX I had just spent all winter modifying may be ruined if he doesn't make it and he said "yep". I told him to get some speed and use 2nd gear. He starts up but doesn't have near the speed that I had so as he got about half way up the motor was lugging in 2nd gear. I could hear the rpm's gradually getting slower and slower and pretty soon the motor is barely running and he is crawling up in 2nd, I swear I heard the motor actually stop running for split second but somehow it kept going. The whole time I was cringing and telling him in my mind to slip the clutch or do something! About this point he is probably 60% of the way up and he finally downshifts into 1st and had no trouble the rest of the way. Whew.

Here were our sleeping arrangements for the night:
<a href="http://www.flickr.com/photos/94196939@N02/10476908345/" title="rps20131025_112357_969 by Blodg15, on Flickr"><img src="http://farm4.staticflickr.com/3678/10476908345_d984458c17_c.jpg" width="800" height="478" alt="rps20131025_112357_969"></a>
It is actually a pretty cool father-son bonding type of activity and beats golf or fishing any day!

[Blodg]

During the build I don't think I shared this pic but here was my kitchen for much of last winter:
<a href="http://www.flickr.com/photos/94196939@N02/8598388715/" title="motor parts in kitchen by Blodg15, on Flickr"><img src="http://farm9.staticflickr.com/8106/8598388715_6eb5e4901c_c.jpg" width="800" height="600" alt="motor parts in kitchen"></a>
I don't have a heated garage so I did some of the motor work in the house, thankfully I have an understanding wife.

For this winter I plan to do normal maintenance, greasing bushings and pull the swing arm pivot bolts etc... The only upgrades I have planned for sure is to install full chassis skid plates on both of them as the places we ride are very rocky. I think the underside of both the frames took more abuse in one summer this year than the 250R frame did in 10 years of racing MX.

Now this part is ironic but at the beginning of this build thread I had described how I was back-n-forth on buying a 450 or modifying the 400EX and I decided to do the latter obviously. Well for next year I am still thinking strongly about buying a 450R for a couple reasons. One is because I have owned more than a dozen ATV's in my life but have never had a 450 so I still want to try one. Another is that my 416EX is still the perfect quad for trail riding for me but next year I want to try some more of the big hills at Wellsville and for hill climbing horsepower is king. And besides the 416EX being underpowered for hill climbing I have a bunch of money and a ton of time in it and my 350RX and I am not willing to smash either of them up if I don't make a hill. My thought is if I buy an 04'/05' 450R for hill climbing I will keep it stock except for the suspension and minor motor work and not worry about making it as nice as my other quads. If I want to do fast trail riding at Wayne or Hatfield I will still bring the 416EX but if I go to climb hills or want to try the dunes I could bring the 450R. Then the following year I could sell one of the three sport quads or even keep all three as my 11 yr-old son will be about old enough by then to start going with us and eventually he could ride the 350RX, my 20 yr-old son could ride the 416EX and I could ride the 450R. We will see, won't do anything until the spring and may change my mind by then but so far the wife is on board.

[MtnEX]

Awesome thread!

Find a solution for the hard starting on the 11:1?

I was thinking about a 110 octane build if possible, but it isn't sounding like an option?
I don't even know what compression that would be.

[beastlywarrior]

Awesome thread!

Find a solution for the hard starting on the 11:1?

I was thinking about a 110 octane build if possible, but it isn't sounding like an option?
I don't even know what compression that would be.

12-1 and 13-1
http://www.jepistons.com/Catalogs/Powersports/ATV-UTV/Honda/trx_400ex.aspx

[MtnEX]

So what would you do to get it to crank... lol? 12:1 or 13:1 and stock cam with decompression?

Hummm...

[Blodg]

MtnEX, the 11:1 416 has not been hard to start. What I described earlier is this - maybe 1 out of 10 starts I hit the starter and after a split second the starter motor just stops. What is happening is the piston comes up to TDC and if it doesn't have a running start it can't turn over past that point. So far I have been able to just let go of the starter, wait a second, and when I hit the starter a 2nd time it pushes the piston past TDC and it starts right up. Since it is working I have kept the stock battery for now. When this one gets low on juice I will buy a battery with a higher cranking power to replace it and I think it will be fine.

I also would be concerned with a 12 or 13:1 build but maybe the stronger batter starts them without a problem? I don't have any experience with anything higher than the 11:1.

[MtnEX]

This is a heavy consideration cause I have no doubt if I build this thing I will race it some and my racing is dead engine starts.

I was thinking of tossing the idea of two identical race bikes and the 400 for trails and just having 2 different race bikes.

A lot of the expensive stuff interchanges between Kawasaki and Honda... Beadlocks, front shocks, etc.

[Blodg]

Today I installed YFZ450 front brake calipers onto the 416EX. The pads have about twice the surface area and with the dual pistons the braking action and feel is improved over the stock EX.
<iframe src="https://www.flickr.com/photos/81874331@N08/13343066173/player/97c4245257" height="450" width="800" frameborder="0" allowfullscreen webkitallowfullscreen mozallowfullscreen oallowfullscreen msallowfullscreen></iframe>

This spring I am also doing some normal maintenance stuff like checking valve clearance and greasing every bushing in all shocks, a-arms, and rear linkage. Also ordered new chain and sprockets, axle carrier bearings, poly case saver, full frame skid plate, rear tires/rims, as well as a +2 swingarm.

[MtnEX]

I have that same mod planned. Looks great like it was made for it. Need to collect a set for myself.

[07.5 lmm]

So those YFZ calipers bolt right up?

[#484]

^^^Yes the yfz calipers are a direct replacement and big upgrade for the stockers. If you guys need the machine to crank faster look into a 24 volt starting system. I ran one on my 400 for the 2nd half of the race season and couldn't believe how fast it would crank. It's simple to make and install, easy to maintain the 2nd battery and helps a ton with dead engine starts. I went from being a back of the pack guy at the first corner to challenging for holeshots on a stock 400 against all 450s.

[MtnEX]

I was able to tune my team mate's 400X to start like that on one stock battery.

Couldn't imagine with a lithium or 24v.

His lights the first time the plug fires every time. If it is very close when it stopped last, it starts instant like first exhaust note pops out before you can get the button bottomed... lol.

[Blodg]

I mentioned some plans above but this spring 2014 I completed:
- installed +2 Eyeball Engineering swing arm
- new front & rear sprockets plus new longer chain for extended swing arm
- installed Moose poly case saver
- 450 front brake swap for larger pads and twin pistons
- installed full frame skid plate
- new Douglas .190 red label rear wheels with Ohtsu MR/501 tires for hill climbing
- grease every bushing in the shocks, a-arms, and rear linkage
- installed new axle carrier bearings
- adjusted valve clearance

Last weekend went on my first riding trip for the opening weekend at Perry State Forest in Ohio. These 3 pics are me from last weekend:
<a href="https://www.flickr.com/photos/94196939@N02/13783492505" title="blodg at perry 4-5-14 (2) by Troy Blodgett, on Flickr"><img src="https://farm8.staticflickr.com/7087/13783492505_630d8a7eeb_o.jpg" width="960" height="658" alt="blodg at perry 4-5-14 (2)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783492945" title="blodg 7 hills at perry 4-5-14 (1) by Troy Blodgett, on Flickr"><img src="https://farm8.staticflickr.com/7075/13783492945_7bc3708299_o.jpg" width="758" height="660" alt="blodg 7 hills at perry 4-5-14 (1)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783832384" title="blodg at perry 4-5-14 (5) by Troy Blodgett, on Flickr"><img src="https://farm8.staticflickr.com/7154/13783832384_f6e99748d8_o.jpg" width="685" height="471" alt="blodg at perry 4-5-14 (5)"></a>

[Blodg]

And these next pics are some of my buddies doing the insane hills/cliffs last weekend:
<a href="https://www.flickr.com/photos/94196939@N02/13783543055" title="Perry opener 2014 (2) by Troy Blodgett, on Flickr"><img src="https://farm6.staticflickr.com/5480/13783543055_9cf278e382_o.jpg" width="540" height="960" alt="Perry opener 2014 (2)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783864194" title="Perry opener 2014 (9) by Troy Blodgett, on Flickr"><img src="https://farm8.staticflickr.com/7436/13783864194_cfa8c448f3_b.jpg" width="797" height="649" alt="Perry opener 2014 (9)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783864044" title="Perry opener 2014 (8) by Troy Blodgett, on Flickr"><img src="https://farm4.staticflickr.com/3691/13783864044_954d448b74_o.jpg" width="881" height="737" alt="Perry opener 2014 (8)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783542803" title="Perry opener 2014 (7) by Troy Blodgett, on Flickr"><img src="https://farm4.staticflickr.com/3745/13783542803_6aed7c8aa3_b.jpg" width="576" height="1024" alt="Perry opener 2014 (7)"></a>

<a href="https://www.flickr.com/photos/94196939@N02/13783526605" title="Perry opener 2014 (10) by Troy Blodgett, on Flickr"><img src="https://farm4.staticflickr.com/3710/13783526605_7dab587688_o.jpg" width="611" height="503" alt="Perry opener 2014 (10)"></a>

[MtnEX]

Seldom can get a pic that does a hill justice but a few of those do!

I ain't sure I would be game on the next to last one, and sure wouldn't be standing there at the bottom of it with my ride to get clobbered... lol.

My wallet is too thin for those serious risk climbs.

[Stickman400]

Some of those look like what I used to do, but wayyy more trees to hit if you mess up. But then again a couple look like the ones I used to do on steroids. I'm assuming you have to jump to the top of those since there is no trail over half way up? Looks fun but those are always sketchy until you do it.

[Blodg]

Yes Stickman, several of those are more like jumps than hill climbs where they are hitting it pinned in 2nd and jumping up the top 10-15 feet or so. Like MtnEX said, pictures don't do justice and even the 1st 3 pics of me are hills that probably 90% of quads don't go up and the insane cliffs 99.9% of quads don't go up. The next to last pic only 1 quad has attempted it with considerable damage and 3 or 4 bikes have tried with no one making it yet. Even the bikes had some broken fenders and bent subframes from tumbling back down the sheer cliff. Some of these guys are definitely a little nuts.

[400man]

Yes Stickman, several of those are more like jumps than hill climbs where they are hitting it pinned in 2nd and jumping up the top 10-15 feet or so. Like MtnEX said, pictures don't do justice and even the 1st 3 pics of me are hills that probably 90% of quads don't go up and the insane cliffs 99.9% of quads don't go up. The next to last pic only 1 quad has attempted it with considerable damage and 3 or 4 bikes have tried with no one making it yet. Even the bikes had some broken fenders and bent subframes from tumbling back down the sheer cliff. Some of these guys are definitely a little nuts.

wow :eek2: that last few pics, did those guys make it??? lol there is no way I would try those :uhoh:

[HondaRacing83]

I love hills but they scare me. Last fall i rolled my 400ex from the top of a hill on top of myself 5 times and broke my wrist. Didnt do anything about it because i wanted to continue archery hunting and i had my schools homecoming the next weekend and didnt wanna be in a cast lol. Then sold my 400 and bought my 450 and havnt done anything to crazy on it yet.

[HondaRacing83]

Looks like the usual wellsville crew in the pics. Is that all you guys do is climb? Lukes done some crazy ****

[Blodg]

I only ride with those guys every once in a while but yes they mostly just climb hills. I like climbing hills but also like to blitz the trails also.

[HondaRacing83]

I love trails. I like some hills but not as much as them haha

[Blodg]

The 416 build and full XC setup from this thread are continuing to do everything I ask of it. A couple pics from my last riding trip and going again tomorrow:
<a href="https://www.flickr.com/photos/94196939@N02/14059517059" title="20140519_115651 by Troy Blodgett, on Flickr"><img src="https://farm3.staticflickr.com/2931/14059517059_41a726a480_b.jpg" width="1024" height="576" alt="20140519_115651"></a>

The hill below is steep but what makes climbing it sketchy is the mud hole at the bottom and the tree roots at the top. The valley stays wet and every time I have climbed it that mud hole is always there, but that's what gets the adrenaline pumping!
<a href="https://www.flickr.com/photos/94196939@N02/14059501108" title="20140519_161732 by Troy Blodgett, on Flickr"><img src="https://farm6.staticflickr.com/5491/14059501108_53c72dd2a2_b.jpg" width="1024" height="576" alt="20140519_161732"></a>

[MtnEX]

Recap the mods for us... I have lost track.

[Blodg]

Recap the mods for us... I have lost track.
2006 400EX
- Cylinder bored to 416cc (87mm) & JE 10.8:1 piston
- Stage 2 Hotcam
- HD head studs
- Cometic Gasket kit
- Lap valves & new valve stem seals
- My own “clean up” port job to remove casting flaws & add knife edge to intake port divider
- CRF450R HD timing chain
- 450R carb (190 main/48 pilot/2.5 turns)
- Fabricated my own custom “Outerwears” lid
- Grind header welds on pipe
- Lonestar +2 a-arms
- Tusk steel braided +2 front brake lines
- Front 450R shocks revalved & dual springs by GT Thunder
- Rear shock revalved & spring by GT Thunder
- GT XC rear shock link
- Pro Taper SE ATV Hi bars
- ODI Ruffian lock-on grips
- Precision shock & vibe bar clamps
- CCP Steering stabilizer
- MSR AOF Clutch perch/lever
- Tusk hand guards
- remove & grease swingarm pivot bolt
- Baja 4 + 1 front rims
- Beadlock 3 + 5 rear rims
- Holeshot XCR front & rear tires
- GT Thunder swing arm skid plate
- TM chain slider on skid plate

[Blodg]

Recap the mods for us... I have lost track.
this spring 2014 I completed:
- installed +2 Eyeball Engineering swing arm
- new front & rear sprockets plus new longer chain for extended swing arm
- installed Moose poly case saver
- 450 front brake swap for larger pads and twin pistons
- installed full frame skid plate
- new Douglas .190 red label rear wheels with Ohtsu MR/501 tires for hill climbing
- grease every bushing in the shocks, a-arms, and rear linkage
- installed new axle carrier bearings
- adjusted valve clearance

[Blodg]

Now starting the 3rd year of running my EX since this build and I add a little more each year. I pretty much only go hill climbing with it now so my setup reflects that.

This winter/spring 2015 I completed:
- installed new Lonestar +4 swing arm
- new Rock 8x8 beadlocks with 22" 4-snow tires for hill climbing
- new 12-40 sprockets for the 22" tires plus new longer chain for extended swingarm
- stiffer rear shock spring for the increased leverage of the longer swingarm
- Teixeira Tech rear sprocket guard
- swapped the rear brake caliper, stay, and rotor from my 250R over to the EX for more ground clearance over that huge EX rotor
- replaced all bushings/bearings in the rear shock linkage
- new CT Racing full exhaust

Yes 12-40 gearing is really low but I run 13-39 with 20" tires and I never use 1st gear. I have tried several combinations and that works the best for the extreme hill climbing I am doing but I will say it sucks for fast trail riding as the gears are so short. As far as trail riding goes I am pleasantly surprised that the +4 swingarm didn't slow me down on the trails as much as I thought it would. I can still loft the front end over obstacles at speed and can still keep up no problem when blitzing the trails with my buddies on their 450's who used to race expert class XC.

I went to the smaller rotor and sprocket guard as I decided to run without a swingarm skid plate this year. Even though I had the GT Thunder XC version that was tight to the swingarm it still would get hung up in the ruts. This is also why I went to the 22" tires but I will run my 20's and change gearing sometimes depending on where I am going.

Pic I took yesterday:
https://farm8.staticflickr.com/7628/16565624604_42c8dfcc27_c.jpg (https://flic.kr/p/reRa4j)416EX 2015 (https://flic.kr/p/reRa4j) by Blodg15 (https://www.flickr.com/people/94196939@N02/), on Flickr

I am the first one to climb in this video from April 4th 2015 (before I installed the CT exhaust). The hills never look like much in the videos but you can tell it is not easy when the next guys tries it several times. He also has a +4 swingarm on his Z400 and he tried the hill 4 or 5 times and never made it. This hill has no run like many of the tougher hills we climb.
https://www.youtube.com/watch?v=r7iUEibSO3Y

Long live the EX!

[400man]

awesome bike. you guys are crazy on those hills. I get nervous when I have to hit a steep hill in a race. ive messed up a few times in the past and it has cost me some dough$ to fix stuff. just wondering if you have tried a 450r rear brake caliper vs the 250r caliper? I know the 450r caliper is a single piston and the 250r is a dual piston, are rotors the same size? yfz450 front calipers are a awesome bolt on upgrade too if you havent done it yet.

[Blodg]

Thanks 400man, I initial thought was to swap the rear brakes over to 450R components until I decided to part out my 250R chassis. That way I didn't have to buy anything so it saved me $180 or whatever it would have cost to get the 450R caliper, rotor, and stay off ebay.

I do have the YFZ 450 front calipers when I upgraded to them last year. And I was glad to have them yesterday going down all these huge sketchy downhills lol.

[crazybob]

For Evereyones information::: DO NOT bother to buy heavy duty Tusk springs from Rocky Mountain ATV. They are NOT any stronger than stock. I bought some. Tested on a spring tester and they Are no stronger !! Same pressure at Installed height and at Compressed height. I called and the acted like I was wrong. I said I tested them and they still did nothing. Liars and thieves!!!

[DragonGunner]

For Evereyones information::: DO NOT bother to buy heavy duty Tusk springs from Rocky Mountain ATV. They are NOT any stronger than stock. I bought some. Tested on a spring tester and they Are no stronger !! Same pressure at Installed height and at Compressed height. I called and the acted like I was wrong. I said I tested them and they still did nothing. Liars and thieves!!!


Thanks for the info and testing so others know. I'm more amazed that you have been a member since 2004 and this is your first ever post!!!!!! I still got my White Brothers HD springs in mine since 2000.

[joker11]

Thanks 400man, I initial thought was to swap the rear brakes over to 450R components until I decided to part out my 250R chassis. That way I didn't have to buy anything so it saved me $180 or whatever it would have cost to get the 450R caliper, rotor, and stay off ebay.

I do have the YFZ 450 front calipers when I upgraded to them last year. And I was glad to have them yesterday going down all these huge sketchy downhills lol.


I love the build story and pics.

I don't understand the need for brake upgrades though. My family lives in the desert. We ride in the desert. I can easily lockup all 4 tires with stock brakes. The problem is that the tires just slide across the hard dirt and rocks. I guess if we had something to bite into like your dirt, it might help!

I love the father son atv camp trip!

[Blodg]

I love the build story and pics.

I don't understand the need for brake upgrades though. My family lives in the desert. We ride in the desert. I can easily lockup all 4 tires with stock brakes. The problem is that the tires just slide across the hard dirt and rocks. I guess if we had something to bite into like your dirt, it might help!

I love the father son atv camp trip!

Thanks joker! I don't check her very often anymore so just now saw this. The YFZ brake caliper upgrade improves the entire braking action. The pad area is close to twice that of the EX pads which improves the feel and control of the brakes as well as the overall power to lock up the front. But of course you want as much braking power as you can get WITHOUT locking them up for the front brakes. And the YFZ calipers/pads give more margin in that area.

[Blodg]

Looks like it has been almost 2 years since I last posted an update. I am now 49 yrs-old and me and the 416EX are still at it! The EX is getting a little love this weekend with some preventative maintenance. Oil change, new spark plug, clean air filter, check valve clearance, new a-arm pivot bushings, new upper a-arm ball joints, new front brake pads, stiffer rear spring, and all linkage/shock bearings greased.
https://lh3.googleusercontent.com/tE8KZ1iG-nlKTPZY-xukJmBMsDHCvqzoYWCDvljuYfK2aGUWfOL5clPRQ0UCX8o66AG MG_vLrMEzBKsC4AEGXgzf3nAbivT9Mxem4BarP23zpYdDQ-U2SVKA9yvRu92qk3_54qceWBoEqzJ7ZPkED010rgMvQagu97VB xHwbKd6srXFUnivMNFy4_jL0_yuBduC6Nx5haEuOADr8w87TOL czBYcq8XS-Omh0pG4zxCrxXugDbMQmfWrvGlmjs_5TbjcuoXP9EexSHoI9mt 6z2fqTjVP4tfKflUKKdzg2qWDz9c9Ie_119y9Yw-gysQSSlkGWoMY6rRWPPwy-ILZh6Kx7Qe0A8y4yERIatJFv3KjI9NcgzQ4a3q-krBUDoGcCV3dsSMmqh1sCUrcwxYXV5jmYqfE6Ha2MaJXYunl1g hwp0QkVC9_dUkd18-Y9ikdy0VQUZcJbz9EARAL8YVu3VBYBreO5XSz7HrNh6k7wmdTi uJREXlHC6n-c0ylwTmEd3zFMPTc9uNFPSVoOkMTvCKB8jwbozmCGA3HHnvKwq nUioCdgFB4-Ti6kQe-QDFLlAcymokhw50p54eBY9HQhKIEUpfm-c5KoEcjKN62UwElAxiX5=w1135-h638-no

I am also testing new jetting since I installed discs on my CT exhaust instead of the open end cap that I usually ran. I assumed the discs would restrict the flow some so I dropped the main from 190 with the open end cap down to 180 with the discs installed. I didn't really test it and went on an out of state riding trip to TN last year and it felt like it lost some power. I didn't know if it was from the discs or the jetting so this weekend I went up on the main until it was too rich and then backed down and ended up with a 192 main in my 450R carb. It definitely feels better than when I had the 180 in so I don't think I lost much if anything from the 14 discs compared to the open end cap now that the jetting is right.

I am getting the EX ready to go on another 4 day riding trip to Brimstone, TN (from Ohio) on March 1st which is only 1 1/2 weeks away now.

[Blodg]

Now time for another update that I have seen time and time again on this forum over the years - I bought a 450ER last year. One difference though is that I will never get rid of my 400EX!

When I started this thread back in 2013 I mentioned that I seriously debated going to a 450 but decided to mod the 400 instead. I have no regrets but I am mostly into hill climbing now and wanted more power on the hills with no run. The 416EX took me to the top of many good hills and on hills where we can get momentum at the bottom it did just fine. But many of the hills we have no run and the 416EX struggled getting enough wheel spin on those or when we let off and on the gas for ruts/tree roots or to go around a tree.

So I bought an all stock 2013 450ER last spring:
https://lh3.googleusercontent.com/X3tymNkTRVbT6k7vD8TUDQ82Z06oCFtTESDqbqxdh3aKmN8-8dFI1idt7poHk8xcSW84uDvvtqZKSXbIFVGbKftslTMTyR3BdT CbFJiuuPve8iBkKoelrHmrsvb7SjrDNDYbBJKEi6fB1j9Qr5kw 9XMbVjquk9kb6bIXG6VTp2VlyYUZ7d44RCQgTf9iEn4Eb8GcxO mpqvg40YI5Nww2QGftRl3t0MSxQxiM2IeVPIbn7R9SV0GqNJbp hJ8DKju7S_yPgxLeWKP3Xp37b0ghOdgd4hyUDw7H7TNhZKHPvQ Su313Kf4H8iMjEd1w6lNihdHOOBxFywrTO3g9l1fmsZ6W11N0j 8XbyNm2ZWsF-y72ULA2K3NCihYOY8zpy7d7b310ds-R-VG1CU3WVTfOXaOoCnII68qtycpS2Qdug_WNRRI_9P4jwz6Dwj1 bKNgJx5vVAR0wJEnUhVU_Q92PS0e-SfzAD6WM40ffP8Mm3D0meeEWeup5UZ46Q7OV-Wmv5dxOY1ykzxmh3HR8jlGFfaJXEwkhQWjnws5SPs3IF4hUk1a WcXVZP8KAB5zRnwi53DZvwdzbKVNXdrRiJI5rVlYrMj14G-kllcZV679dPjr_ubX4tG1Fz=w1135-h638-no

It was fairly new but had some hours on it so as soon as I bought it I tore it down to install a new crank and bearings, new piston, new cam chain, and full HRC kit to the motor.
https://lh3.googleusercontent.com/lq_gCCMzQl6b4FvcgNE4AuTedaMmP34_5XoZG12n20bENxkLCN tW1rN7yaD7XQEPql8N806nsrXuwyqnwveHbl_vF-pGTCpS-4sf1JFEQ2XozvgUCcwyeSjJiCdfCGAya178wiAiQSrvo0xVLnM fBnEtbPalpMarjNd4MOJ8mPP2QO1fQapRQRWnMgN150XN9mvZG Hj1_PNVCO5mH0qzv17Q8QlLWm3TSopZBqYUHfm1RJP3xwY0XO0 T_TXNjp5CEbCnJYDQSO2_EO2y_MMhpNZ_BaQT5kY-U5vQUaB7oo1iYcZnQilMW5oGiD3V2NTVkxVsAoMGvLgQM7vZ2h ric_0EcJ0ZZxj5E0KEPXcuP_DJJn-WL3f-re_zFC3T0zhjbiDEFNG1Q8WgYU8O-zffsif1Emlry4Ux_AT6Yf5OMUyQrJiwf1MgSlHwtEMhPtKrKBH mr110iGvLUfdmbrromJDxgbHIPcweHkbmORfiJjxws6dxDTSyE QL5mhFOPg9q52J2lUzsnZrhOlxU5xR55dZxjYVKc1cylYcvako 8sNKP2qe5udbMsfOm5MlRbAcNWMKbyzozSZpa2rw9a4PT1xXIn ao7OrBd8C_iF4U1Ncjja2LarWWV=w720-h540-no

I also added a bunch of mods to the chassis with a full XC setup: suspension, steering stabilizer, anti-vibe clamps, Rath XC footpegs/heel guards, and +4 swingarm for the hills. Here I am checking clearance for how much to raise the airbox for the GT Thunder rear link:
https://lh3.googleusercontent.com/noy5JiCSKYH_KkGswnz2uFhpTOc9orEOUMfhEs3IlFW4Km1BgA xKacAyiQeunoWBKa5dZ37uP8E5570eTGaVEHWJGqthwD9DvuBw 6o-DS2jXDE_suDcYBZeqyzTKmdJhAIq6-qIGf3Xf6i6mS0s98HMraeKNGIvO5LR4_IZ9AHWns4tvP2aOH7b KC9H7ucLm5sbbr_zqSOnb2BMMcL5YKb5a-hZaH0ngxsyhr8wPK__SnnCRLHVGXB_ii1Z__p-SgEpVVb0gSGNH5yKJpgO9l-eZ4pjFr9QljD2dorf4gLNSaakPXn8JgXu7t4p_lprAk5UktmEC PMCZB_DXMtCpAwj034hl9Ad_mxOy_9Q-raYV95ikccwG_K3Wv2HUPshdZ-grwyPlNUJGvJeECFQUhhyqDwTrqw69ZqEZ5pGaXLRfM119EYBo i3UHz3bbsjYyBbBqDu0CyA93RKJI9w2WEuCrxgmR8OzLtw7OkM jaUlGYnD9lC8SWkoPpiIDZGr6qJiD6w9uNqD6eqSZiaqsqz3OJ mAOArtVu1cnp8COvCc6Ae2JLCZFurAbgxFeSgTcF8IcXFg6NbF KI_zTN4jbKwZDy-oHodgUI4lhQlbfqC3kvp3DE5S-L=w1135-h638-no


And here is how it sits now:
https://lh3.googleusercontent.com/a94A558Z1bDck-X6qcc52DgZtqw-5tl-_5YDhKlbWeBB9P2c0Z3uSOPOZNmJGs5mPNDcSBAgsy11rN4F9f ZZYXNLU3F8nugz-QzN7lCuh3Qk7tbrgWMG0mSxg1nqOjxiRxumrkr6xr2w19YBEY2 3YGH_vKMsp_ifK8IwUDyal5hhFmLm5krQ7vcS1e_vGQ8ATY9QP 4HYZxto51bf7VLayyHGr3MvxwX_GNN-UysMD777n7pFYs_0frfBmWbK64AMHQGXaArgKCgOeXtVJiWWab 5ZvxiExumJhfen5AfZNfqQUsNHi42Et5E_m9fzl8IhPjauyWVe jGcdH96lXA0HTf5_Vu9gi9NrN2YjebkLC0_GQXjWMrERL_jRtg aaAJ5cJkR16etj_PSXjZqyICNolw5_jBadP4cAIyDriW65SLzC AbKf1Nz098RSoJTRij94xMWbwckMIr8QMMeCiDIA7uuUz_DkAw lUtq1PB3gGKaLO-qYhRcN3PzFxpKTYYHtvfEtQNtMNUEyNAL9p4w7M8f19bLAhTef fl59tqpTSYLNMHzOH9CQP5-_qTlzYnTkxMTHCj_bgKocXXTu5kXEdB8rR3YgeGJ8Aa5YyRHfF bjQISWcLBBXA=w1135-h638-no

And like I said I will never get rid of the EX:
https://lh3.googleusercontent.com/39uENpX52sLoIfzAYLZIhUNPLgNsnayJpgTezqxDxGRB9_mOhW qn54A9XiwgmckOIHI6DpRB7uh_pZqzjBPnz6uh5ZvY_u3ZkPSV eT50lP1kkyirc1CUzVf6c03SPhIsfWg3SuZAkfnmyxBk2owgfR lvqd7H3q0OWhLexJUB0sWHW_ZYn2jjdbZWKG6muSCXg1UVrNnV vPT3EKGYvhDb6e6tGLk9NA7S6p3LhA6VBCmNRUeuc5anEVMR1x ry25fccSIu4CYz7sZ8gNYWL_dMvBUqYYoLmsnrFU2lQkngtBBD fubJKTmXgz1xm43PufoB_mPMaosDR2_fm8gwovj7XeCm7xlRAM mE-dkbEz6-iOBaRw2evD32OkapvORJaPvafsuxUFsNNSz_zTrTK7l6VUTfkJ UFuz_Nb1NWURia7GbQ4pyMe56CjHVsdETCs4LJI0pi5F6e4S3u CTzpH9LDEdMBRlFAlF3kCiujMyG6cN1yKOMY3qXdWhl6dUqKnY 1RZLSeC2UBg9jHVnzowtK-4ljTLjiBtE4kARTwHogJIG0GHb6oNEukM8f6ws8u3F4hs9TXLP IzJ9Y_E3d5uxzDUsFUFUpMn4I7GQd797t1NaooJjZQ=w1135-h638-no

https://lh3.googleusercontent.com/2aVdkS0mH3muVyUSfKHuur51-gVvXGGjttTgvvUt1BoM_q42acAAihAOd9QMVBhe0pLU6wRqwn8 a40H0_5m6M7SxJLXLa6Rbqjm2IA_lXeoXZ_f6vCalfOHte9slP eBi98y_GkRFkQZmvjDJ7UQp1DlXgd6XQZT-7G_MeDCyuM_ZgZhtoIES_d5l1VrQnyOrpVig__imQCiqQ0fiG1 z1p7jS4o8zcycbhdcbcQFzqcKpOp78xssiCNIUHQdxg4x955he 54-n7nfIwopT_h8utd-uyF5GxMTJXPKdNxEkFwye6pNFF2srQF_Xg-rWv1FoEgyspzufXPVIV_U2rZqJC58tAnJIcrRDw5INU6uhefox 7KiV3Hoj8WL0p5E2bMdrK-XpjfgAwbzyLPkuqnW2MHNOfMacadirhqvmJjheZSHLHp4v8Epl LBFYE5MpQOziJPcRp-msQgf8OG2NOOnUsg8PpmkGV1XH2c-YPp_3fLeqICT0C2HHfM1Rsp32Df1Z8fdhv-8jjQUB3K0xcpNP5a2UUK48V4JkZlGB3TAliX_KPPQfT0wfg2J9 8P6lESWcNtxMNne0lDU5k_Q3YPKSPjGKlnTMwcEYCH8yoERUR0 S4UiG6=w1135-h638-no

After a full year of running the 450 it definitely is my preference for tough hill climbs. But for my technical trail riding trips such as going to Hatifield-McCoy or the upcoming Brimstone TN trip I prefer the 416EX. We mostly do the red/black trails at those places and the smooth power of the EX makes it more manageable over all the rocks. Long live the EX!

[Blodg]

A couple pics of me and the 450ER in action:
https://lh3.googleusercontent.com/XEaHZJEQke9NZwwdTgkg-g1YGkTVSjcdLR6gKpZU1pdVUuTv30rSe8Dljg9MAtbBoIEBaCo 8c7xMMO3gh-O49GII1swAbynKu8zo5tQKiDkElY7_Oq9AIGNXi8DcK6tc_Yyp-GFo-Vq-9fAFRy_jQ9YhPCu78IoHKK1odkj36OCiVlztQxHo0Bx6YLQpes PldBX1ksAp8BCRJWDKGticowrtLeDinZbAqHXFWTCri3uIIGCR 9m23t61YMxrFXLKRlDM2zlFDjZV6FOQpyo1Gso1cSR75ntuz7N gxSkQlVwQaAVfDvWNpNFYQsGjOJvDGfogwUn0xEJ_9lpl9nTCD p2c-l0bGx-g9xrmVGcpKCzw41_GUVAVpPVgEtWb1_BKPfj4pYcz0ztR7KHW8 9oIuD88CUo_44eaFMUbolvN2feaxJO7M085LSW1-ogkFDW9QVfgHQLFbNYgywFMlNsNZLqLUHvETgaywqeys5KYurV 9_ZYKcUTShpLQiHj_ggDJ8h5_f-oTrSM51aXD9pJhSkKHxASsFb9YGNyfFlhWCT9IgUlCtcOl7fLB 1EZMqikUGkdMSNPJfA3VG6eR10a_kAXLb1O3dhq-6_8dEijRwlSFsb3J85vDt=w960-h589-no

https://lh3.googleusercontent.com/gL58U98r_QYOdTfmANLyD9hwqh9PMhmdI6qGK13R9er5iOe-rEg_1aNvcfQCN6iMtn51Ih96xmi1Fwz8YyWrmg-XeJj8y4IJNVdoBkGThBIQamw9xQcXZO0E4-R5pkowTQ48wEUXI0HkXssd7tgJVlBd6uqGMzBss1YRceo5mC2B nYxxLw6yihwS7OSY_SHWWSmVIQz5nqVFt_jWqhspssKvU35uGn 4DURSYGy5YN2V4Z4Cns9t9TDzijFkioGz-9W6ueYdS3M7hTU6cA3HubcPYr8siQ7m6zvl0uJrdS_0LW2zs40 rB6q0GZDYHivoc5tJUDOad48yA1-X-or38OQHC91q_i8Jv9kLMfyDfmGUwhctRbj-R6UUT7SKvvLOnomKe4nMiNqUH86zy-fxcESNA91sSaP0FHUBw3pPZPLZsNdbNus7CamFAgVSmVDfQQEM YtN8_hzueIjGNVsZZeGdcKW3TgBgB0w4AKLopT0EfPfwqHcr_C IMWY2p1qTqB8KQa50aFF6w_naxSCrJUG6OOKn040Yn5dRxLnaa V2Pidgl8HrPIKbIYTWtwdVMcfJ72BDdRfEjFezC0AYc3OxS_rN 7TV44hhgVIx21Uv-Qa6JuMj=w1024-h638-no

https://lh3.googleusercontent.com/3OAQcTOlt8WxU_Z7S_gnUqsQoUsIox-rdH04RD0sKpZ8M4XrEBqOsC8Kk1JhEGZZL28UXksB8CJ6aUG7M RXEUIXK5Y0GZHht8LpATyD2-V37C7wj2tOny33iScjHyteol2fTwXmHOW_LG1zT3riAQFq5mGt HrwIVphpHDbrtzWdzKFhKF_J9nvhjkHalf-sWyxeGrB4_fT9bY684HfPWnhLjVF1NL5bdBJKQxqyjAmmFPRhU fXqqJs4deLwf2op_9pN0RzDQ1ClSg7kDfTgFc2B_KiL0ukpbjW qC6aN9h3zU6PQOMwQ0ksT4xjzXCeF9EdCedJFWXMUAtI69VaOH KV6ET9mHCLjvkQ_s8KrouZCgtn8-Rwrla9J7SYIzHNuwDoWPCrNlwu9mEGv1r25Dtk1UDco50C3kt-4M--scyq119TPbziCH5YCEWqx3FTcfB_SNJNADvLcBquSlx15_TM5N KvwDb5Q18-3S-KR0cAoaUA-lSoVMse-cHBcGOEHGJrsQJkfFHqOa2u_mw76ogT7p2pziO28XhbwfQKtRi d3K6Oki12tFbKXvQ-_RG_v8IdQZfAT3CPOMHlgfheEqMKZp89uJng-RpzAdssLZ8q6_97Em=w937-h638-no

https://lh3.googleusercontent.com/P8_0Y0-yZRSdlch2Z1Q3a92dq_E1-JyqGRP5A7nmyr9oQjWu7ThMqTnyHrLhNSXvXKZWGpr54pVuIGJ N-lyu2ahgkUxVTxykoaCX0kntAJ7L8G96QIB6NMbpQqPMmF_wdQS JDbXGIgefwmINe1HCmXopSUtSXyP_IyWL0QAWUOdh61GOGp16C JJ1eAmGJ1tkDhBsKzjFRv_cELGOoqLADwlTRwJ0PXRn1Mn95Xe mnwmV80jCmoE0pSBMjJKRd93z9LdGGzjvY93w7lz_G1dkVGYkQ I1aPxU1hHEx_ifLk4vd_DuEIS8i1Zd2VObtZ5FC_ns7qgbr8WM mlyqG2_V6E-J10rLL407CDF_w8xYSOJVS8wBsiTWzVrotEfJgkXkLIiu8TpBN EDaYPutsQ-0rgsh0zmuF2tqT9JdjYgXvRpWS-WR7_Spf6byRtzWwYPcS3-pMLkeP17fd99kCKHqKwGnTonuXw2qqYWM9kmhiqVNkuygU4PD0 ju1K5JFDVLTZyrNDg4ktqiApasrzSsp08vtQgpxPQSmypHElaM 4QUNEsiOhj1HkSM0tCNHCkomMHcxBRgmqOczRQCbShbkyEab1R RpCLSXS5slx2Ae8W0_X7bJ2A=w902-h589-no

And a link to my Youtube channel if anyone wants to see some climbing action:
https://www.youtube.com/channel/UC6PoPFfw9u5tR4clmWvyXZg