2000 Honda TRX400EX Build/Restoration.

[Zhutch7]

I have finally got enough put together to start my build thread. I bought a 2000 Honda TRX400EX about 4 months ago for $700 + a Browning .22 pistol. When I started negotiating with the previous owner and after I seen some pictures, I thought "this shouldn't be too lengthy of a project" but boy was I wrong. As I am winding down to the last few weeks before starting it up, I am as anxious as a young boy on Christmas Eve. Now don't be too harsh on me when you see what it looked like when I first bought it because it looked pretty rough honestly. You all will wonder why I bought it but I wanted to rebuild something from the ground up and that's exactly what I did. I hope you enjoy all of the pictures and the progress made as much as I have throughout this process. I will post all of the pictures I have taken so far and I will post more as I finish it up.

[Zhutch7]

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[Zhutch7]

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[Zhutch7]

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[Zhutch7]

When I bought it, the only parts worth anything were: White Brothers full exhaust, Pro Taper handlebars, ITP front tires, full skid plates except a-arm protection, and it was recently rebuilt with a 406 kit I believe. The previous owner wasn't positive on what was put in it and he couldn't find the receipts so I am still unsure as of right now lol. The plastic and seat was held down with zip ties, the rear tires had a couple plugs in them and the frame/plastic/and nearly the entire four wheeler was spray painted blue. If they wanted something blue that bad, they should have simply bought a Yamaha. Fortunately, my dad owns a Powder Coating business so I have easy access to the "goods".

[Zhutch7]

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I started tearing it apart the night I bought it. I probably should have cleaned it first but I couldn't contain myself lol.

[Zhutch7]

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[Zhutch7]

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[Zhutch7]

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Sand blasted and getting ready for PC.

[Zhutch7]

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[Zhutch7]

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We went with a low gloss black (Satin Black) on most of my parts.

[Zhutch7]

We started to powder coat the stock a-arms but the ball joints on one of the upper a-arms ceased up on us so I decided to go with Houser +2 Slicast arms instead.

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[Zhutch7]

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I know I'm not using these but here is a comparison of before and after the PC.

[Blodg]

Zhutch, those last 3 or 4 attachments are not working for me so I can't see the pics. Or is it just me?

[Zhutch7]

Zhutch, those last 3 or 4 attachments are not working for me so I can't see the pics. Or is it just me?

I will re post them a bit later. They are working for me but I will check it out.

[Zhutch7]

Before, middle and after.

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[RNL]

Very cool!

[Zhutch7]

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A few parts together of what I had at the time.

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I decided to get the 2.0 pad to update my Contour bars a little bit

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My E-Sticky graphics turned out nice!

[Zhutch7]

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My 250R hood before we modified a grille for it.

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Pro Armor XC nerfs that we had to force on. The mounts weren't even made correctly.

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And of course, my Holeshot HDs!

[Zhutch7]

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My beautiful bundle of parts!

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Oury grips/Maier hood/E-Sticky graphics.

[Blodg]

Now I can see the pic attachments. It is going to look very nice, what are you doing with the motor?

[Zhutch7]

Now I can see the pic attachments. It is going to look very nice, what are you doing with the motor?

The previous owner had it rebuilt before I bought it and he told me that he thinks it has a 406 in it but he wasn't for sure. I can definitely tell that it isn't a stock motor. He doesn't have the receipts for the work either. But I'm not going to mess with the motor other than cleaning it up and prepping it.

[Zhutch7]

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CFM!

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I have continuously heard good things about the Tusk/G-Force rear axle. So I went ahead and bought this one and saved me some money rather than spending $3-500.

[Zhutch7]

Now it's time for the reassembly! I went ahead with some 450R shocks, I will have them revalved soon by Dirtworks. We installed the CFM air box and the bigger oil can. We polished the motor mounts, spindles and other misc parts.

[Zhutch7]

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[Stickman400]

Lookin' good, kinda looks like mine from the front. Same a-arms (mine are +1s), shocks (before I had mine rebuilt), nerf bars (before I PC'd mine red), same frame color, even the same Craftsman ATV lift, lol.

[Zhutch7]

Lookin' good, kinda looks like mine from the front. Same a-arms (mine are +1s), shocks (before I had mine rebuilt), nerf bars (before I PC'd mine red), same frame color, even the same Craftsman ATV lift, lol.

You must have good taste then lol. I appreciate it man. How have your nerfs held up so far? I heard mixed reviews on the XC nerfs but Pro Armor were about the only ones that I liked.

[Zhutch7]

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Fresh PC!

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I definitely benefit from my dad's PC business!

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[Fix29]

Looks awsome so far, can't wait to see how the finished product turns out. Keep up the great work!

[Zhutch7]

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Love the rear shock cover.

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I have heard good things about Oury grips. Very soft

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I got some goodies in today. New DID X-Ring chain, Tusk sintered brake pads front and rear, Pro Design case saver and Tusk gas cap!

[Zhutch7]

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I have a lot left to put on!

[Stickman400]

You must have good taste then lol. I appreciate it man. How have your nerfs held up so far? I heard mixed reviews on the XC nerfs but Pro Armor were about the only ones that I liked.

I had to have them re-welded after they broke the factory welds from underneath the heel guards and where the bar under the foot peg meets the main hoop. Other than that they're decent nerfs for what I paid.

[Zhutch7]

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Got my hubs done in a Candy Apple Red. Matches pretty close to the Honda red.

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Finally we PC'd our last part, the swinger. Low gloss black with a polished rear shock link.

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AC Racing Blackline bumper puts a nice touch to it.

[2001400exrida]

i run the oury grips and g force axle you won't have any issues with either of those products. the grips hold up quite a long time for as soft as they are.

[Zhutch7]

i run the oury grips and g force axle you won't have any issues with either of those products. the grips hold up quite a long time for as soft as they are.

I read great reviews for both products so why not, right? I'm looking forward to the many hours of riding time that we will get to spend together ha.

[BIGTEX400EX]

Anything new? Looking forward to the next round of photos.

[Zhutch7]

Anything new? Looking forward to the next round of photos.

I will post more pictures later this evening of the current progress we have made. Be ready!

[chronicsmoke]

PC on that stuff looks good! Did you have a hard time getting the needle bearings back in the swinger?

[Zhutch7]

PC on that stuff looks good! Did you have a hard time getting the needle bearings back in the swinger?

Not at all, we put them in the freezer and greased it up real good inside of there and they went right in with no problems.

[Zhutch7]

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Got the rear end put together. Loving the red sprocket.

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Finally got a roller!

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[Zhutch7]

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[Zhutch7]

I polished up the exhaust and decided not to put the disks back in. It sounds a lot louder than I remember, what exactly does that do?

[BIGTEX400EX]

Looks great, I really like the black frame.

[murph812a]

Looks awesome, I am in the process of putting mine back together. I tore it down and had mine PC. Frame, front bumper, spindles, stem are gloss black. Hubs, swinger, a arms, motor mounts, handle bars are all blood red.

[Zhutch7]

Looks awesome, I am in the process of putting mine back together. I tore it down and had mine PC. Frame, front bumper, spindles, stem are gloss black. Hubs, swinger, a arms, motor mounts, handle bars are all blood red.

Awesome! It will all look good once put back together.

[Zhutch7]

After a long 5 months of working on this newly built quad, it is finally done!
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[Blodg]

Nice work!

[Zhutch7]

Nice work!

Thank you! This thing will run like a scolded dog.

[Stickman400]

So shiny, shame you have to ride them after you do all that work and make it look so good. But that's that point I guess. Sweet bike.