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Honda 400EX Project
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| Honda
TRX400EX Project |
The Honda TRX400EX had set the benchmark since its release
in 1999. It was no doubt Honda's answer to a growing
sport segment of the market and it had big shoe's
to fill following in the legendary 250R's footsteps.
The racing scene soon filled with the model and
the aftermarket eagerly accepted the new Honda
as many upstart companies began producing parts
as well as well known and established companies.
A full aftermarket quad could be built to run
in any class or be the local big shot on a mild
to wild machine. With other manufactures missing
the boat, the Honda soon started racking up wins
and gained a loyal following.
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2008
Honda TRX400EX |
2008
Honda TRX450ER |
Skip forward to today, and the 400EX seems
more like an entry level ATV when compared to
what amounts to full factory race quads. The
400EX lost its shine in the glow of the venerable
Honda TRX450R. Not to be forgotten, many riders
still feel the 400 model suits them better than
the new race bred machines. With a broad, smooth
and predictable power delivery, the 400EX is
as comfortable riding the trails as it is running
in the GNCC series. The MX tracks of today beckon
the power of the 450cc machines, but a good
rider can hold his own on a slightly modified
400EX.
After owning the new 450cc machines, the 400EX seemed
the logical choice for us to build as an inexpensive
project quad for motocross and some trail riding.
With the proven reliability, recently added reverse
and updated styling, the 400EX was getting the call
to pull duty for us as a project was planned. A 2006
model was acquired and planning set forth to build
an inexpensive all around sport ATV using many time
tested parts and even some new ideas that would be
tested.
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Gusset kit installation
can be time consuming and costly, but
it still cheaper than replacing the frame,
and the 400EX frame has a tendency to
start cracking after extensive riding
and normally the first spot to fail is
the front upper shock mounts |
After breaking in the engine, a timetable was
set and the excitement started to build as the
stock 400EX was turned into a pile of parts!
The machine was disassembled to a bare frame
that was to be sent to BK Performance for installation
of a Bare Performance gusset kit, which is a
necessity for the 400EX to withstand the flexing
the frame receives from the abuse of riding
on a motocross track. The most common spot for
frame failure on the 400EX is the front upper
shock mounts. Once, the frame was gusseted,
it was time to powder coat the frame stealth
black to set our project apart from others on
the track.
One of the weakest points of the 400EX is its stock
suspension, which lacks adjustable front shocks with
reservoirs, and the rear end tends swap back and forth
sideways through rough whooped out terrain. To fix
these problems, we decided to take the route of many
400EX owners and run TRX450R shocks up front as a
way of gaining some adjustment and better ride without
the expense of installing aftermarket shocks, and
the stock rear 400EX would be converted to a dual
spring and rebuilt to match the front suspension.
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The
Stock Rear shock was utilized & take
off stock 450R shocks were purchased online
to save money on the supension upgrades,
and C&D Racing rebuilt the shocks |
The stock Honda 450R suspension was sent to
Colby at C&D Racing for a triple rate conversion
and re-valving for our riders weight. The rear
also received a re-spring and re-valve courtesy
of C&D. In order to keep the project inexpensive
and within the reach of most riders, we utilized
eBay for purchasing many of the items including
the shocks. Our greatest find was a used set
of Walsh A-Arms that were soon disassembled,
inspected, and powder coated stealth black to
match the frame. They were mated to the 450R
shocks and soon the quad was starting to look
like something! The stock swing arm was retained,
but mated with a new G-Force axle to extend
the rear to motocross width. The stock gearing
was also kept in place, although a DID chain
X-Ring was installed to withstand the abuse
we would place on this quad.
