[highmark923]

Picked up an 02 400ex bone stock 1k from a nice guy locally. Test rode it and everything seemed to work as normal so I put it on the trailer and came home. And like everything in life I told myself I wouldn't touch it. That I'd leave it bone stock; you know for longevity. Well that lasted not too long so here is a shortened version with pictures of what we have done in the first 6 months. For all of the images you can check them out on our Google Album.

Day 1

First up new rear tires.

Next was a thorough cleaning and paint. I decided to pain the plastics with Krylon Fusion. We had good experience in the past and I knew it wouldn't be long before I'd be getting some new plastics.

 

[highmark923]

The stock rims were used up pretty good so I decided to pick up some steely's from ITP for the cost.

All plastics painted. Now off to the do the seat. I used a vinyl paint from Autozone. It worked pretty good. It does rub off but nothing you can't touch up.

Ok, so here it is. Never did a paint job like this before. My son loves camo so I figured what the hey. He loved it so that's all that matters.

Got the new tires mounted on the wheels. Went with something cheap on eBay for wheels and they are doing quite well so far.

 

[highmark923]

The camo had to go and quick. It was fun but I really like the look of a racer type ATV. I'm always watching racertv and just enjoy that type of look. So I decided to go back to flat white and put on some racing numbers and stickers.

So now the fun begins. Enough of the cosmetic stuff. The clutch was toast. I ride pretty hard so 3 months in it was slipping pretty bad. Along with that, toooo much riding on the rear tires wore out the rear bearings so I replaced the carrier. And while your down there you might as well do the chain and both sprockets. This was my first time ever attempting something like this so it was very nerve racking to say the least.

Old Clutch

Had the old gasket machined off at a local automotive shop. These guys were awesome and have dealt with them before. They didn't even charge me!

New clutch in, all buttoned up. I went with a Tusk HD clutch with springs. So far it's been handling all I can throw at it. I ride mostly trails.

Installed some performance scoops to keep things more cool.

So at this point with the new work it was set. Then on this ride I noticed a horrible tick, louder than normal.

I went right home and did some research on valve adjusting and timing chain replacement. I purchased the valve adjustment tool after getting some local quotes to do a valve adjustment. Oh at this point I also purchased a Cylmer service manual which worked well for torque specs on the clutch. It turned out the valves were just off a bit and tightening them up got rid of that tick.

So with the valve work done and the atv back to sounding like normal it was time to move on. While researching valve adjustments I accidentally ordered a whole mess of parts, I'll try not to forget some stuff.

• ProTaper Clutch Perch
• Tusk Clutch Cable
• Tusk Throttle Cable
• New OEM Carb
• Big Gun Evo R Slip On
• DynoJet Jet Kit
• Uni Air Filter
• Maier Plastics
• AllMotorGraphics.com Graphix Kit (Custom)

How it looks as we speak:

Again, link to the full Google Album.

 

[highmark923]

Some more 400ex goodness :yeahbaby01:. The cold is really putting a damper on my progress and riding.

IMS Shift Lever - the stock one is pretty worn out and I hear they break even though this hasn't happened to me. Why take chances

Battery Tenders are a must...

Installed a Tusk Thumb Throttle Cap & a Moose Racing Front Brake Reservoir Cap.

Some new banners for the workshop.

 

[gerry300ex]

This bike is getting nicer man, keep it up!

 

[acej1024]

is that a custom front bumper ?

 

[highmark923]

is that a custom front bumper ?

You know that is a great question. I don't know it came on the machine. I haven't seen another one like it. I actually have something else now so it's hanging on the wall collecting dust...

 

[sleekrider]

Nice build!

 

[highmark923]

Nice build!

Thanks!!

It's been a fun project and with this nice weather in the midwest we have been out enjoying it as much as possible. I think some of the next changes will be around suspension and bushings. It's getting creaky.

I do think my valve seats have to be replaced or worked. Getting a bit of blue smoke during start up but it goes away in a few seconds after it warms up a bit. So I'm debating on doing that this winter, maybe a 416 build is coming .

Picture from this past weekend.