I really appreciate the work you have put into the these videos. I've recently purchased my first ATV, which happens to be a 99 Honda 400ex and I don't know anything about them. So watching everything being built from the ground up has been so helpful trying to learn and understand how these machines work. Thanks!
Really appreciate the detailed videos! Currently rebuilding the engine on a 02 400ex post a broken gearshift spindle. After putting the gears into the left case and testing the gears they seem hard and not smooth when turning the drum. Any suggestions? Don’t want to join the cases until i know the gears work smoothly. Thanks for any suggestions. Also looking forward to a video regarding possible install of all balls kit bearings into rear engine mount/swing arm pivot had a super tough time getting it out due to it being seized.
@@vic10jr The gears will shift a little rough until you get the cases together because all the shafts are loose until they are fully secured in both cases. That being said your shift shaft should fit tightly around the return spring and could be the cause of "extra roughness". You want to make sure everything is tight in the seals and all the transmission parts are in there proper orientation. This is one of those situations where you have to make the call yourself ... is something missing? are the shafts seated in the seals properly? does it shift "too" rough where you think something is not right? Mine shifted kinda rough until I got the cases sealed ...
@@vic10jr as far as the swingarm pivot bearings ... I have already done those and I didn't film the process but I had to use a 17mm socket, some washers, and a press to eventually get the old bearings out. You may be able to use a vice in place of a press to achieve the same results (if you get lucky).
@@11GalleryATV I’ll go through and reassemble the gears one more time following your video just to be sure. Thanks for the advice I’ll go ahead and try and use the vice for the swing arm bearings hopefully I can get them out.
Hey man great video's. Can I get a link to those nickel plated case bolts? Also I seen you have pictures of the cases and where everything goes. Could I get those as well?
Here is the SpecBolt "Nickel Wurks" bolt kit I used - specbolt.com/honda-engine-bolt-kit-nickel-wurks/ and I saved and printed all the diagrams from here - www.motosport.com/oem-parts/honda/2007/trx400ex (use google chrome browser, right click diagram image, choose "save as png", open saved image and print it)
@@joshuabeard8244 just do a google image search for "400ex crankcase" and you should find some. Also look on eBay, people upload high quality images when selling stuff
It's a Motorsport Products MX Engine Stand (#60-1002) - amzn.to/3jLxmRC ... I absolutely love this thing. It can be adjusted to all kinds of easy to work on positions.
I don't think so, they are totally different dimensions. The 400ex clutch plates have 12 tabs and the 300ex clutch plates have 10 tabs. You will definitely want a second opinion though ... or try it, and see if it bolts up and fits under the cover.
I really appreciate the work you have put into the these videos. I've recently purchased my first ATV, which happens to be a 99 Honda 400ex and I don't know anything about them. So watching everything being built from the ground up has been so helpful trying to learn and understand how these machines work. Thanks!
Thank you and glad I could help
Really appreciate the detailed videos! Currently rebuilding the engine on a 02 400ex post a broken gearshift spindle. After putting the gears into the left case and testing the gears they seem hard and not smooth when turning the drum. Any suggestions? Don’t want to join the cases until i know the gears work smoothly. Thanks for any suggestions. Also looking forward to a video regarding possible install of all balls kit bearings into rear engine mount/swing arm pivot had a super tough time getting it out due to it being seized.
@@vic10jr The gears will shift a little rough until you get the cases together because all the shafts are loose until they are fully secured in both cases. That being said your shift shaft should fit tightly around the return spring and could be the cause of "extra roughness". You want to make sure everything is tight in the seals and all the transmission parts are in there proper orientation. This is one of those situations where you have to make the call yourself ... is something missing? are the shafts seated in the seals properly? does it shift "too" rough where you think something is not right? Mine shifted kinda rough until I got the cases sealed ...
@@vic10jr as far as the swingarm pivot bearings ... I have already done those and I didn't film the process but I had to use a 17mm socket, some washers, and a press to eventually get the old bearings out. You may be able to use a vice in place of a press to achieve the same results (if you get lucky).
@@11GalleryATV I’ll go through and reassemble the gears one more time following your video just to be sure. Thanks for the advice I’ll go ahead and try and use the vice for the swing arm bearings hopefully I can get them out.
Saving sport quads , deff nice to see an older guy still in the game and not converted to a razr 🤙🏻🤙🏻
Thanks! ... from the "Older Guy" lol
Hey man great video's. Can I get a link to those nickel plated case bolts? Also I seen you have pictures of the cases and where everything goes. Could I get those as well?
Here is the SpecBolt "Nickel Wurks" bolt kit I used - specbolt.com/honda-engine-bolt-kit-nickel-wurks/ and I saved and printed all the diagrams from here - www.motosport.com/oem-parts/honda/2007/trx400ex (use google chrome browser, right click diagram image, choose "save as png", open saved image and print it)
@@11GalleryATV Thank you. I got my diagrams off partzilla. I was refering to the photos that you had.
@@joshuabeard8244 Do you mean this at 9:40 ?
@@11GalleryATV no it was an actual photograph of the left or right case. I though you may have be using that as a guide.
@@joshuabeard8244 just do a google image search for "400ex crankcase" and you should find some. Also look on eBay, people upload high quality images when selling stuff
What is the stud with blue tip on the left case?
Never mind i found the info for the special stud
@@Walt-c9m glad you found your info ... I just a rubber sleeve over it to protect the threads while I'm building it ...
What engine stand are you using sir?
It's a Motorsport Products MX Engine Stand (#60-1002) - amzn.to/3jLxmRC ... I absolutely love this thing. It can be adjusted to all kinds of easy to work on positions.
Can you put a 400 clutch on a 300
I don't think so, they are totally different dimensions. The 400ex clutch plates have 12 tabs and the 300ex clutch plates have 10 tabs. You will definitely want a second opinion though ... or try it, and see if it bolts up and fits under the cover.