400ex Winter Overhaul

[Reece616]

I decided that I wanted to strip and overhaul my 400ex this winter.
Last year on my 250ex, it wasn't that great in the snow, so I figured the 400 wouldn't be much more fun haha.

My plans are:

Strip it down completely
Powder coat frame, swingarm, a-arms, etc...
New seat cover
Replace bearings and seals
New bars/grips/clamps
New brake pads / SS lines
New wheels
New Chain/Sprockets
New nerf bars
New battery
New Bumper...
I dunno if I'm forgetting anything...

I started the strip down today, but didn't get too far.
I got the plastic off basically haha...

I'm attaching some before pics of the quad and the before pics of the bars and wheels I got. I'm pretty cheap so I got great prices on everything.
$25 shipped for the bars and $100 shipped for the wheels.

[Reece616]

I did a rendering (just for color) on a pic I found online to plan my color scheme. (My nerfs will be black with gray nets and I'm planning on an aftermarket bumper, no hand guards)

[TRX2fiveO]

thats going to look pretty cool bro. you know you could make alot of people on here happy. I see you can do image manipulation. Im on a forum for my car and tey have a section called image manipulation where you can hve people make alteration to see what things will look like. you should try it

[Reece616]

Thanks.
Yea I've done photoshop stuff like that on a car forum before.
Other than just color changes, atv stuff can be hard.

[chevymuddman]

I like that color man. it would look pretty cool if you'd paint the ring on them rims orange.

[yamahasucks]

just put 01 on the plastics

[atvrider13]

Originally Posted by chevymuddman

I like that color man. it would look pretty cool if you'd paint the ring on them rims orange.

Yeah!! That would look nice!!!!

[Reece616]

It would look good, but I'm having the rims painted by a shop and don't really feel like having them do that as well, as it would probably cost more.

Anyways...
I got a little further today.
One of the screws on the throttle assembly on the handlebars is stuck and won't come off, and the 2 allen screws that hold the rear brake master cylinder to the frame are seized pretty good.

I have most of the wiring disconnected, all the airbox off, carb, front shocks, exhaust, most of the handlebar stuff, i'm working on getting the oil system off.
I need a 1/2" drive ratchet in order to take the hubs off (front and rear) and then I'll be working on the a-arms.

I'm thinking I want to replace the exhaust studs.
What's the best way to get them out?

I'll post up some pics when I get my light in the shed working better (or tomorrow when it's light out)

[Helmut]

Originally Posted by Reece616

I'm thinking I want to replace the exhaust studs.
What's the best way to get them out?

Just double nut them. Screw two nuts on the stud and tighten the two nuts together tightly. Then, just put a wrench on the bottom nut and turn it and it should turn the whole stud out. If both nuts try to turn off the stud, you haven't got the two nuts tightened together tight enough.

You might also clamp ViseGrips on the studs and turn them out, but I prefer the double nut method. You can also buy a stud removal tool, but the double nut method works fine for me.

[Helmut]

And don't forget to use anti-seize on the new studs. You will be glad you did the next time you have to take them out.