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    Thread: My 440ex Duner Build... Take #2

    1. Member .T.o.n.y.'s Avatar
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      05-26-2012 10:54 PM #1
      Well I've owned this Honda 400ex for roughly 6 yrs. I rode it stock for a very long time, two years ago i decided to do a rebuild and mod it a bit. Here is how it sits now and the mods currently.





      Mods:
      2001 Honda 440ex.
      Wiseco 12.5:1
      Hotcams stg. 3 cam
      Mild Port & Polish
      Large polished aluminum air box
      K&N air filter with OuterWears
      CRF450 cam chain
      GT thunder head studs
      GT thunder 8 plate clutch kit
      Wiseco Billet Clutch Basket
      MSR easy pull clutch lever
      TRX250x clutch cable
      Large oil tank with cooling holes
      Spal fan - thermostatically switched
      Additional oil cooler
      Polished Air Scoops
      White Bros modded E series exhaust
      Brand Unknown big bore header
      Dial-a-jet
      Dual H7 6000k HIDs in headlights
      Yamaha R6 LED brake light
      TRX450r Rear Brake light switch
      Hayabusa Battery
      i5500 Complete Front Suspension System - w/NEW F8 iShocks
      G-Force rear extended axle
      Renthal 14t front sprocket
      Renthal 39t rear sprocket
      Renthal non o-ring chain
      T.M. Designworks Chain Slider
      T.M. Designworks Powerlip Chain Roller
      Yamaha YFZ dual piston front brake calipers.

      Just some videos from Glamis last season, messing around on China Wall








      Pulled it out to take some more detailed pictures before i start the tear down. I'll update with all the new goodies later once i get more pictures loaded.








































      Last edited by .T.o.n.y.; 05-26-2012 at 11:01 PM.
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    2. Member Mk1Racer's Avatar
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      05-27-2012 09:16 AM #2
      My buddy's g/f has that exact bike. She even has the Hellbound Racing stickers on it!
      Quote Originally Posted by MRVW00
      my GF's love to show me their t!ts....and I like to motorboat them so much they call me Chris Craft...

    3. Member joefrompa's Avatar
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      05-27-2012 11:21 AM #3
      looks. good. i had those grips on my cafe bike i built. they will start to wear out after a few rides tho lol

    4. Member .T.o.n.y.'s Avatar
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      05-27-2012 11:52 AM #4
      I love the 400, all my buddies are on 450s and they're great and all but i love how the 400 is easy to manage power wise. After this project i'll be jumping into my 250r and that will be my dune drag bike.... im shooting for 75-80horse with that one.







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    5. Member .T.o.n.y.'s Avatar
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      05-27-2012 01:35 PM #5
      Took some pictures of the items i've already purchased.

      Dual Slim HID Ballasts




      B&M Super cooler


      Miscellaneous AN fittings both 6 & 8AN


      5 Row CX racing cooler to replace the stock one.


      LED air stem caps for night riding at the Dunes


      Red El Wire for my whip


      Ozuim waterproof illuminated ( white ) button for my headlights.




      Thermostatic switch for my Spal fan, 6AN it'll screw right into the B&M cooler, this sucker was expensive.


      OMF 8" rear beadlocks, they need some prettying up but i got a great deal. Did a quick polish on one of the rings, it'll need much more though before im happy with it.


      Also picked up a new set of Douglas Blue Labels for the front.




      I still have a laundry list of things to buy and have done by October but i have time.
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    6. Member .T.o.n.y.'s Avatar
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      10-15-2012 11:28 PM #6
      sorry guys its been a while but im still working on this thing.

      CX racing cooler mounted, roughly same size as stock just more efficient.






      B&G cooler mounted in the front. Still have to attach the SPAL puller.




      Made up the brackets to hold both coolers.














      Fan switch for activating my SPAL fan.


      Clutch cable bracket bent to clean oil fitting & head pipe. Using 250x clutch cable as well.






      Full custom harness starts now.




      New airbox too


      If you cant tell this is where i eliminate any crap i can from the factory harness.... this job sucked.


      Getting there, eliminated a bunch of crap and replaced it with 10 gauge wiring for power to SPAl fan as well as HID ballasts.




      Hooked up everything temporarily to test everything.




      Great success!


      My temporary power source until my GEL Hayabusa battery arrives.


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    7. Member .T.o.n.y.'s Avatar
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      10-17-2012 12:28 AM #7
      Harness is complete, going to fill her with oil tomorrow and hopefully get her started.



      ASV lever on


      Exhaust back on






      Im completely happy with how the harness turned out.










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    8. Member Knock Sensor's Avatar
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      10-17-2012 06:30 PM #8
      I need more pictures please.









      Do the air cooled honda motors lose out on power compared to their liquid cooled bretheren?
      Quote Originally Posted by winstonsmith84 View Post
      It ain't easy being an overweight, uneducated, Sunfire driving whoop whooping clown.

    9. Member .T.o.n.y.'s Avatar
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      10-18-2012 12:00 AM #9
      Yes this is why i have extensive added oil cooling. Especially with the bore and compression of the current motor.
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    10. Member .T.o.n.y.'s Avatar
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      10-20-2012 12:52 PM #10
      Well got her running leak free and cooling system is working just as intended. Made my SPAL fan mounting bracket & hooked it up last night.







      Used a bunch of VW hose separators to secure my lines.





      Scoops mounted & modified to clear lines.



      Im not liking the IMS oversized thank AT ALL, fenders fit like crap and it looks like a giant tumor... im going to pull it off tonight and just keep this tank for my 250r project.





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    11. 10-20-2012 05:50 PM #11
      looks really good man. i wish i still had my 400ex that thing was a straight work horse.
      R32R1 "whore-tex.com the volkswagen fappers enthusiast website"

    12. Member .T.o.n.y.'s Avatar
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      10-28-2012 12:49 AM #12
      Quote Originally Posted by 97audia4 View Post
      looks really good man. i wish i still had my 400ex that thing was a straight work horse.
      Thanks man i love this thing i don't ever see getting rid of it, i may upgrade sometime in the future but this will stay in my stable for sure.
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    13. Member .T.o.n.y.'s Avatar
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      10-28-2012 12:49 AM #13
      I decided to change up the wiring in regards to the HID kit as well as replace the cheapo ballasts i had with some better quality ones.







      Relay's new location in airbox as well as simplified wiring.




      This is how i wired the system:

      1. Ballasts in front attached straight to bulbs.

      2. Relay moved to airbox next to battery

      3. 12 gauge power & ground to relay.

      4. 14 gauge signal wire to relay from headlight switch/key power.

      5. 10 gauge power wire run up to ballasts from relay.

      6. 9 gauge high current power wire from battery to solenoid to starter.

      7. 9 gauge high current ground wire from battery to frame.

      I feel this is the optimum way to avoid any future issues. The lights ignite every time now with no issues whatsoever. I cannot WAIT for my dune trip in 2 weeks!
      Last edited by .T.o.n.y.; 10-28-2012 at 01:38 AM.
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    14. Member BlkMkVGTi's Avatar
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      10-29-2012 10:54 AM #14
      Cool vehicle and excellent build thread

      I love build threads will lots of pictures and few words

    15. Member .T.o.n.y.'s Avatar
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      10-29-2012 09:57 PM #15
      thanks man!
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    16. Member .T.o.n.y.'s Avatar
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      11-03-2012 12:57 PM #16
      Glamis trip next weekend!
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    17. Member .T.o.n.y.'s Avatar
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      11-03-2012 12:57 PM #17
      How many posts until page two starts? This is a huge one page post...
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    18. Member .T.o.n.y.'s Avatar
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      11-03-2012 01:01 PM #18
      Well ive got updates so i guess its going on page one still.

      Glamis trip planned for next weekend, took the bike out for a rip today. It ran GREAT and pulls HARD i cant wait to go against all my friends this year. Last year i would BARELY loose to the modded ones every time..... though i greatly feel this year will be different.

















      Last edited by .T.o.n.y.; 11-12-2012 at 03:06 PM.
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    19. Member .T.o.n.y.'s Avatar
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      11-03-2012 01:05 PM #19
      Also finally got to put my bead-locks to use, my Haulers arrived yesterday so i mounted them and set them in the sun with 20 psi in them so they regain they're shape before i use them. They're shipped collapsed ( flat ) so mounting is a pain and they're all deformed until aired up.







      What do you guys think?
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    20. Member .T.o.n.y.'s Avatar
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      11-03-2012 09:51 PM #20
      Wanted to post mods to date:

      Wiseco BigBore 440 kit
      Wiseco 12.5:1 piston
      Ported rebuilt head
      GT Thunder HD head studs
      Modded/Jetted carb ( choke removed )
      175 main
      42 pilot
      3 clip on needle
      Unknown brand BigBore header
      Modded ( shortened/polished ) WhiteBros exhaust
      PRM airbox
      K&N airfilter w/ Outerwear skin
      One step colder NGK spark plug
      Dial-a-Jet leanest setting
      Hotcams stg. 3 cam
      CRF450 cam chain
      GT thunder 8 plate clutch kit
      Wiseco Billet Clutch Basket
      ASV clutch lever
      TRX250x clutch cable
      Extra capacity oil tank with cooling holes
      Spal fan - thermostatically switched
      B&G additional oil cooler
      CX racing factory oil cooler replacement
      6AN & 8AN oil cooler fittings w/ Stainless hoses
      Polished Air Scoops
      Dual H7 6000k HIDs in headlights
      Yamaha R6 LED brake light
      TRX450r Rear Brake light switch
      GEL Hayabusa Battery ( dry cell deep cycle )
      i5500 Complete Front Suspension System - w/ the new F8 iShocks
      PRM front bumper ( LineX coated )
      ProTaper Fat bars
      Kawasaki dirtbike kill switch wired in for starter.
      Lucas Oil 15-40 Synthetic oil
      G-Force rear extended axle
      Renthal 14t front sprocket
      Renthal 39t rear sprocket
      Renthal non o-ring chain
      T.M. Designworks Chain Slider
      T.M. Designworks Powerlip Chain Roller
      Yamaha YFZ dual piston front brake calipers.
      OMF 8" rear bead-lock wheels
      21x12x8 8 paddle haulers
      Sandshark front sand tires
      Red L-wire'd whip
      Complete custom bike engine harness
      Luminis super slim ballasts
      HID relay w/ heavy duty wiring
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    21. Member .T.o.n.y.'s Avatar
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      11-11-2012 10:40 PM #21
      Back from Glamis











      Took some more once the sun was going down.











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    22. Member .T.o.n.y.'s Avatar
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      11-11-2012 10:41 PM #22
      Two short clips my girl took shes not very camera savvy.



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    23. Member mad8vskillz's Avatar
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      11-12-2012 09:18 PM #23
      very cool, though i'm terrified of quads. i'll ride anything with two wheels, but quads, trikes, and sidecar rigs evoke a feeling of "i'm not getting on that"
      Demokratikally Elekted Fist Lieutenant of the Outside Cavalry of the Independent People's Republik of Offtopikstan
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    24. 11-12-2012 11:03 PM #24
      Quote Originally Posted by mad8vskillz View Post
      very cool, though i'm terrified of quads. i'll ride anything with two wheels, but quads, trikes, and sidecar rigs evoke a feeling of "i'm not getting on that"
      haha never heard that before.

      OP: if i had dunes like that around were i lived, i would be riding it 24/7. Does the 440 kit require more frequent valve checks?
      R32R1 "whore-tex.com the volkswagen fappers enthusiast website"

    25. Member mad8vskillz's Avatar
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      11-13-2012 08:33 AM #25
      Quote Originally Posted by 97audia4 View Post
      haha never heard that before.
      something about them actively trying to throw you in a turn...
      (yes, i know... ride slower... but why, i can go faster on a bike)
      Demokratikally Elekted Fist Lieutenant of the Outside Cavalry of the Independent People's Republik of Offtopikstan
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    26. Member .T.o.n.y.'s Avatar
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      11-13-2012 09:47 PM #26
      Quote Originally Posted by 97audia4 View Post
      haha never heard that before.

      OP: if i had dunes like that around were i lived, i would be riding it 24/7. Does the 440 kit require more frequent valve checks?
      Well i maintain it the same as you would a stock bike and i haven't noticed anything out of the ordinary. The only thing that i noticed was how crazy hot the 440 runs, but now my oil temps never go over 185-195. Its been super reliable regardless of me riding the hell out of it.
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    27. Member DuB-P's Avatar
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      12-08-2012 06:19 AM #27
      I used to have 2 of these, back in day when I use to race GNCC, I bet your cooling set up helps alot! The only thing I hated was trying to start them in the cold and changing spark plugs every month (from maryland)

      Beautiful build man, them old 400ex are wheelie machines! I miss mine!

    28. 12-09-2012 09:28 PM #28
      I had a '00 400EX new back in the day.. was SO much fun!
      Seems to run well w. all the upgrades.

    29. 12-10-2012 01:24 AM #29
      Quote Originally Posted by j0oftheworld View Post
      I had a '00 400EX new back in the day.. was SO much fun!
      Seems to run well w. all the upgrades.
      yea me too, i had a 2002 and with the wide front end kit on it and it was a blast but after PA shut down a lot of state game land they had open for free to ride on I was kinda stuck because I wasnt going to travel 4 hours to ride when i could get a bike and ride all year long
      R32R1 "whore-tex.com the volkswagen fappers enthusiast website"

    30. 12-10-2012 02:48 AM #30
      I grew up (and owned mine) in Youngstown, OH..
      We used to ride in PA just across the border all the time.
      We called it Hillsville: https://maps.google.com/maps?q=41.00...t=h&gl=us&z=16
      Also Wellsville, OH.. http://www.wellsvilletrails.com/Imag...oMapwithLL.pdf

    31. Member .T.o.n.y.'s Avatar
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      12-10-2012 11:01 AM #31
      Nice! Well i picked up my 450r carb so installation will commence after Christmas being i have a dune trip planned after the new year. I cant wait! I'll for sure get good video on that trip, you have to see it to believe it i pull on bikes that are very much "out of my league." I am extremely happy with out the overall out come of the overall performance, i just hope it all holds together.... lol
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