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New to me 2004 Honda TRX 400EX
07-06-2016, 11:37 PM
Post: #1
New to me 2004 Honda TRX 400EX
So last week my boss came through with an awesome bonus just in time for me to find something for our Anniversary Run. I ended out pulling the trigger on a 2004 Honda TRX 400EX. I have a couple small electrical issues to repair but it should be good to go for Saturday. I plan on making her look even better at some point in time but she's at the bottom of the project list.

Anyway here she is after I gave her a quick rinse with the hose and wipe down.

   

Alvarez Metal Works
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07-07-2016, 01:10 PM
Post: #2
RE: New to me 2004 Honda TRX 400EX
Nice wheeler! Love the Hondas, hard to kill!
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07-11-2016, 09:06 AM
Post: #3
RE: New to me 2004 Honda TRX 400EX
I think it got killed.

Mike
2000 XJ Cherokee - 3.5'' lift / 32'' Tirerecapper Pizza Cutters / Front Locker
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07-11-2016, 09:55 AM
Post: #4
RE: New to me 2004 Honda TRX 400EX
Not killed but definitely broken lmao

Alvarez Metal Works
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09-15-2016, 10:52 PM
Post: #5
RE: New to me 2004 Honda TRX 400EX
Update:

Got yet all fixed. Took her out to Scott's place and immediately started having issues with the clutch again. It was sticking. It wasn't disengaging and then would start working properly and then not working again. I got pissed off and we left it behind and I road in Scott's jeep the rest of the way through the trails. Once we came back and got it. We pulled it to flat ground and I started it in gear and drove it back to the trailer. Along the way the clutch started working properly again. Go figure lol. Anyway at that point I decided I'll stay off the trails and just ride it around in the flat area of the propety and see it it started messing up again. That's when I started having another issue lol. The starter would engage all on it's own and run until I disconnected the battery. It's done this before but I was having trouble tracking down the source of the problem. I decided to tear about the push button start switch and found it leaded full of dried mud. I cleaned that out and it ran great for the hour or so that I tore up the field on the property.

So now that I know what's the issue with the starter and I know I still have a clutch issue that needs to be addressed. I'm really close to having this mechanically and electrically sound lol.

Between this post and my last post I completely rebuilt the front suspension and steering. I installed new brake pads front and back. I also installed steel braided brake lines front and back. I fixed a bent steering stem. I also replaced the rear axle carrier and bearings. They were shot. I also installed some new nerf bars. Oh and I fixed my bend up trailing arm skid plate. Oh and yeah I installed a new clutch and clutch hub. The clutch issues I had at Scott's is because I did not replace the clutch basket. I plan on doing that though over the winter. Need to get my truck finished first.

So long story short. She's alive, looks a little different, but still needs a few more bugs worked out of her. She's very fast and quite a bit of fun when I have enough room to open her up a little. Wish I had some space to make a small track to play on. In due time Wink

   

Alvarez Metal Works
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09-16-2016, 12:34 AM
Post: #6
RE: New to me 2004 Honda TRX 400EX
Sounds like she's almost there! Let me know when you want to come up for a test ride.
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09-28-2016, 07:49 PM
Post: #7
RE: New to me 2004 Honda TRX 400EX
i have a nice 2003 400ex. I bet your clutch cable is hanging up not allowing it to return properly. they are very good atvs and reliable.
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09-28-2016, 08:09 PM
Post: #8
RE: New to me 2004 Honda TRX 400EX
(09-28-2016 07:49 PM)luvsmud Wrote:  i have a nice 2003 400ex. I bet your clutch cable is hanging up not allowing it to return properly. they are very good atvs and reliable.

It's the clutch basket. The cable is nice and free. I check that right away. I haven't done a damn thing to the quad since this last update. I'll be taking it to Broome this weekend for the Bro lite races. It seems to be working good now that beat on it over at Scott's but I do know the basket needs to be replaced.

Winter project.....

Alvarez Metal Works
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