400ex New Parts and Maintenance

In today's video I install new Alba nerf bars and a new Factory43 bumper. I also added a universal Pro Taper clutch lever as well as doing a thorough deep clean of the quad replacing some worn control cables. This was a fun project to work on since I've never made a garage video of this size sharing my wrenching experiences. I recorded pretty much everything and this video has been cut down from 10+ hours of footage!
My Website petehager.com/
2004 Honda 400ex
Factory 43 front bumper
Alba Nerf Bars
Alba Gas Cap
Pro Taper Universal Clutch Lever
K&N Air Filter with Outerwear
0:00-0:21 Intro
0:22-0:59 Nerf Unboxing
1:00-5:50 Nerf Install
5:51-11:01 Broken Bolt Extraction
11:02-12:36 Bumper Install
12:37-18:22 Maintenance Tear down
18:23-24:09 Cleaning Parts
24:10-26:47 Parking Brake Delete
26:48-31:46 New Clutch Lever
31:47-36:34 Assembly
36:35-37:28 Starting Up
37:29-40:21 Outro
Music sourced through www.epidemicsound.com/
Cleaning Music "When To Stop" by Lofive
Camera Gear-
GoPro Hero 7 amzn.to/2MHvxVl
**Must purchase GoPro adapter to run microphone amzn.to/2SjdM3O
Mic Purple Panda DISCOUNT LINK www.purplepandastore.com/prod...
Iphone 13 Pro
Follow Me On:
Instagram- / pete.hager
Facebook- / pete-hager-media-21519...
#savesportquads

[@lebro6253]

Friendly tip, never use a torque wrench to break bolts loose, it can throw off the calibration of the wrench, the reverse is only for if you over torque it a little bit.

[@kadenk1123]

I love these types of vids. You should definitely do them more often

[@gaugeschippers]

Couldn’t agree anymore!!

[@PeteHager]

Thanks guys! I hope to mix this style content in with my ride videos this season! It was a great learning experience editing something like this since it was new for me! 😊

[@foxpuremage]

That work table is an excellent idea. Never thought about something like that

[@conniestevenson226]

Seems pretty silly to me

[@PeteHager]

I love it, works great for simple maintenance. Plus it's nice to have a big table in general, we have the same size shelf underneath that I can store parts on👍

[@mironkochergin6614]

Hi Pete

[@Ja-fh8io]

​@@conniestevenson226 yeah it seems pretty sketchy they got hydraulic jack stands that can lift the whole atv about 4ft more then enough to comfortably work on the without being on your knees

[@outdoorfunwithb]

Definetly love these kinda videos it just teaches other ppl who have never done anything like this before something new u know.keep up the great work looking forward to seeing more videos from you take care 👍🤘

[@blaqmagic4833]

Good job getting that bolt out. On the positive side ,, you now have a new skill to add to your tool box...

[@OdysseyOffroad]

Nice video man, nothing more satisfying than wrenching on your own stuff. No matter the size of the project from small to big, its nice to look at it when you're done with a sense of accomplishment. Keep it up.

[@luminairy923]

If there is ever a broken bolt you can't get out take it to your local welding shop. If you put a nut with roughly the same inside diameter as the broken part you can weld the inside of the nut on the broken piece. Then you can turn the nut with a a wrench and the broken piece comes with it. Obviously careful of gas tanks and carbs near welders. Good job getting it out. Those are not easy to get out and you did. Nice job!

[@davidjurkowski5588]

Always awesome to see the machines getting some love!

[@lifeatv]

What’s up Pete, loved this style of video. Showing the ole 400ex some love 🤟 Riding season is almost upon us 🤟🔥

[@Davido50]

Yes, startin here in Ohio! Weather up/dwn. Was 2.5mo winter at best 😆 . Maxima 📦 just arrived w/ oil , air filters & iridium plugs !

[@dustinbeardy9397]

You inspired me to get out and work on my 400ex myself! Thank you for that! You also showed me how easy it is, I need to take the gas tank off and carb to clean! I had no idea where to start but now I do!

[@emfelling8384]

all the mods you put on where so cool, love the 400ex videos, gives me ideas for my 400ex, thanks Pete for the great video really hope you get the Rossier exhaust soon would love a video on that

[@bigmurph1447]

I use to delete the parking brake on my sport quads back in the day. If u still want a parking brake I use to put a zip tie on the front brake lever and around the bars to apply the front brakes

[@PeteHager]

Thats actually a really good idea, I didn't think about that!👌😬

[@that_400ex_guy7]

More 400ex content 💪🏻 let’s go

[@austinsteurrys1228]

love watching your videos with the 400ex 🔥🔥

[@omert9681]

Great job and great video.thank you . I own a ex 400 1999 been seating for 20 years and now I am planning to ride it this year. Great Honda products.

[@petes_powersports7438]

Hell yeah Pete. Going to look at a project 400ex tonight!

[@jaredkwak9454]

Hey Pete!! Ready for spring and summer man!!

[@DocAtrox]

My previous comment was still mid viewing of the video. I can't express how much I LOVE this video of you wrenching!!! Absolutely awesome video Sir!!

[@PeteHager]

Thanks RJ! This video was a big project and took me awhile to put together. I learned a lot while making it, it's a bit tedious to film yourself but I got better as I went. I drew a lot of the inspiration for the video style from one of my favorite youtubers, Andrew Camarata. I definitely plan on mixing this style content in with my ride videos throughout the year. Hope all is well and we can get together for a rip sooner than later! 😊🤘

[@erichemmelgarn4623]

Great video Pete, Just put a full set of nerf bars on my 02 400 yesterday!

[@cadman9615]

Pete…I’ve used the 4-sided tapered easy outs before with pretty good success…always back em out by hand with a wrench. Make sure wrench is tight & turn til it pops loose. Then continue to back it out slowly but surely. If you get a 1/2” ratchet with adapters & extensions, you could get more leverage to break them suckers loose. The male thread cutter is a tap, the female thread cutter is a die. Just a few tips I’ve learned over the yrs…great vid. Love your raptor vids.

[@manel_cafao]

Nothing like a old quad to learn how to wrench. Love this video's

[@TheATVWorldVideos]

Really liking this video, nice change of pace. As always keep it up Pete!

[@DocAtrox]

I wanted so bad at the beginning to just call you and say "Drill it out and re tap it" but I knew this was obviously filmed prior lol Persistence is something I envy you for my friend! Hope to see you again soon!

[@ZachVizzuso]

I am battling a broken stud on my yfz at this very moment. You have given me motivation to keep going!

[@4.5.0.Garage]

Both my 450r have a broken bolt in that same exact spot as Pete's lol

[@deborahchesser7375]

Nice results man, she looks good, clean and simple.

[@evangarbison1576]

Such a great machine. Keep the videos coming.

[@longboardguy]

Nothing like getting new parts or packages in the mail lol. I love that. Also I do love that 400ex and these type of videos. I’d like to find a clean 400ex this summer if possible.

[@seanwilbur8296]

I have a 2013 trx400x and I love it, I race mx with other 450s with it so it has its disadvantages even with a 426 kit, but it’s a great quad, I put on that tusk shifter and it completely shredded my shift shaft and I had to weld it on for the season, I Reccomend looking at your shift shaft before you put a new shifter on, the aluminum ones just strip way easier

[@BrandonBigB956]

Just picked up a 400EX Saturday for my 13 year old son who has been on a 250 for a couple of years. We got the Alba nerfs on it along with Alba bumper and they are pretty good for the price and the oversize peg is nice. We put YFZ450 front shocks on it with a 2 inch rear lowering link to sit it level and a HMF exhaust with quiet baffle in currently. Put bead locks on it with a set of GBC tires and streamline steering stabilizers. Just waiting on gaskets to arrive so I can tear the engine down and ensure that everything is healthy and see if its got stock cam or aftermarket. I have owned at least 4 of the 400ex/400x machines over the years and they just work so good. Got that same gas cap for my sons I like it but its heavy. A little heat with the PB blaster helps a lot. Also they make a manual impact screw driver (craftsman one is like $20) you hit with a hammer and it drives it into the screw slot while putting 200 ft pounds of turning force. You can then cut a slot in the bolt and use that tool.

[@PeteHager]

Thank you for the insight! I'm gonna have to get a simple torch set up so I can apply heat in the future if I need to! Your son's 400ex sounds like it's coming together nicely! I've head about the YFZ front shock swap as well. I'll have to see what I can source in the used market when the time comes! A stabilizer would be a really nice upgrade as well! 😬👌

[@codybonson8134]

make more of these man! i really enjoyed it and could tell you learned a lot from it love the content

[@chriscallas9483]

It's just rewarding to do things yourself. You did great man and I'm like that l gotta clean everything I can get to. You should install the big 3 next. Great vid Pete!

[@dakillerklown]

I love that you have a work bench big enough that you can just pull the quad on top of it so it at a higher height so you are not arched over working on the quad.

[@PeteHager]

It's been a back saver for sure. I honestly made it just to help with oil changes but it's came in handy for all sorts of things. It's super heavy and has never moved on me when driving up 😅👍

[@dakillerklown]

@@PeteHager I wish I had one like that. Working on mine and my buddies quads right now trying to get ready for riding season. And we wanted to make the trip up to silver lake before my daughter is born

[@timpence825]

Great video Pete... Way to stick it out on that bolt.. eager to see and hear the exhaust upgrade..

[@luan6097]

5:58 - I re-did my bike a few days ago and LITERALLY the exact same bolt broke off. Jeez Honda is consistent! XD

[@dabears22]

u really take great care of your machines man

[@joshsrc1327]

I love when you post

[@puresportoffroad]

Good job man, good lookin 400ex

[@brianvera2353]

Nice work Pete looks great!

[@Davido50]

Seems like it got seriously over- torqued @factory bk in day Pete. Keep up good work.👍 Preppin the YFZ450X & new Raptor 700R-SE for spring ridin! *Box 📦 of 4qts Maxima Pro Plus 10w40, 2 Maxima pre-oiled air filters & 2 Denso Iridium plugs arrived Sat* . Not a bad Honda 400ex for us Yamaha guys. 😉

[@dakotaknight676]

Man that’s slick driving up on the table like that haha. It’s nice to see you giving the 400 some love! Hope to see ya down towards the west va, Virginia area some day so we can ride bro!

[@ttatvoffroad2632]

Hell yeah pete, i miss my 400ex, recently havent been riding because ive been fighting 250r callipers

[@Wheeler_Bros]

Love the Table it's sure beats a jack

[@rexg5807]

Looking good buddy. I swapped my seat out for a black one soon as I got my 400ex 20 years ago, looks a lot better. Love the content and the T-shirts get me a lot of attention. 👍🏻👍🏻

[@yamawarr962]

Good job on that bumper bolt Pete. That’s how we all learned 👍🏻

[@mrqz6166]

Let’s goo!!! You know it’s a good day when Pete uploads

[@cheetosbruh2293]

Love to see someone using the same exact nerf bars as me

[@ItsHisComedy4You]

“Call me a whimp, I’ll pass” 😭 you funny bro, keep up the videos 💯

[@christopherkirk1939]

Like the new bumper looks good

[@ryderakins7503]

You don’t know how exited I was when I got the notification that you posted

[@dezow5674]

Hey when you put that lever on you gotta grease the pivot

[@PeteHager]

Thank you for letting me know! I'll have to back it out and add some grease! 👍

[@4.5.0.Garage]

Love this vid Pete

[@stephencrisson3595]

Hell yes a bug 👀 400ex my favorite 4stroke. Sports quad/trail monster ever made love them nice 🎥 man🤙‼️

[@23MikeJ22]

Hard work always pays off😊👍

[@philhascandy2161]

Job well done, clean 👍

[@patrickyasko7443]

I like that yours is an 04 just like mine. I gotta change the sparkplug 😂 fun fun

[@ryanchapman9492]

I have a 2020 raptor that I just bought the same nerf bars and I went with the alba front bumper too. Great video though, a lot of people don’t every clean under the plastics and I’m a big believer of every year stripping the quad down to wipe everything down. Doing this also let’s you keep up on catching problems early and bolts that rattle loose.

[@BigCodyFPV]

Awesome you got a 400ex bud you will not regret it!!!

[@smr4712]

Cant wait for you to put the pipe on aswell, looks good brother,,,400 ex all the way!

[@LilGreeke]

Love getting new parts! Been a while for me 😅

[@jessejames6361]

Awesome video Pete

[@nikobellic7668]

Love your video's man keep it up!

[@leedimatteo5078]

Sabo is probably loving this video, lol

[@Junior-fd8ux]

Props on getting that bolt off and not giving up bro.. that’s one of the little things that turn into being such a headache. You might want to invest in a Heli coil kit.. check them out soooo much easier! I’m looking for another (clean) 400 right now to build up. I had a 03 once I let get away and have regretted it since. Ps I had those same nerfs and I think you will def like them esp for the price tag.

[@gilbertohernandez2752]

Hell yea!!! Thats how I am brother still learning learn something new everyday!

[@bradmcdaniel7258]

Magic eraser on the seat will take the stains out 👍😎 very awesome video of a normal every day guy just trying to figure out how to manage ,true to life. You Rock brother 🖐️

[@SQUARE1SpeedChannel]

It's funny; I'm running a 400EX bumper from Rath on my TRX450. 😆 Daryl said they fit with maybe a 1/16 inch difference.

[@dauoodamjad5797]

I love it looks cool Awsome vids man

[@jamesarneson7769]

You seriously need to buy an ULTRASONIC CLEANER. They don’t cost much and make anything clean as long as it fits in the container!

[@joecarini7863]

I enjoyed every minute of this video i had the same issue with my front bumper bolt took 3 hours to do it and get it right and i thought “Oh yea i got this it’s just 4 bolts” so i felt your struggle cause i was there

[@PeteHager]

Thanks Joe! I'm glad I challenged myself with that task, I was close to bringing to a shop to have them weld a nut on it and back it out but figured why not see what I could do lol Hope your liking your new SBC set up on your 400, I cant wait to get our's once the Houser stems come back into stock 👍

[@joecarini7863]

@@PeteHager going to badlands Sunday for the first real test with it but i did have some fun in the snow already but can’t wait to feel it all on the trails between all that and the stabilizer it should be like a new quad

[@patty2Strk]

The wet rag music was pretty good!

[@lovekillslife7753]

love these vids

[@thedudeinthestude6442]

Everyone has to start somewhere, nice job diving in and working on it. Next time you get that far into it check the valves and adjust them if they need it. Oh and skip the ez outs, just drill and retap.

[@PeteHager]

I 100% agree! I actually had this machine with my mechanic when I picked up last summer and they went through the carb and adjusted the valves for me. Since then it only has a couple hours ride time so everything should be in spec! I'll definitely skip the EZ outs in the future 😅👍

[@tonyfoley9988]

When extracting the bolt only do by hand. In my experience they never come out using the drill, the bits always break.

[@leatherneck69]

Nice 400! Needs an HMF on there though >:)

[@PeteHager]

I considered going with a full HMF but they're the most popular set up and I'm looking to having something a bit more unique with the Rossier 😊

[@leatherneck69]

@@PeteHager will definitely be interesting to see how the Rossier does! Looking forward to hearing how it sounds, the 400 has one of my favorite ATV engine notes.

[@ALDA2479]

After getting my newer 450s I forgot how harsh my 99 400ex rode hope ur getting some suspension eventually especially after riding them new Yamis for so long

[@danielhansen377]

Nice dude

[@wyattkohle]

Hey Pete, in my opinion I wouldn’t be to worried about the top motor mount. A lot of guys don’t run the top motor mount on the 450s. I know your not pushing 450 power but I’m almost 99% sure you don’t really need the top motor mount.

[@PeteHager]

Thanks for the insight! I actually talked with Brewer about it and he does metal work so we may be able to fix it for me next time I'm down to his place. Who know's how long it's been broken, could've been for several years 😅👍

[@dustinrichards8401]

I have these on my yfz the Alba needs and check the bolts a good bit they tend to get loose a lot on mine

[@KingKamp92]

Do you have to cut the wires if deleting parking brake and adding new clutch lever or can they stay hooked up oem

[@15brucet]

With the propane clutch i open that white peice enough to go over the bars and slip it on with no problem for future so you don't have to remove everything haha

[@mikejiskra7976]

I would double check the routing of the clutch cable, it looked like its routed in between the exhaust pipes. You will be buying another cable shortly.

[@PeteHager]

The OEM cable routing goes through the stock header. Most aftermarket headers require different routing 👍

[@kriscox969]

as long as i have been watching your videos i honestly thought you knew how to work on bikes lol kodos for doing a good job . these 400ex's do have ups and downs one down is they will start smoking and its basically the oil ring . i actually messaged you awhile back on ig trying to practicly give you my 400ex just to give it a good home lol

[@arptv806]

FINALY ive been whating for this since you got the 400ex!!!!! also i have the same alba nerfs you got ,ime do not have any slop in them at all thats something you might whant to check over with alba

[@PeteHager]

Good to hear! The right side was super snug with no play. The left side play was really minimal so we'll keep an eye on it and see how it is throughout the season 👍

[@arptv806]

sick man

[@onesweetxj]

I just picked up an 2001 400ex as my first ever atv and I picked up Lucas Semi-Synthetic engine Oil, because that’s all my nearest store had available… curious what you use or recommend…

[@ChristianHelser999]

Id definitely get a new valve cover. That bolt holds the top of the motor... I'd would get that fixed sooner then later.

[@THATLTRFOUR50]

Pete my question is why did you splice those wires couldn’t of you just left the wires with the sensor ? I’m a little lost if you could explain please or is it a bypass ?

[@wallygator7508]

Hopefully someone can help me out. Are there any mods out there for a trailer hitch for these Honda400ex? Please any advice would be great

[@johncordova2089]

Nothing wrong with being a noob. At least your willing to try! That’s how we learn 👍

[@evesoffroad9302]

Just a tip for seats or white plastics is to use a Mr.clean magic eraser to get rid of the dirt stains . It works greats 👍. Also keep up the great content

[@PeteHager]

I plan on getting a custom seat cover for it but that's a great tip! Those magic erasers truly are magic 😅

[@andrewraden4011]

I run Alba nerf bars and I put rath foot pegs on it. They pretty much bolted right on.

[@PeteHager]

I saw Sabo do that with his Alba nerfs on his KFX. I considered ordering the pegs but at that point I was close in price to the full Rath nerf bar set up and should've just went that route if I was gonna spend that much! If these are more slippery than I'd like I'll definitely do that upgrade! 👍

[@ttatvoffroad2632]

Id defiinetly check the swingarm, see if that bolt comes out and grease or anti seize the crap out of it. My 400ex when i bought it had very badly seized bolt and never got it out and I sold it that way. It was soo bad

[@adcewayne]

broken bolts are not fun to deal with....good job getting it out pete!

[@jth_printed_designs]

Every time you were putting your hand/thumb in between the ratchet and the foot peg when breaking those bolts loose had me looking away. Your hand will still go "crunch" even with a glove on.

[@eddiel5189]

A great video. I have two of the 400ex machines and all they want to do is run. Maintenance and cleaning like you showed on this video is not my strong suit tho :( One thing I wanted to let you know is, on one of mine, the clutch got increasingly hard to pull like you were describing. I tried lubing the line several times which worked but only for one or two rides. The cable eventually broke and had to be replaced and it was much, much better afterward. I'm not sure if it was fraying and that's what was making it more difficult to pull, possibly?? Either way, I would say it was a good call to replace your clutch cable, potentially before you had a failure like I did.

[@ChrisTheCrisp563]

I have a 400ex in black and it has a big bore cylinder, but I don't have my quad yet but hope you can try going to this place called dumont dunes, it's near vegas. Love the content

[@lightyagami8639]

Hey Pete how often should I be doing maintenance on my yfz 06 I ride it pretty hard ?

[@diegoo3138]

Hey just wondering what bars you have on the 400 I need some for mine like that

[@Silvis117]

Interesting, footpeg mount looks like it has a chance of snapping pretty easily, not sure tho!

[@gsgarage3521]

When he's taking off the pegs Me: use a fucking impact!!!!!

[@jeremyhallam5392]

The nerfs and the front bumper look great. When you were trying to remove that broken bolt in the bumper mount, you were using "screw extractors". Easy outs are square shaped when you look at them from the end. People do call them both easy outs. I may be wrong on this, but I don't believe that you hammer the screw extractors in. I think you just screw them in and the "threads" are supposed to grab the bolt. You do hammer in easy outs because there's not other way for them to grab onto the bolt. I have been running what looks like the same exact clutch lever on my ATC350X for 5 or 6 years and have no complaints with it.

[@PeteHager]

Thanks for the insight! I watched one video on extractors and got a little over confident haha. Now I know for the future! Great to hear you've had good results with the same clutch lever! 😊