I am in the process of rebuilding my son in laws TX 400EX that has been bored out to a 440cc. He would llike to bring it down to a 416cc. What do I need to do to accomplish this or can it be done with minimal cost?

Thanks,

Brian

 

You will probably need a new or used stock cylinder, the 440 is bored out too big to resleeve back to smaller size, if my information is correct, someone please correct me if I am wrong. Ebay is a good source of used parts for this, you might even find a 416 kit or modded jug you can buy and save you all the work. And, of course, you will need a top end gasket kit, also available on eBay, aftermarket catalogs like Dennis Kirk, Rocky Mt. ATV, etc. or dealer. The piston for this can sometimes be bought in a kit with the needed gaskets, so check into that as well. The piston usually runs from 105 - 150 depending on the brand and where you get it.

 

Ebay or check out the site Motosport.com for OEM new parts for about 1/2 the price I could find any place else. They also sell kits from aftermarket manufacturers with all the gaskets and trimmings.

I just rebuilt the top end of a 350 honda that had the oil drain plug fall out while it was running. Needed the hole top end rebuilt and cost about $600. That was less than 1/2 of the local Honda dealer plus it was shipped FedEx to my door 2nd day express.

It made it easy to take the engine apart, making a list of the parts needed then ordering parts. Two days later I was putting it back together with no extra trips to get parts I forgot about.

SJ

 

try and go to BABBITT'S online.com they are the cheapest place i have found online or any dealer so you might be able to buy a new head and everthing you need there so check it out