[HOW TO relocate 400ex battery] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs

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HOW TO relocate 400ex battery
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Posted by: j450rking

here is how you relocate your battery to your air box in a 400ex (might work in other models)
1. you want to remove your air box from your atv

2. remove your air filter

3. draw a line like in picture 1,2,3 and 4

4.then use a dremel or cut off wheel to cut out the plastic peace

5. use dremel or file to smooth edges

6. place original battery box in place to check cut then remove when happy with your cut

7. take a peace of plastic or sheet metal and place it like in picture 1 and 2

8. then cut air box in 2 places like in picture 2 make shoure you don't cut the slits to long or wide or it wont hold as well

9. then place the battery box in place then place a small peace of wood under the left front edge of the battery box then remove battery box and drill 2 holls in wood and air box and bolt the peace of wood in place (you could use somthing else other than a peace of wood if you wanted to but that is what i had at hand)

10. place battery box in place (for the last time) drill some holes in air box and battery box and make shoure that thay line up

11. bolt or rivet battery box in to air box

12. drill hole in battery box were it will make contact with the peace of wood (from the inside)screw the battery box to the peace of wood

13.then drill a hole in the bottom of the battery box in the rear left corner and drill a hole in the peace of plastic or sheet metal and bolt or rivet the peace of plastic or sheet metal to the battery
box

14.your almost done seal the cracks around the battery box with red silicone cawk or rvt i think thats what it's called you can get it at napa or any auto parts store and let dry over night

15. then the next day paint over the cawk if you want to

16. place battery in the battery box and use the original battery strap to secure the battery by drilling a hole in the rear air box saport and bolt it in and srew the bottom of the strap to the peace of wood and your done

(warning) you may have to make your battery cables longer and it is also harder to remove and install the air filter with the battery box installed i used a K&N air filter witch might be shorter the the original so the original air filter might not work

pictures coming soon

Posted by: j450rking

picture 1

Posted by: j450rking

picture 3

Posted by: j450rking

picture 4

Posted by: j450rking

picture 2

Posted by: j450rking

i am sorry i don't have pics of the air box before the mod so i can't show you were to actualy cut but you should get the idea

Posted by: j450rking

finished producted

Posted by: j450rking

2

Posted by: zdowell

Can you take some pictures of the side of the box. Are you still able to use your air box lid?

Posted by: j450rking

i am pretty positive that you can use the lid i will check tomorow

i'll take some pics and post them on some time tomight

Posted by: BOOSTED2V

Looks good but looks complicated... Maybe you can post some better pics than these please. I want to see the inside of the airbox without the battery and a pic of the air box on the quad from the bottom rear so I can get a better idea of what you did. Thanks... -chad-

Posted by: j450rking

well i will give you some better pics but i can't take one of it on the wheeler b/c i am in mid build and i don't even have the frame right now

Posted by: j450rking

it's not that complicated it's just hard to exsplan here is some pics of the side of the air box like zdowell asked for

Posted by: j450rking

other side

Posted by: j450rking

here is some pics

Posted by: bigballz400

lol shakes head back adn forth

Posted by: j450rking

quote:
Originally posted by bigballz400
lol shakes head back adn forth

why whats wrong with saving $100 and haveing a nice little project

Posted by: Toadz400

quote:
Originally posted by j450rking
why whats wrong with saving $100 and haveing a nice little project

He's just mad because he didn't think of it first.

I've seen this done before and it's a good idea, as long as you are able to keep that battery nice and clean. Shouldn't be too hard compared to the stock location...

Posted by: j450rking

well it won't get dirty at all with my modded lid. i cut the lid with a dremel and used a hot glue gun to glue in a peace of my old outerwear

Posted by: sportrax stu

what is the benefit of doin this? just out of curiosity

Posted by: j450rking

it will make it easyer to take off and put on your rear plastic it will put the wheight of the battery in the center it will protect the battery more and keep it clean and it will make you wheeler lokk better but DO NOT do this mod if you have a long travle linkcage

another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

Posted by: Justin#38

i thought this was pretty damn cool nice job man!!!

Posted by: j450rking

thanks

Posted by: sportrax stu

another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

hey i can get one, do u have any info?!

Posted by: extremejrowe

that plastic mount is bound to break

Posted by: j450rking

that may be i have't used it yet so i don't know but if it dose break then i will just renforce it

Posted by: 400ex_BG_Rider

quote:
Originally posted by j450rking
it will make it easyer to take off and put on your rear plastic it will put the wheight of the battery in the center it will protect the battery more and keep it clean and it will make you wheeler lokk better but DO NOT do this mod if you have a long travle linkcage

another good mod you can do is hook up a cbr 1100 oil cooler they are bigger so it will cool your 400ex better if you have one if you need any more info just ask i hope this helped

Taking the plastic off and on is very easy, I don't see what's the problem with that. Putting the battery in the airbox pushes the center of gravity too much to the right side coze the battery and the exhaust balance each other out. My battery is packed in rubber very good so it will take a lot to make it dirty. So I think this is kinda pointless mod!

Posted by: j450rking

well i think it makes it look cool and i have an aftermarket pipe so it's not that bad

imo i think it is a good mod and i had nothing to do so i went to town on it

Posted by: j450rking

and that just your apinion and the 4lb battery is't going to make it off balence that much

Posted by: Toadz400

quote:
Originally posted by 400ex_BG_Rider
Taking the plastic off and on is very easy, I don't see what's the problem with that. Putting the battery in the airbox pushes the center of gravity too much to the right side coze the battery and the exhaust balance each other out. My battery is packed in rubber very good so it will take a lot to make it dirty. So I think this is kinda pointless mod!

I think it's a very good mod as I along with a lot of other people that have owned 400EX's have problems removing and putting the rear plastics back on because of the location of the battery. As for the center of gravity issue I doubt it makes that big of a difference that you could tell while jumping or cornering.

Posted by: ninja

Taking off and putting on rear fenders is the easiest thing to do on this quad. Not reason to relocate battery IMHO. It would be more for looks and keeping battery clean.

Posted by: j450rking

well i did it b/c i wanted it to be diferent and i don't think i'v ever seen it done in a stock box and it can't be that bad if all the aluminum air boxs relocate it in there

Posted by: DF400ex

my rear fender is a PITA to put on and remove, that's why I did it. I did mine slightly different though. I bent up a piece of aluminum to support the bottom, sides, and rear. That's what I have attached to the frame to support the weight of the battery. If anyone wants pics I can get some.

Bottom line, you have to reinforce your mounts so the weight of the battery doesn't crack your airbox.

Posted by: 400EXTRA

never even would have thought of that

Posted by: j450rking

quote:
Originally posted by 400EXTRA
never even would have thought of that

thought of what?

Posted by: hontr35

Hey more power to ya! That's how good ideas get off the ground, guys like you just go ahead and do it and hey if it works great, if it don't just start over. Live and learn. I like it, beats my 138 buck aluminum one (for price anyway).

00 400ex
Tons of stuff

Posted by: j450rking

i like it but i know i need to make it stronger and it dose't look as nice as the aluminum ones but it will work

and i'll most likely get an aluminum one from insane performance anyway lol

Posted by: maxitout77

I think I'm going to have to try this on my 250EX

My Battery gets wet and crappy all the time...

Posted by: j450rking

go for it just remember to make the mounts stronger

Posted by: j450rking

hey guys i got a um airbox for cheap so my modded stock airbox is up for sale! $15+shipping it dose't have the intake tube b/c i had to use it with my um air box

Posted by: REDRIDDER

isn't putting a battery in the air box taken up valuable air space?That's why you drill holes,better filter,remove lid to gain more air right,imo its alright were it is,unless someone convinces me different,what are the advantages of this if any?

Posted by: DF400ex

I have plenty of space for air to flow and I have seen no power decrease. It's just easier to put the plastics on and off.

Posted by: j450rking

pretty much just easyer to put the plastic on and off and makes it look better. but it is harder to take the air filter in and out

Posted by: honda6490

quote:
Originally posted by j450rking
hey guys i got a um airbox for cheap so my modded stock airbox is up for sale! $15+shipping it dose't have the intake tube b/c i had to use it with my um air box

Send me a pic of that modded airbox you have for sale, I might be interested.

Posted by: j450rking

it's the same airbox from this post

pics on the first page and it comes with the modded lid i glued a old outerwear in the lid after i cut a large hole in it

Posted by: airman88

i decided to try this when i did my complete rebuiild on mine heres some pics

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4774.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4775.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4776.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4773.jpg

i have the rubber that goes over the battery to keep it from getting all oily but this was actually a pretty easy mod took about and hour or so...

Posted by: Ruby Soho

i did this aswell.. heres a few pictures of mine

Posted by: Ruby Soho

#2

Posted by: Ruby Soho

last one

Posted by: j450rking

looks alot stronger then mine

hey ruby were do you live in ct?

Posted by: Ruby Soho

i live in newtown.

have you ever been to walden mx?

Posted by: j450rking

no my bro lives in farmington

Posted by: 400exMO

man that's quite a bit of work. I just mounted all my stuff on my front frame rail. Added alittle weight to the front end for me.

Posted by: airman88

i did this mod and it turned out great heres some pics

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4776.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4775.jpg

http://img.photobucket.com/albums/v22/86suzuki/ATV/100_4774.jpg