2001 Honda 400ex Engine Rebuild Plan

Hello everyone,

Newbie to the forums I have read a lot hear but need to ask.

I purchased my 2001 Honda 400ex early this year. It already has the following mods:

  • White Brothers eSeries Full Exhaust
  • Hot Cams Stage 1
  • K&N Filter and Power Lid
  • Dyno Jet Jetting (Not Sure which but spark plug looks good)
  • 14/39 Sprockets
  • Works Front Shocks
  • Extended front A Arms
  • Lonestar Swing Arm and Bearing Carrier
  • Stainless Steel Brake Lines Front and Back
  • Nerf Bars

I love the quad and it’s a lot of fun to ride. I mostly ride Forest Roads and ATV trails. The torque is awesome but the top HP is lacking when playing with my buddies Stock Raptor 660 and yfz450.

I don’t care if I loose a drag race just want to be competitive and keep the engine reliable on 93 pump gas.

I am an amateur mechanic at best but I can follow directions fairly well. I am a 2 stroke guy so the 4 stroke is a new world to me.

So my question is, what would be the best plan of action with what I have and what riding I like to do. I am 6’5” and 300 pounds so I need to make up the weight with HP 🙂

I have done a bunch of research but can’t really narrow down what I need for a 416 vs 426 vs 440. What compression for 93 octane and what cam, valves, CDI, etc. for the rebuild.

Looking for a reliable trail bike that is faster than what I have without sacrificing too much torque.

Thanks In advance.