My $400 400 "rehab/build" thread - Can-Am ATV Forum
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post #1 of 69 Old 01-23-2019, 10:23 PM Thread Starter
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My $400 400 "rehab/build" thread

Let me preface this by saying I do what I do or don't do, solely for my bike, lol, and don't advocate anyone else following suit, and many/most of these pics were taken during progress, and not to be confused with the final product. As my sig indicates, I've previously owned several different atv's over the years (mind you, those were just the note-worthy ones), and wanted to get my little boy one a few months back as he's now old enough to ride and work on them with me. A fourtrax 300 was found and took up residence in the garage, which led me to consider "if he's riding out of earshot, how am I supposed to teach him how to operate it?" I needed to ride alongside, so the decision was made to source myself a bike again, after having been without for awhile.

-quick backstory fill: life has dealt some seriously shitty hands lately, so it's not like I've just got a truckload of money to plunk down on something......but since everyone loves a good picture-loaded build thread to scroll through, here goes:

Killing time scrolling across marketplace I spot an ad for an outlander 400, reasonably close to me, and at a price I could "afford", because it's not running, primarily, it would seem.



Bonus it's a max chassis, which I prefer



Apparently it was just taking up space in the barn, and the guy was ready to get rid of it. We settled on $400 ($400!) for a complete max chassis bike! I was stoked. He said it needed a CDI due to no spark. Other than that it looked fine, just neglected/filthy/covered in barn dust. Pushed it up in the back of my truck and headed home.



First thing I noticed was at the fuel lines leaving the tank, the lines/grommets/90s had just crumbled away to nothing, which I addressed with OEM stuff.



Put a little fresh gas in just to see if it held, and moved on to the spark issue. Just randomly removing panels and got to the ignition switch to find this:



The damn rats had chewed slap through most of the ignition/CDI wiring, but it was a relatively simple fix.

So we've got some fresh gas in it, got good spark now. Oil's clean and full, so what the hell, let's see if it'll fire



DaveB and CanamDave650 like this.

"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted

Last edited by BombardierBomb; 01-24-2019 at 05:24 PM. Reason: movie not playing
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post #2 of 69 Old 01-23-2019, 10:39 PM
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drumroll,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,??
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post #3 of 69 Old 01-24-2019, 07:24 AM Thread Starter
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Quote:
Originally Posted by jimmycream View Post
drumroll,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,??
aggravating technology

lemme try again

"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted
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post #4 of 69 Old 01-24-2019, 05:38 PM Thread Starter
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alright! its running great, considering how long it sat.....

next up let's reassemble it and see how it rides. Put it in gear, aaaaaand nothing happens. Lot of dust blows out the beltbox exhaust, I hear something rotational, but nothing. Figuring the belt's either been eaten or dry-rotted away to nothing. Ok fine, let's dive into the belt box:



MOTHER OF!!!!!



The rats had built their own little beach resort in there....ok, so proceed to pulling/blowing/washing all that crap out of there.....finally get the whole area back into some semblance of reasonable function, and can't get the outer sheave to pull in and grab the belt. Mind you, it's well after 2am at this point and I don't think I'm making any friends of my neighbors while banging on the primary and revving the engine in my driveway. So that's enough for now, put it away for the night and get back on it the next day.

Finally after quite a bit of effort I get the outer sheave to start moving like I'd expect it to. Enough for a test drive anyway, and away she goes. Can feel the flat spot in one of the front tires from having sat for so long, but those tires aren't gonna do what I need them to anyway, so they're gonna be changed.
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"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted

Last edited by BombardierBomb; 01-24-2019 at 06:12 PM.
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post #5 of 69 Old 01-24-2019, 06:11 PM Thread Starter
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Bike's none the worse for wear, gauges work, temperature holds steady, but there is some alarming growling coming from the frontend while grabbing the brakes:



Well that explains that....new pads are ordered and replaced.

Some old friends want to go riding now, despite my hesitance, lol. But I mean I did get it to ride it, so let's give it a shot. But not on the factory tires, lol, no, not where they want to go. Again, on marketplace, find an ad for 28" outlaws that I can put on my factory 12" rims. I'm reeeeeeaaally trying not to spend much at all on this "project", but these are a necessity, so





And at this point, I mean, the bike's cleaned up and rolling around/stopping, etc, it's ready to ride once I swap the tires on. Even has the toolkit still intact:





But I just can't bring myself to retain those factory wheels, they are just the worst, lol. Luckily I've got "a source" that hooks me up with some OEM beadlocks for a song.

DaveB likes this.

"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted

Last edited by BombardierBomb; 01-24-2019 at 07:29 PM.
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post #6 of 69 Old 01-24-2019, 08:52 PM Thread Starter
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My first experience with beadlocks was a positive one. So now I'm tooling it around the 'hood, it acts like it could go, just in time for that weekends ride.





And it did fine, when it was running it kept stalling out. I traced the fuel line into the carb and discovered the last chance screen was caked over solid. Way we figured, the gas tank was full of dust from the lines being broken while it sat. When I topped it off for that days' ride, I washed all that dirt right downstream into the carb. Must've cleaned that screen 3 times that day. The last time it cut out on me, it was dark, and I was done for the day. Limped it back to the truck, couldn't see sh!t with the factory headlights all covered in mud, and loaded it up.

Next day I took the carb down yet again, that screen was stopped up again:



After the day's discoveries, I said there were a couple of things that just weren't "going to work": that fuel system, and the factory headlights. Set out to address 'em.



wasn't thrilled with this approach, but thought it'd be worth a try. Also took the belt box down again cause it was getting harder and harder to shift, didn't really discover anything "obvious:"



Just a lot of dust, but did discover an oddity:



Can't explain that, but I sealed it back up with some RTV molded into form.
DaveB and CanamDave650 like this.

"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted
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post #7 of 69 Old 01-24-2019, 09:24 PM
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Very interesting unit and story!

Renegade 1000 X XC, Full Muzzys Exhaust, Flexx Bars, Ricochet A arm skids Hayden Fan Mod!
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post #8 of 69 Old 01-25-2019, 08:17 AM
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Good luck with this atv. I hate to say it but I think this $400 is going to turn into a lot more than you thought. If nothing else youíll learn a lot from wrenching on it.


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2014 Outlander Max 1000 Limited
BRP snorkel kit
BRP radiator relocation kit
Muzzy dual exhaust
Dynojet Power Programmer 5
Opt-7 14" Led light bar
Tricled halo rings
Blue Led tail lights
Can Am 60" Alpine Flex plow

2017 Outlander Max 1000R Limited
BRP Snorkel kit
BRP radiator relocation kit
RJWC dual split exhaust
Dynojet Power Programmer 5
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Blue Led tail lights
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Can-Am 60" Alpine Flex plow
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post #9 of 69 Old 01-25-2019, 10:06 AM Thread Starter
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Ah c'mon, don't rain on my parade

But the way I look at it, as long as I don't get "upside down" on it, I'm fine. I know I have nowhere near what it's worth into it at this point. So from that stance it's all been positive so far.
DaveB likes this.

"Barn find" 05 Bombardier 400 MAX XT - stock
Upgrades:
12" Beadlocks and 28" S/W Outlaws
WildBoar Radiator Relocate
OPT7 C1 Lightbars 14" and 22"
SYATV Snorkels

Previous bikes:
07 Brute 785
07 Renegade 800
08 Outlander 800 Gorilla edition
08 Outlander 800 Max XT Gorilla lifted
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post #10 of 69 Old 01-25-2019, 10:20 AM
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Iím not trying to rain on your parade. I just hope you get it straightened out so you can ride and not have to spend a lot of time or money working on it. Riding season is coming quick.


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2014 Outlander Max 1000 Limited
BRP snorkel kit
BRP radiator relocation kit
Muzzy dual exhaust
Dynojet Power Programmer 5
Opt-7 14" Led light bar
Tricled halo rings
Blue Led tail lights
Can Am 60" Alpine Flex plow

2017 Outlander Max 1000R Limited
BRP Snorkel kit
BRP radiator relocation kit
RJWC dual split exhaust
Dynojet Power Programmer 5
Tricled halo rings
Blue Led tail lights
Opt-7 14: Led light bar
Can-Am 60" Alpine Flex plow
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