[xr 650/400ex hybrid] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs

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xr 650/400ex hybrid
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Posted by: bansheemorphine

had anyone ever done this i have say one or two but never had any information on one what problems did you have making the motor fit and work? some pics would be nice

Posted by: cbr

i'd like to see honda and suzuki make a 650-700r, in a 'smaller' frame,like a 250r-450 rolling chassis!! when are they going to build one??????????

Posted by: rustyATV

quote:
Originally posted by bansheemorphine
had anyone ever done this i have say one or two but never had any information on one what problems did you have making the motor fit and work? some pics would be nice

This is more common with the desert/baja racers. You might try to track down a team that does this out West.

Posted by: dtmichau

Yeah, its been done...

http://sandsports.off-road.com/dune...d=353848&ref=25

Posted by: firefighterjosh

quote:
Originally posted by dtmichau
Yeah, its been done...

http://sandsports.off-road.com/dune...d=353848&ref=25

Thats COOL!!!

Posted by: Grant Casey

that thing would be a machine to ride

Posted by: nmotion700

how heavy are those engines ?

Posted by: XR650

The xr650L that I run in my Warrior and 400ex conversions weighs 105 lbs., I believe the 400ex motor weighs 98 lbs., so it is not an issue, Raptor and DS motors weigh over 100 as well.

Posted by: bansheemorphine

could we see some pics of this conversion

Posted by: XR650

I'll try and post a few soon, need to resize them.
Some video is up on planet sand under "other places to ride/race", click on clash pics,vids,results page 14or 15 I think

XR650

Posted by: XR650

try this one, see if it works ?

Posted by: XR650

still trying to work on pic sizes, sorry

Posted by: XR650

another try

Posted by: XR650

abc

Posted by: XR650

I am being tech. challenged with pics right now , wil return with more later.

Posted by: XR650

as of right now, it runs down 300' @ 4.64 on all motor, but is still in raw state and better times are to come no doubt.

XR650

Posted by: CHEVYZ

Hey, I remember that bike from the clash. We were the a-holes that parked next to you LOL.

That bike is incredible. It is crazy fast down the track! When are you gonna build me one?

Posted by: XR650

Posted by: CHEVYZ

If you have any problems with the pics, you can send them to me at vicknair@rtconline.com and I will host them for you!

Posted by: Aceman

http://www.exriders.com/vbb/showthr...hlight=650ex%2A

Posted by: charles ford

I'm building a TRX650EX right now the motor is setting in the frame.(400ex) it's a honda NX650 motor (XR650L) I'm working on the motor mounts and the oil lines,exhaust. then I'll get to the wiring and the gas tank,carb,gearing. hope to have it rolling this week end. my plan is to have it looking like a stock 400ex. I do mudding and hill climbs so I will love this when I'm done. my photo was to big or I could show you what it looks like right now or as I get going.
Chas

Posted by: TampaBoy813

what kind of power does the XR650 make?
I had a Raptor 660 and it was weak lacked power.

Posted by: XR650

In stock form it is a dog, putting out low 30's at best, this is a very low comp. motor, it at least needs the JE 10.5:1 comp. shelf piston, web's cam, xr600 Yoshi head-pipe mated to a very free-flowing slip-on, and a Mikuni TM45 carb, that will get you around 48-50 horse, this motor un-modded will not run much better than a 400 at all, but will have more torque.
We've been building the NX650/xr650L power-plant for many years now for 300' flat-drags, in the end it will respond to how-ever much $ put in it just like the rest out there, the 754cc stroker has been one to really run good for us in drags, but slightly modded as stated above will stay together for yrs. and run decent for all-around use.

Posted by: XR650

Here's a pic

Posted by: XR650

another

Posted by: XR650

another honda nx650 of mine in a Warrior chassis from the early years of just trail riding, still going strong

Posted by: XR650

try this one, pic kinda small

Posted by: blingshack

actually i have put a 01 xr 650 in my 250 r fourtrax... a bit of a pain in the ***,but i got it all figured out and it works kick ***.. just need to go up a couple of teeth in th back... if interested, i have pics.. bump me for pics.. im also got a post up for lookin to convert over to 400ex plastics...just due to the facttheyre cheaper to get ahold of...

Posted by: XR650

Post them pics, always nice to see xr650 conversions.
A good sprocket set-up is 15/50 due to the cycle tranny ratio.

Posted by: blingshack

thats funny you responded with that, cause that was going to be the next bulletin i was gonna put up... so 15/50 is a good setup huh... will it give me more bottom end ?

Posted by: blingshack

heres one of the process.. and will post more tommorow..

Posted by: blingshack

heres few more pics... let me know what ya'll think...

Posted by: blingshack

trx 650r

Posted by: blingshack

its not totally done, needs cosmetic stuff now.

Posted by: blingshack

this thing works great... tons of torque... now i have alot of work to do blingin it out... let me know what everyone thinks bout it....thanx

Posted by: Slimyslipknot

quote:
Originally posted by XR650
The xr650L that I run in my Warrior and 400ex conversions weighs 105 lbs., I believe the 400ex motor weighs 98 lbs., so it is not an issue, Raptor and DS motors weigh over 100 as well.

You got a xr650 hybrid?.. is it better then the 450's?..

What did you have to do to make it fit and work?

Posted by: XR650

to make 'um fit, well the usual cut and chop on frames, make room here and there, make all new motor mounts, it's not a walk in the park.
Is it better than a 450, well that's everyones preference, I prefer a big-displacement engine rather than the small-blocks, but they both run well

Posted by: blingshack

well actually it is kinda a pain in the arce.. i wanted the bike to look fairly stock,so i chose to cut the bottom of the frame instead of the top. but i already added the new bottom bars before i cut the old ones... keeps the frame from twisting from the heat of the welding.. and yes,new motor mounts,custom made pieces,including exhaust.. but in the end...well worth it.. if ya have questions or need any help feel free to hit me up.

Posted by: blingshack

hey xr... have you done any coversions on these bikes?and if so.. what did ya use for sprocket config.???

Posted by: XR650

I have only done the air-cooled L motor, if the tranny ratios are anywhere near the same with the R motor, the best rear sprockets for me have been 50 and 52, that is with a normal weight (370lbs) or so bike, and a 15 on the front.
If the bike is extremely light you can go with more like a 44 on the rear.
Hope you have Yam. bolt pattern sprocket hub, large rear honda pattern sprockets are hard to find.
It all depends on what you weigh also, I'm @175lbs.

Is your frame powdercoated or sprayed ?
What color name and # is that blue ?

Posted by: blingshack

actually.its a 3 stage deal..its called siver vein,first. then a candy blue over the top of that..and its powdercoat.

Posted by: rustyATV

blingshack

Why did you lean the motor forward? Was it for weight bias (front), lower center of gravity, to clear the gas tank, or to raise the rear sprocket above the swingarm pivot?

How does the balance and center of gravity feel compared to the stock 250R?

Did you have to do anything special to get the kick starter to clear?

Posted by: blingshack

actually, I place the motor a bit forward to clear the gas tank a little,and also to clear the sprocket. as far as the kick starter, i neede to trim up the frame a bit,then reinforce it from the rear. as you proably noticed i lowered the frame instead of raised the top,due to plastic fitment. as far as i can tell its all centered pretty well. a few of my buddy have rode it says it seems centered really good. if ya need more pics,just hit me up.

Posted by: J_bob_28

quote:
Originally posted by blingshack
actually, I place the motor a bit forward to clear the gas tank a little,and also to clear the sprocket. as far as the kick starter, i neede to trim up the frame a bit,then reinforce it from the rear. as you proably noticed i lowered the frame instead of raised the top,due to plastic fitment. as far as i can tell its all centered pretty well. a few of my buddy have rode it says it seems centered really good. if ya need more pics,just hit me up.

post more pics..that thing looks cool

Posted by: CHEVYZ

Charles ford sent me these pics of his monster for me to post. Sick bike and nice work on the build...it looks great. Keep us informed on it!

http://img244.imageshack.us/img244/7683/1001408ww0.jpg

http://img104.imageshack.us/img104/6257/1001409xh7.jpg

http://img235.imageshack.us/img235/322/1001412wf3.jpg

Posted by: blingshack

that would be nice to have a l motor,just cause kickin my bike is a pain in the arce..lol... im lazy!

I'll get more pics up by tommorow.

Posted by: charles ford

I got my TRX650EX KONG running I'm working on the rear light,finishing the wiring,rear brakes,gearing,and jetting. I want to buy a set of stock red 400ex fenders,rear cailiper,frame skid plate,supertrapp pipe, to finish it up. I plan on riding it around the yard this weekend. I can't wait to take it to my local mudpit. I'm trying to get a guy to make me a set of TRX650EX KONG stickers for it.I plan on sending a photo to dirtwheels for there monster quad page and if someone has a shop or extra parts and helps me out with this build. I will have there sticker on the air scoop. Thats my plan anyways. 440-322-64778 charliekat@eriecoast.com

Thanks for posting my photos so I can show where I'm at.
Chas

Posted by: rustyATV

quote:
Originally posted by blingshack
actually, I place the motor a bit forward to clear the gas tank a little,and also to clear the sprocket. as far as the kick starter, i neede to trim up the frame a bit,then reinforce it from the rear. as you proably noticed i lowered the frame instead of raised the top,due to plastic fitment. as far as i can tell its all centered pretty well. a few of my buddy have rode it says it seems centered really good. if ya need more pics,just hit me up.

Do you think, if you had used an 86-87 style swing arm, that you would have been able to put the swing arm bolt through the rear mount, such as on a 400EX, or would the afor mentioned sprocket clearance still been an issue?

Posted by: mikesutphin

I used the xr 650r motor and a 250r radiator i did it all myself except for the some of the welding. The conversion was fairly easy and its a blast to ride. thanks Mike

Posted by: blingshack

actually, the swingarm had noting to do with mounting the motor,and really had not a problem with alignment.. I also used the 250 radiator, built a oil bag for the oil in the rear,and used the big gun 650r exhaust, with full header pipe,and just had to remake the rear can section to fit through the frame right. this beeotch is loud! and my next plan is getttin a set of yellow 400 ex palstics...and fittin em on the 250r frame...

Posted by: blingshack

to mikesutphin, nice sled, you have more pics? and is that a 400 conversion of 250 conv. with 400 plastics?

Posted by: mikesutphin

its all 400ex, i just modified the frame for the 650 engine and i have more pics but there to big , i dont know how to downsize them but i will try to post some more. it also has a 680 big bore kit from thumper racing thanks mike

Posted by: mikesutphin

heres another pic

Posted by: mikesutphin

other side

Posted by: mikesutphin

one more

Posted by: rustyATV

quote:
Originally posted by mikesutphin
I used the xr 650r motor and a 250r radiator i did it all myself except for the some of the welding. The conversion was fairly easy and its a blast to ride. thanks Mike

It looks like the big XR's more at home in the 400EX frame than the 250R's. Did you have any clearance issues with the gas tank or other parts?

Posted by: mikesutphin

there was a throttle bracket i had to modify and also to make it a thumb throttle and that was it. the tank and fenders bolt right where there supposed to. the 650 engine felt lighter than the 400 when i had them side by side. the quad weighs 375lbs wet. it

Posted by: blingshack

ya, looks real nice bro....I had to modify the throttle bracket on mine too.. those brakets look factory... nice job. if you got more and wanna send em to my e-mail....blingshack@hotmail.com.. by the way if your interested in billet parts foryour bike i sell em...

Posted by: charles ford

best offer or trade for a street bike or enduro.?? 2001 honda 400ex with a title.it has a NX-650 honda motor in it. new one way gear and newer tires. the nx 650 motor is the same as the XR650L motor.it has extra parts like a frame,sub frame,gas tank,misc for it and the nx motor. very fast it and does need jetted and the rear brakes leak. the atv looks stock just like a 400ex. it has a k/n filter and racing pipe with nerfs. I'm taking offers and will trade for a street bike or enduro.?? I have new never on the bike IMS gas tank,frame skid plate,air scoops for an extra $125.00. I will be putting it on e-bay and the paper if I don't sell it soon. I can send you a photo.
440-864-0743 charliekat@oh.rr.com
Chas

Posted by: my88r

what year motor did you use

Posted by: charles ford

the motor is a 88 or 89. I do have a repair manual for it.
Thanks Chas

Posted by: XR650

quote:
Originally posted by charles ford
best offer or trade for a street bike or enduro.?? 2001 honda 400ex with a title.it has a NX-650 honda motor in it. new one way gear and newer tires. the nx 650 motor is the same as the XR650L motor.it has extra parts like a frame,sub frame,gas tank,misc for it and the nx motor. very fast it and does need jetted and the rear brakes leak. the atv looks stock just like a 400ex. it has a k/n filter and racing pipe with nerfs. I'm taking offers and will trade for a street bike or enduro.?? I have new never on the bike IMS gas tank,frame skid plate,air scoops for an extra $125.00. I will be putting it on e-bay and the paper if I don't sell it soon. I can send you a photo.
440-864-0743 charliekat@oh.rr.com
Chas

Did your bike ever sell Charles ?
Here's a pic of my latest, 760ex sand drag bike...

Posted by: XR650

another

Posted by: toxicd

mikesutphin, bike looks great, my hre atv trx450r frame for my barnumspro xr680r motor is almost complete and hope to have everything done by christmas. i have spoken with xr650r about his setup but he is using the xl motor and you have the xr motor like what i am using. just wanted to know what kind of problems you ran into during your project?? i believe i have the oil tank covered and also the oil cooler and radiator. i will be using the stock trx450r radiator and oil cooler, but unfortunately the motor is so big i will have to take the cooling fan off which may be a problem. i have the xr650 wiring harness and i am an electrician which helped me modify the harness so instead of just a push button kill switch, i actually mated the factory trx450r start and headlamp switch to utilize my lighting circuit. i also have a big gun exhaust which will be modified slightly to fit, but that shouldnt be too hard. i have the xr650r rear break pedal and master cylinder to clear the kickstarter and the chromoly frame will be mated with a tcs long travel suspension all the way around. if there is anything i missed please let me know. also i plan on running a taper bored fcr carb, but havnt figured out what i am going to do for an airbox yet. i may just run a clamp on filter like xr650 mentioned, but i believe the rear shock is in the way so i am probably gonna try like a custom aluminum airbox and just get different snorkles and try to find one that will work. anyways i put my spare xr650r motor into a factory trx450r frame just to see how close it was and to my suprise it actually fit, was just very tight and the gas tank wouldnt go down, but it could defenitely be made to work, i will see if i can post some pics of the motor in the stock frame.

Posted by: toxicd

well photobucket is down for maintenance right now, but i will post the pics tomorrow. also as i mentioned earlier i have an extra 2001 xr650r motor for sale right now. the head is fully ported and polished and there is nothing wrong with it that i know of except a siezed rod bearing which is common on the 650r's from what i have read on thumpertalk. the motor is mostly broke down, i just slid the cylinder back on to put it in the frame. i have an extra piston, cam, and many ther parts just dont have the rod or lower rod bearing. anyways the motor is on ebay right now if you guys want to check it out or you can always pm or email me, thanks guys.

Posted by: toxicd

well here are the pics, the motor actually fit perfecting into the rear motor mount and the sprocket alignment is very close. like i said earlier all you have to do is drop the lower fram rails and remove the factory front motor mount brakets on the stock frame and that should give you clearance since the head actually fits bewteen the upper frame rails, although it is a very tight fit and i am thinking about widening it about 1/8 of an inch. again the motor you see in the pics is for sale.

http://i40.photobucket.com/albums/e227/toxicd32/xrmotor-trxframe1.jpg

http://i40.photobucket.com/albums/e227/toxicd32/xrmotor-trxframe.jpg

Posted by: rustyATV

Did you have any issues with the XR engine clearing the fuel tank?

Posted by: toxicd

quote:
Originally posted by rustyATV
Did you have any issues with the XR engine clearing the fuel tank?

yes, if you look at the pics you can see that the gas tank is not sitting all the way down. the motor needs to be dropped an inch, because it is actually sitting on the motor mount brackets in the front. if you cut those brackets the motor should tilt and drop down quite a bit. also under the motor the two little bars that have the skid plate mounts need to be removed because they are also preventing the motor from going all the way down. if you need just a little bit more clearance you may be able to heat up the bottom of the gas tank and re-mold it a bit to make it fit.

this is not the mod for beginners, but if you have a bit of welding and fab skills it isnt that bad of a job, i have seen much worse trust me. also an xr650r exhaust system needs very little modifications if it is they style headpipe that both the headers run behind the frame rail on the xr frame as opposed to the style where one header pipe goes in front of the frame and the other behind it. another problem is oil tank. if you can fab up your own tank then you can actually use the oil lines that are on the motor. all you need to do is get some adapters from jegs and then some oil lines to run to the factory oil cooler. on the oil cooler the easiest is to just cut off the old lines at the aluminum tubing part and thread the outside of the 90 degree aluminum tube which is almost the exact same diamter for a certain thread, i cant remember the size at the moment but i have already checked it. the biggest problem to me is the carburetor which i am still working on.

Posted by: 250Renvy

quote:
Originally posted by toxicd
[B my hre atv trx450r frame for my barnumspro xr680r motor is almost complete and hope to have everything done by christmas. [/B]

Are you getting a conversion or a complete chromoly frame?

Seems like bad timing when Suzuki is supposed to have a big bore 750cc quadzilla coming out. I'm sure it'll put out much more HP than the XR motor.

What's the reason for doing these if they don't pump out big HP? I know the old XR motors were bullet proof.

Posted by: rustyATV

So you're going to allow the motor to tilt forward? I was concerned about this, which is why I opted for the 400EX frame (that, and a blown 400 was cheap)

quote:
Originally posted by toxicd
also an xr650r exhaust system needs very little modifications if it is they style headpipe that both the headers run behind the frame rail on the xr frame as opposed to the style where one header pipe goes in front of the frame and the other behind it.

I gather that you grabbed the Big Gun exhaust that was on eBay a couple of weeks ago. I was considering it as well; I had thought of modifying the XR exhaust for my 400EX hybrid, but lost track of the auction. Are you going to have to change the angle of the silencer, or just modify the mount?

quote:
Originally posted by toxicd
another problem is oil tank. if you can fab up your own tank then you can actually use the oil lines that are on the motor. all you need to do is get some adapters from jegs and then some oil lines to run to the factory oil cooler. on the oil cooler the easiest is to just cut off the old lines at the aluminum tubing part and thread the outside of the 90 degree aluminum tube which is almost the exact same diamter for a certain thread, i cant remember the size at the moment but i have already checked it. the biggest problem to me is the carburetor which i am still working on.

I'm still working on piecing my motor together (wish I had been able to find a complete one). I was considering a stock 400EX oil tank, but looking at pictures I thought it might get in the way of where I might put the radiator. Someone else here built their own "low profile" tank to fit underneath the radiator. Looked pretty nice.

Posted by: toxicd

no i bought the big gun exhaust from a guy off of thumpertalk a few months back for like $100 shipped. it is the older style that has the ceramic coated steel instead of the stainless headpipe, but when i get it finished i am going to have it re-coated. not sure exactly how i am gonna modify it but its not gonna be too hard however i decide.

also where do you plan on mounting the radiator since a 400ex doesnt come with a water cooled motor and what kind of radiator do you plan on using?

Posted by: toxicd

quote:
Originally posted by 250Renvy
Are you getting a conversion or a complete chromoly frame?

Seems like bad timing when Suzuki is supposed to have a big bore 750cc quadzilla coming out. I'm sure it'll put out much more HP than the XR motor.

What's the reason for doing these if they don't pump out big HP? I know the old XR motors were bullet proof.

i am having a complete chromoly frame built. not bad timing since all i will ride is honda, i have owned, raced and built just about every sport and racing quad ever made and i prefer honda's. yes i could have easily gotten a raptor, or 700xx, or waited for something else to come out, but this is more to my liking and i prefer to have something different.

also i doubt it will be putting out more hp then my motor. i dont know who told you they dont put out big HP, but they can defenitely be made to do so. the problem is nobody really makes any kinds of stroker kits or anything for the xr650r motors which is why you dont hear too much about them. I have done some talking with falicon and we discussed making a 6-9mm stroker crank for my bike which they calculated would be making upward to 100hp on my motor if i could find a big enough carburetor. also i would have to get a custom piston cut which isnt to bad exchept i would have to buy a minimum of 4. all the mods to make the crank work would cost around $4k which i dont feel is worth it at the moment. right now we expect to get close to 80hp on pump gas which isnt shabby. only thing i would like to have done different is to use the 700xx motor with the fuel injection but i am not sure if it will work with the way the drive output is setup, not to mention im sure it would cost a fortune to get that motor new.

Posted by: XR650

Good talk going on here, I like to hear of honda 650 conversion stuff, home-made rides are always the best, now throw some paddles on that beast and let's line up in the sand one day and see what them water-cooled 650's are made of, I'm sure it will run well.
You mentioned quite a bit of $ for stroker crank and 1-off piston, not so...

A honda 650 stroker can be done for around 5-600$ and CP will make a 1-off piston for the stroker, (1 by itself and not 4), for around $350

You also mentioned trouble with your carb set-up clearance and so on, you just have to make a few things from scratch and put intake, carb, snorkle, etc. where you want them, not where they used to be...

I know this won't help you , but just for grins here is a pic of my carb & snorkle set-up on my 760ex

Posted by: toxicd

now that is awesome. does the 650l come stock with dual carbs or did you fabricate your own intake??? i didnt even think about dual carbs but that may be an option if i could get them to fit. what are those air boots (snorkles) off of?? also where did you have your crank work done?? if i could do everything for under $2k i may go ahead and stroke it to get the maximum cc' and hp out of it. the guy said he believes 100hp is possible but i have my doubts as that would be almost double of what the factory numbers are, but then again the 650 is a beast of a motor so i guess anything is possible. i already have plans to have the flywheel lightened significantly but i was wondering if it is possible to do a counterbalancer modification to lighten the rotating mass freeing up some horsepower??

honestly this is my first real go around with a 4-stroke bike motor with this much modification so i am still learning. i have built many before but never experimented with the things i am thinking about doing with this one.

Posted by: rustyATV

quote:
Originally posted by toxicd
no i bought the big gun exhaust from a guy off of thumpertalk a few months back for like $100 shipped. it is the older style that has the ceramic coated steel instead of the stainless headpipe, but when i get it finished i am going to have it re-coated. not sure exactly how i am gonna modify it but its not gonna be too hard however i decide.

A friend and I were thinking we could get away with cutting out and rewelding back in sections of pipe as wedges, like custom two stroke pipes. I'm a little way from thinking of that, though.

quote:
Originally posted by toxicd
also where do you plan on mounting the radiator since a 400ex doesnt come with a water cooled motor and what kind of radiator do you plan on using?

I haven't gotten to that point, yet, but I've got a pic on an XR/400EX Hybrid that was posted on here a little while ago that looked as if they cut and re-welded the frame to be like a 250R's frame up front. I don't think I'll remove any tubes, but I do want to try to add a vertical member like the Roll Design Lobo II frames, so there isn't such a long length of tube for the upper members.

For a radiator, I had my eye on the Afco 250R radiator, but finding one reasonably priced will be a challenge.

quote:
Originally posted by 250Renvy
What's the reason for doing these if they don't pump out big HP? I know the old XR motors were bullet proof.

The numbers I've seen go something like this for the XR650R:

45hp - Showroom stock ("corked")
55hp - "Uncorked" ( intake boot, silencer drilling, intake mod, etc)
65hp - "Uncorked" + HRC kit.

Also, the XR650R is geared internally for the bike to hit 105mph; not sure what the 700XX or the Quadzilla are supposed to do.

Anyway, having the most powerful quad you can make isn't the point I'm trying to make with my hybrid, it's more just to do it.

Besides, there's always things I can add, like this:
http://www.aerocharger.com/

Posted by: toxicd

you are right, it will be a very hard challenge to find an aftermarket radiator for under $200. i have a spare factory one i will sell you cheap if your interested.

you are going to have to cut and re-shape the pipe where it goes past the frame anyways i believe, you may want to bolt the headpipe to the motor once it is in the frame, the bring it to a muffler shop and have them fab it up before you paint or powdercoat your frame. dont know how far along you are but remember you have to make sure the kickstarter will clear everything. i actually bought the rear brake pedal, master cylinder and resevior for an xr650r since it is designed and bent specifically to clearthe xr kick starter.

Posted by: XR650

toxicd

you have a pm

Posted by: FoxHondaRider

my dream is to make the ultimate "sleeper". Because the air cooled xr650 motor looks so similar and seems to fit so good in the 400ex frame... 65HP with an HRC kit!!! And geared for 105MPH! I will be crappin on everything and people will be scratching their heads thats for sure.

Posted by: rustyATV

quote:
Originally posted by toxicd
you are going to have to cut and re-shape the pipe where it goes past the frame anyways i believe, you may want to bolt the headpipe to the motor once it is in the frame, the bring it to a muffler shop and have them fab it up before you paint or powdercoat your frame. dont know how far along you are but remember you have to make sure the kickstarter will clear everything. i actually bought the rear brake pedal, master cylinder and resevior for an xr650r since it is designed and bent specifically to clearthe xr kick starter.

I'm still getting my motor together, but am very close to done. Then I'll place it in the frame for the first time and collect the exhaust, intake, and cooling parts. I'll also get the TIG attachment for my welder, so I can try my hand at doing the fabrication myself.

I knew there would be interferences with the kick start, but I was thinking it would mainly be with the rear fender. I've seen one XR hybrid that just rotated the kick lever forward, but I don't know how practical that ended up.

I'll keep the XR brake parts in mind. thanks!

quote:
Originally posted by FoxHondaRider
my dream is to make the ultimate "sleeper". Because the air cooled xr650 motor looks so similar and seems to fit so good in the 400ex frame... 65HP with an HRC kit!!! And geared for 105MPH! I will be crappin on everything and people will be scratching their heads thats for sure.

Keep in mind those hp estimates are for the liquid cooled XR650R

The air cooled XR650L numbers are likely going to be less impressive, but should still surprise some people.

Posted by: thebig450es

Id love to drop a 650 in my 400ex frame, cheaper in the long run for the power