[250r/400ex hybrid...] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs

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250r/400ex hybrid...
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Posted by: jcs003

i am in the begining of a hybrid consisting of a 400ex chassis and a 1986 250r engine. i had some stock parts left from my 1999 400ex build up throughout the years, along with a couple extra 86 250r motors i acquired after the purchase of my 250r in 2002.(i think it was '02.lol)

anyways, i will have pics of mediocore quality(cell, no digital). i hope to answer questions and maybe get some help if needed.

Posted by: jcs003

here is a side view:

Posted by: jcs003

other side: you can see i used two right side 400ex mounts and removed a section from each to clear cases.

Posted by: jcs003

the radiator has been modded to allow better access to filler neck. the outlets were switched to the opposite side in the same location. now the filler is on the left.

Posted by: jcs003

another view of radiator:

Posted by: jcs003

some random pics:

Posted by: jcs003

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Posted by: jcs003

the ESR TRX-6 pipe. needs rechromed. the mid pipe will need an inch section cut out and rewelded to clear the inner tie-rod end.

Posted by: jcs003

zoom. the pic may be decieving but there is no interference issues with the a-arms throughout the travel.

Posted by: jcs003

closer pic of left side motor mount:

Posted by: jcs003

random:

Posted by: jcs003

the actual motor that will be installed in the finished product. i did some polishing.

Posted by: jcs003

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Posted by: honda400-4-ever

check this out it might help a bit!!!http://www.servicehonda.com/service.html

Posted by: jcs003

quote:
Originally posted by honda400-4-ever
check this out it might help a bit!!!http://www.servicehonda.com/service.html

thanks, i seen that. it is what actually inspired me.

Posted by: DMC-4OOEX

Awesome man! Gonna be cool when its done.

Posted by: jcs003

here is the radiator mounted: tell me what you think. is it offset badly...will it get in the way of the fenders...etc.

Posted by: jcs003

more:

Posted by: jcs003

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Posted by: michaelopfer

wow, that radiator is smart, did you do that your self, how did you fill in the original holes and how did you weld the tubes on the otherside. my exr hybrid radiator also runs really close to to the pipe, but i have not expeirienced any issues conserning overheating or melting the hose. but nice clean way to get everything spred out and not so cluttered. can't wait to see it finished

Posted by: jcs003

i just used aluminum plugs and built up the weld/ for the other side, i used a hole saw the size of the outlets and then just welded them on. took it to a radiator shop to test it and that was it.

im not sure i can run the hoses to the opposite sides yet, but either way its not a serious issue.

Posted by: jcs003

UPDATE: got motor mounts welded and refinished some parts.

**COMMENTS APPRECIATED**

Posted by: jcs003

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Posted by: born2ride14

Looks Awsome, Just get a yfz radiator, that one is too big

Posted by: jcs003

quote:
Originally posted by 300maniac
Looks Awsome, Just get a yfz radiator, that one is too big

thanks...it fits well actually. i offset it on the other side of the rails since the pic was took so it will be more centered when reassembled.

Posted by: jcs003

sandblasted and painted frame with PJ1 frame paint, then went over with three more of acrylic clear to better simulate powdercoat. saved around $150. lets just see how it holds up.

Posted by: jcs003

another:

Posted by: jcs003

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Posted by: jcs003

updates:

Posted by: jcs003

got the ESR fit beautifully.

Posted by: jcs003

from this pic you can see the V-spike pegs which are well made, but the powdercoat is terrible. i may chrome them.

Posted by: jcs003

you can see my CDI mount which is very solid and saved in the need to weld them on.

Posted by: michaelopfer

so,, as for the exhaust... u think a quadzilla, lt250r or blaster expansion chamber would fit on the front of the 250r motor.. it's an idea i have been thinkin about for a while now, but don't know if the diameter of the exhaust port would match up.. but the bends look better suited for the 400 frame then the actual 250r pipe... mabey an atc pipe if a guy could clear the front motor mounts... what you think..

Posted by: jcs003

quote:
Originally posted by michaelopfer
so,, as for the exhaust... u think a quadzilla, lt250r or blaster expansion chamber would fit on the front of the 250r motor.. it's an idea i have been thinkin about for a while now, but don't know if the diameter of the exhaust port would match up.. but the bends look better suited for the 400 frame then the actual 250r pipe... mabey an atc pipe if a guy could clear the front motor mounts... what you think..

i used a ESR trx6 and cut out 1" from the header section and welded it back together.

Posted by: michaelopfer

so was it a perfect fit after you cut it or did you still have to muscle it in to fit... did you cut after the springs or rite at the edge,,(pics please)...

do you have this beast close to bein done yet,, you've been taken a while on this..

heres mine after i got done rebuilding it a 2nd time,,(polishing, greasing, and moved the radiator a hair so i could open the cap

Posted by: michaelopfer

2. also,, in your pic with the esr silencer, I needed a spacer so the silencer didn't hit the top of rear brake caliper. I used my old white bros e series spacer for that

Posted by: jcs003

i am basically done. i just ran short on money for fenders and wheels and tires.

michaelopfer: i did not use a spacer for the reason i cut about an inch of the other end of the pipe. i think some call it the "stinger". i used a yz400 caliper on my hybrid.and it sits differently than the ex one.

how did you do your intake?

did you use the 400ex rear shock?

will try and get updated pics.

Posted by: michaelopfer

i used the stock 400ex one.. and i have a works remote ressie and moved the hose to the other side..so it would fit,
i was thinkin of geting a cr intake boot and reed cage to move the carb closer to the cylinder to get the carb further away from the frame to make it fit better.

Posted by: michaelopfer

2

Posted by: michaelopfer

you should post some updated pics....

Posted by: jcs003

i need to get access to a digital camera. i borrowed one for the original pics.