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View Full Version : TRX650ex, yes I did it



STILLinFRONT
01-19-2005, 10:46 AM
I have just completed my project. Stuffing a XR650L motor into a 400ex frame.
The L motor has electric start off of the dual sport bike.
I had to cut off the motor mounts, and relocate them:
http://www.imagestation.com/picture/sraid154/p83b2cecb6a3465a84e7d661b01f7885a/f5708821.jpg
Make new mounts
http://www.imagestation.com/picture/sraid154/p087342316e65649dc17cb9d91f72b0fe/f570881c.jpg http://www.imagestation.com/picture/sraid154/p990b64c81c046188f253dd17953a6388/f570880f.jpg
gusset the frame
http://www.imagestation.com/picture/sraid154/pd9d5ac8b7ed78bae17c98fe1959e3fad/f570884b.jpg
modify a 400ex exhaust
http://www.imagestation.com/picture/sraid154/pd1131d0eae784c817df0354a183f9eba/f570880c.jpg
I do my own powdercoating
http://www.imagestation.com/picture/sraid154/p61f9557cee1ac0e31fc207b6b31f062f/f5708813.jpg
Install Hot cam
http://www.imagestation.com/picture/sraid154/p7e29cf9bd90a2ec69ab2bcfbfcd5633b/f5708810.jpg
Finally done!!
http://www.imagestation.com/picture/sraid154/p3e250ef1b4c021d990b0a82d8cc526ba/f5708845.jpg
http://www.imagestation.com/picture/sraid154/p27b5145d7c2652d8c68f1b26007ba51f/f5708824.jpg
I rode it all weekend, I do need to change sprockets, 1st gear was like 25mph, it would not pull 5th

yfz450admirer
01-19-2005, 10:55 AM
Your quad looks great! That engine looks like it was made for that machine. How much did it cost to pick up a 650 engine? Did you fabricate the exhaust? Good choice on the rear tires.

STILLinFRONT
01-19-2005, 11:03 AM
It was realy hard to fit it in, I have no clearance anywhere, I even had to reshape the gas tank.
It got the motor, carb, cdi, and reg. after I powdercoated a friends quad frame.
I took a stock 400ex exhaust, cut one side off, cut both headers 1 inch shorter, repositoned it, then welded it back up.
My intention was for it to look just like a 400, until we raced!

Zingnut
01-19-2005, 12:04 PM
Very slick and very Impressive!!!

beak7707
01-19-2005, 12:07 PM
That is a sweet quad. How is the power, how do you think it will run when you get it geared right?

Tommy 17
01-19-2005, 12:16 PM
how did u reshape the gastank????:confused:


very nice conversion thou...

sled_ed 300ex
01-19-2005, 12:17 PM
thats awesome !!
realy nice work its even clean it almost looks like the 400 motor !!

im realy impressed it looks great!! :cool:

exrider360
01-19-2005, 01:00 PM
very nice job it looks stock. did you alreayd tell everyrone you ride with your doing it if you didnt dont tell them and smoke them

Jawzy
01-19-2005, 01:30 PM
Aw man you beat me to it... I still haven't found a motor. I found a bunch or 650R's. But I dont want water cooled or a kick start.

It kinda looked like it was going to be a bolt on fit to me but I guess not. What did you have to modify on the fuel tank??

STILLinFRONT
01-19-2005, 01:50 PM
The gearing was way too tall, but it easliy pick to front end off the ground. It is much faster than a stock 400, It sounds sweet. It has a very deep sound, but not much louder than a 400.
To reshape the gas tank you need a haeat gun, spray water bottle, and a teflon coated spoon.
After I drain the gas and vented the tank, I filled it with a gallon of water.
I just heated the tank slowly, pushed with the spoon, and sprayed water to cool it off, then released pressure.
It will only move 1/4 inch at a time. You need to do it slowly.
If you heat it too much, or push too hard you will tear the tank. If the tank looks "wet" you heated it too much.
My tank had no leaks when I was done

STILLinFRONT
01-19-2005, 01:53 PM
Originally posted by Jawzy

It kinda looked like it was going to be a bolt on fit to me but I guess not. What did you have to modify on the fuel tank??

I had to push the bottom up, to fit ontop the motor. I moved it about 1/2". I had to concave the rear part of the tank in, to fit around the carb. It was like 1" deep depression.

sprtrx300ex
01-19-2005, 02:15 PM
Thats sweet! About how fast does it go?

Rico
01-19-2005, 02:24 PM
Guess Harlen needs to make a 650ex forum for ya....:o

Very nice conversion....:cool:

You need ta throw an aftermarket pipe on that sucker and let it breath....:eek:

Jawzy
01-19-2005, 02:25 PM
Any issues with chain/sprokets alignment?

397ccEX
01-19-2005, 04:30 PM
That looks realy nice iits gonna be a beast once the gearings set congrads!

user101
01-19-2005, 08:44 PM
talk about a sleeper





i want one!!!!!!

STILLinFRONT
01-20-2005, 05:17 AM
I put my HMF pipe on it, it was too fricken loud. I will probably buy White Bros. silencer for it.

It was a little tricky to get chain alignment during mock up, but it was done with no further mods. I had to make my own shifter to bend around the case and come out further.

Next weekend I am going riding, If there is not too much snow, I will use my GPS and find out the top speed.

Cody_300ex
01-20-2005, 01:03 PM
Nice conversion man! Very slick. At a quick look nobody would think it was a 650L hybird! Looks like you need some suspension work tho!

JDiablo
01-20-2005, 01:11 PM
wow even with a quiet core you think the HMF is still loud?i bet that thing will be alot more powerful with it,but its up to you man,nice looking sleeper,and def need to get some suspension componets on er

parkers30
01-20-2005, 03:22 PM
definitely need a better exhaust, maybe even make something up custom

BUILT TO RIDE
01-20-2005, 05:48 PM
All I have to say is nice work man. That thing looks like a stock 400ex at first. Are you going to do suspension mods?

TheFontMaster
01-20-2005, 06:35 PM
WOW that is a really clean motor swap you did there. When you are on it and your legs are somewhat covering up the motor, I bet most people won't even notice that its a 650 engine.

muddy400EX
01-20-2005, 08:43 PM
saaaawweeeeet! you definately need exhaust on it though. i bet that HMF sounds awesome:eek2:

STILLinFRONT
01-21-2005, 05:32 AM
Suspension:
For the rear, I have an adjustable Durablue shock linkage, to lower the height about 2 inches with stock shock.
For the front, during build up, I cut the top shock mounts off, and raised them 3/4", which lowers the front 1.5".
There is no problem if you know how to weld, I did this to my other frame also, which I race with.

This quad sits about 2" lower than stock. It feels more like a 250R now.

2001400exrider
01-21-2005, 07:22 PM
that is sooooo sweet!!:devil: you are the first person ive seen do that conversion! is there any motors that do fit in the ex frame with mounts messed around with?

Mxjunkie
01-22-2005, 01:26 AM
thats one badass sleeper, looks like a 400ex motor :D

good job excellent swap

Hon300ex
01-22-2005, 07:13 PM
That looks really good. Ive never heard of that before. That would be an awesome sleeper. What kind of back tires do you have. What are they best used for?

BassGin3
01-25-2005, 12:22 PM
wow, definately a sweet bike. Nice job!

wilkin250r
01-25-2005, 03:22 PM
Whats the estimated HP of a XR650L motor?

sickmojave
01-25-2005, 04:09 PM
Look Honda!!!! it's not that hard..GIT-R-DONE...:devil:

blue416ex
02-18-2005, 07:32 PM
this has got to be the number one all time BEST sleeper ive ever seen it looks BONESTOCK :eek2: its amazingly clean nice build good luck with that sleeping monster but once you get it breathing it will really haul *****

clutt225
02-18-2005, 08:07 PM
that is ah wow

STILLinFRONT
08-04-2005, 05:27 AM
This quad is now for sale.
Conact me or view the classifieds

murrays400ex
08-04-2005, 07:56 AM
that thing is going to be a beast i thought a 465 kit with a new cyclenders big but damn man.....ways alot though doesnt it

Quadworks
08-04-2005, 08:09 AM
Looks good! Even at a great price! You shouldn't have any problem selling it.

STILLinFRONT
08-05-2005, 01:19 PM
I am asking $3800 with a bunch of extras,
If you cannot afford that, we can negotiate with the extras.

08-05-2005, 01:40 PM
you have a pm

2001300exguy
08-06-2005, 04:50 PM
how hot does that thing get it doesnt look like it has any type of oil cooler

STILLinFRONT
08-12-2005, 01:42 PM
Take a closer look, it uses a stock 400ex oil cooler and resivoir. It does not get hot.

STILLinFRONT
08-12-2005, 01:43 PM
Still for sale.....


I am reducing my price to $3500.
That's it to get this sweet bike. I want to get rid of it soon.
I am not interested in trading

yamaharaptor350
08-12-2005, 03:17 PM
hp and top speed???? thing is soo sick

UglyMotha™
08-12-2005, 07:25 PM
there's a 400ex frame with with a 650 engine in her setting in my garage as we speak grinding and welding starts tomorow :devil:

STILLinFRONT
08-13-2005, 05:20 PM
HP is somewhere in the 30's
Top speed is around 72 mph.
I have the gearing set for trail riding. It will pull the front end up in 4th gear.

sled_ed 300ex
08-13-2005, 06:30 PM
i put the front end up in 5th on my 300ex with 13 hp!!!!!!

its still impressive cuz the swing arm is longer and you did a rely good job on the fram and stuff it looks stock!!:eek2:

zeppelin
08-14-2005, 07:59 AM
i think the 650 would put out more than 30hp, the 400 puts out 28 ill go check it out

EDIT: this one is just with simple restrictions removed but still stock and it says it has 61 so im guessing with a little more hp loss ant the rear wheels because of the quad you have around 55 :eek2: http://www.mcnews.com.au/Testing/hondaxr650test.htm

Kansas T
08-14-2005, 01:13 PM
Originally posted by zeppelin
i think the 650 would put out more than 30hp, the 400 puts out 28 ill go check it out

EDIT: this one is just with simple restrictions removed but still stock and it says it has 61 so im guessing with a little more hp loss ant the rear wheels because of the quad you have around 55 :eek2: http://www.mcnews.com.au/Testing/hondaxr650test.htm

That's a XR650R. The quad in question is using the XR650L motor which is air cooled and puts out less power.

JRP
08-14-2005, 01:43 PM
looks good man... very nice job.

Rocco
08-29-2005, 08:22 PM
Dude that things sick!!! Thats like the best conversion i've ever seen. I bet in trails you don't even go into 2nd.

nicktrx400ex
05-21-2006, 04:52 PM
why are you trying to sell it? it should go real fast

sled_ed 300ex
05-21-2006, 05:15 PM
dude the post is like 8 months old !!!!

GPracer2500
05-22-2006, 12:13 PM
Nice build--I like it!

A stock(ish) XR650L is similarly lazy as a stock 400EX--just more displacement. Stock XR650L engine is LOW compression (as in 8.3:1 folks!) with a mild cam and they put around 35hp to the ground. That's a healthy improvement over the 400 engine...not to mention loads of torque on the bottom.

Now, up that compression to maybe 10.5:1, fit an Edelbrock or (better yet) an FCR, throw in a cam, get her all tuned up and you'd really have something. [not to take away from what it is in stock form though...I like it as is]

05-22-2006, 02:42 PM
I agree a bigger piston and a hot cam will make this think just flat out rip.. I wouldnt want to meet it at the drag races :scary: .. What kind of exhuast did you add to ur atv?

400exowner
05-22-2006, 07:26 PM
Did i paint ur exhaust?

trx400EXtreme
05-22-2006, 07:46 PM
SWEEEEEET!!!

400exowner
05-23-2006, 08:10 AM
Can u paint an exhaust without it burnin off?

Halter
05-23-2006, 08:32 AM
U can get High Degree paint.....stands up to like 1200* F or somthing

400exowner
05-23-2006, 12:02 PM
Where can i get it?

05-23-2006, 02:58 PM
the high degree paint does not work. It chips and starts to melt in about 1 month, The temperature changes kill that paint, cooling from 90 to 60 back to 90 hurts that paint it wont last. And then the heat of the exhuast without the sun shining on it also doesent help.. exhuast are WAY hotter then 90 after a 3 hour ride

DieselBoy
05-23-2006, 03:14 PM
did you ever sort out the gearing issue? you said it was too tall, does that mean you have to ride the clutch alot?

400exowner
05-24-2006, 07:51 AM
So is there nething i can do for my rusted exhaust besides buying a new one? and i only need to paint my silencer

PismoLocal
05-24-2006, 10:33 AM
go to the forum called BK Performance and ask pappy what he can do with your silencer. Once your in that forum you can click on the thread titled WB e-series and look at pics of my exhaust that he is refurbishing. Pappy could probably ceramic coat your exhaust and powder coat your can for under $200.

400exowner
05-24-2006, 07:24 PM
Thanx

Tecate
12-12-2006, 04:34 PM
Old thread but still cool to people like me that just found it.

Curious to know if you can pull the sparkplugs while the motor is in the frame or even with the plastic/gas tank still on? What about changing oil filters? Did you ever figure out the gearing?

I plan to start this same project sometime in the new year. Finishing up my KX500 motor into trike swap at present.

xben719
12-12-2006, 05:59 PM
Hey tecate, good find man. I was just daydreaming about this quad today. I bet that thing can lug you up any hill without even breaking a sweat. They say the horsepower is similar to a 400ex but the torque has got to be amazing! I bet it feels close to a raptor but i would say that the honda is way more reliable. There is rumors of honda making something like this but nothing ever happens. If they do make it I hope that it is closer in size to a 400ex than a top heavy raptor.

Tecate
12-13-2006, 04:39 AM
This thing would be a great woods machine and thats what I want. Something for fast technical trails other then my main ride. :macho

charles ford
12-15-2006, 09:29 PM
great job on that build.!! Hey what did you do the gearing did you change the front or rear.??? I'm building a TRX650L right now. I have a 01 400ex and I'm putting a NX-650 in it's the same as a XR-650L motor. I've cut my motor mounts and I'm trying to get the rear end lined up. my swing arm bolt is stuck in the 400s frame so I will be needing a new one before I can go on as I'll have to cut it out. I bought a front head pipe from a xr650l and it looks stock the motor is sitting in the frame and looks very nice. I have a extra frame and plan on selling the extras. how did you hook up the oil lines coming from the motor to the tank and cooler. how hard was that rear motor mount to make do you have any other photo's of it.?? I built a 500x and it had lots of mud slinging power put I came across this motor so I sold it to start this. it was my dream for about ten years.now I'm very close to having my TRX650L KONG will live soon.!! I would love to put this on my quad but I don't want them to know what it is.let me know if you can help.I seen one for sale two years ago in Toledo for $2,500.00. I can't belive how much they want for a swing arm bolt. anyone got an extra one lieing around.??

STILLinFRONT
12-18-2006, 10:00 AM
I had to change front and rear gears. I think I used 13/41.
Stock XR exhaust is too restictive, go aftermarket header.
I used a stock 400ex header, cut and welded it to fit, so it looked just like a 400ex.
I can send you a bunch of picks if I had your email.
You can find what you need on Ebay for cheap!

charles ford
12-18-2006, 02:45 PM
charliekat@eriecoast.com 440-322-6478 or my cell is
440 864-0743 I got the swing arm bolt off and have the chain on so I can line the motor up to make the motor mounts. I'm thinking of cutting the bottom back motor mount off the motor as I think it will let it set better in the frame. how did you get the oil tank to hook up to the xr650l oil line.?? did you make the spacer in the swing arm one piece. I would like to put one shaft through the swing arm and a bigger one over it to weld the mount to coming from the back of the motor. I want to us the stock pipes I have so if I don't like it I will sell it on e-bay. why did you sell yours or did you change your mind.??
Thanks Chas

12-19-2006, 11:41 AM
what year motor?

charles ford
12-19-2006, 12:22 PM
The motor is a 1988 honda NX-650 Dominator. it looks just like the xr650l motors. I only have the wiring harness and the motor for the NX. I have a front header pipe,wiring harness, cdi, rectifer, fuse box,and I would like to get the starter switch and soliond from a 93 honda XR650L (or close to that year). my buddy is really good with wiring so he said he would go over what I have. I also have the complete system from the 400ex as I've seen my buddy put cdi's from suzukis to yamahas. I would rather get the whole system from a NX650 but they are hard to find even on e-bay. let me know if you can help.
Thanks Chas

STILLinFRONT
12-20-2006, 05:31 AM
OIl lines,
I cut the 650 and the 400ex line, then brazed them together.
I used both rear motor mounts for my engine mounting bracket, see pics I sent you.

I sold it because it had the same power as a Raptor, and was the same weight, it felt just like raptor, so it was not that unique. So I sold it and moved onto a more extavogant project. I do a project every other year.

STILLinFRONT
12-20-2006, 05:47 AM
The was the project I did after that 650.
It was buget racer, I built this for less that 1500, most was bought on Ebay.

charles ford
12-20-2006, 07:14 AM
you have a gift in building awsome bikes. thats what honda should be making. looking at your carb boot on the xr650l motor. the ones from the NX650 go straight back and are longer. more in line with the air box. I took my wiring w/the dieagrams over to my buddys and he said the wiring would be a piece of cake. he asked what I was waiting for. my goal is to build this for under $1200.00. I'm not a racer just a dad that likes hills and lots of mud.!!! a guy down the road built a 2 stroke ktm four wheeler and has $15,000.00 in it. that's way to rich for my blood I could build a lot of bikes for that. I need to get the motor mounts and oil lines hook up plus build the exhaust. you should make a pattern for those motor mounts and sell a kit.(e-bay,on this site) you could hook the motor up and would only have to remove the top motor mounts and reweld them on the frame.just a thought.
I would glady give you $50.00 for a set of them. I going to try and use the 400ex carb if I can rejet it. my buddy said he has some srockets and carbs to try on it.
Thanks Chas

Tecate
12-20-2006, 07:55 AM
Originally posted by STILLinFRONT
The was the project I did after that 650.
It was buget racer, I built this for less that 1500, most was bought on Ebay.


What are the details on that black bike? Its real mean looking.

STILLinFRONT
12-21-2006, 05:30 AM
2002 400ex
It was mostly stock parts, I powdercoated everything.
Alum. airbox
LSR axle
Hot cam stge 1
HMF exhaust
maier plastic
450r front shocks
no headlight, custom wiring harness.
It weighed 365 lbs with 1 gal of gas.
Top speed was 70mph

charles ford
12-21-2006, 07:10 AM
do you have a manual for the XR650L motor. if so can you look at the gearing for the motor. I want to see if the gears are the same from the NX to the XR. mine says.
Gear ratio 1 is 2.666 (32/12)
Gear ratio 2 is 1.750 (28/16)
Gear ratio 3 is 1.250 (25/20)
Gear ratio 4 is 1.000 (23/23)
Gear ratio 5 is 0.840 (21/25)
primary driven 2.029 (69/34)
final reduction 3.000 (45/15)

I got the spacer made for the swing arm and it looks stock. I bought some metal to make my mounts and I plan on painting them black for now there is a guy at work that powder coats and I'll check him out this summer.
Chas

thumper169
01-21-2007, 10:45 AM
hey, you should try a clutch basket from a 600 xr and crank gear. this will lower the primary drive a little. i have a xr600 in my 400ex and run 14 37 with stock tires. it rides wheelies by 450s! hope this helps

JW450R1
01-22-2007, 05:34 PM
that thing must really rip.did u sell it or what

charles ford
01-23-2007, 09:14 AM
I have a new e-mail it's charliekat@oh.rr.com 440-864-0743
I ordered a skid plate and air scoops for my TRX650EX KONG I'm going to see if I can have stickers made for it. I hope to ride it this weekend I was waiting on a chain cover and it came yesterday. I need to work on the gearing and jetting. I hope to get a photo of it when I'm done.
Chas

Ebrown
01-23-2007, 09:55 AM
great job, i think it looks really good

hillbillydeluks
01-23-2007, 11:12 AM
that is a total sleeper quad man nice job. when you get it geared right and ridin right tell us how the balance is ie doing wheelies, jumping

STILLinFRONT
01-23-2007, 02:34 PM
yes i sold it.
somebody saw it and offered me a bunch of money.
It pretty rare if you buy/build a quad , ride it for a year, then sell it for profit!!!!!!!!

kalebarellano
01-23-2007, 08:44 PM
How do you do your own powder coating? Did you make a oven large enough for a frame?

STILLinFRONT
01-24-2007, 09:53 AM
My dad's business has a few big ovens that they do not use. I just go in there on the weekends, and do my powdercoating. You can powdercoat real cheap with an electric range. Large ovens are quite expensive. You can get the powder and gun real cheap from Eastwood.

kalebarellano
01-24-2007, 10:29 AM
Just put the parts over the range? Dont they need to stay at about 450 for 20min? Wouldn't this take forever using a range?

STILLinFRONT
01-25-2007, 06:11 AM
No, You put them inside the oven. You need to bake most powders @400 for 20min.
Therefore, you only can coat parts that will fit inside your oven.
You could make an oven big enough for a frame, but once you tally all the cost, it would be cheaper to have a company do it.
Most places would charge 250-300 to sandblast and coat.
Do it yourself:
gun and powder $150
sandblast$75
working oven and coversion:$300+

kalebarellano
01-25-2007, 09:21 AM
Ya, I have been looking into this:
http://machinebuilders.net/plans/gallery%2FBig%20Kids%2FPowerCoat%20Oven1.pdf

It would be cool to be able to coat whatever you want. I think I could get alot of the parts need for free, but it would still cost a few hundred.

weedo0o1986
01-25-2007, 08:00 PM
so could i get the powdercoating spray it on, nd go stick it in my moms oven at 400* for 20 mins and have it turn out fine

thumper169
01-26-2007, 12:39 AM
i wouldnt recommend using your moms oven for cooking up chemicals. a retired oven from preparing food would be better.

derocha11
08-22-2008, 08:49 PM
i now have this quad i bought it for $450 it now has 450r plastics and brand new tires and rims the stator went on me so i need to get a new one anyone know where i can get a cheap one from

Yippie-Ki-Yay
08-22-2008, 08:54 PM
Think you could post up some pics, the ones on the original post arent showin up.

justin1022
08-22-2008, 09:15 PM
Originally posted by Yippie-Ki-Yay
Think you could post up some pics, the ones on the original post arent showin up. \


ya can you re post those pictures?

08-22-2008, 09:23 PM
this is the type of hybrid i plan on doing either if I grenade my motor or I buy another frame. Preferably the new frame to make a project quad