TRX90 front end conversion

[dirttrack71]

Well here it is

[bracey]

looks good who a-arm set up is that thanks

[dj250r]

looks like the one iv seen on ebay well dose it work as good as it looks ?


Dwayne

[dirttrack71]

Yes that is the kit off of ebay. Those are stock 300ex a arms. The width is 45.5 inches. It works great but not without some extra support that I had to design and fabricate myself. Sunday is the first race on this setup. I can tell you now that he is on average 5 seconds a lap faster with this setup in practice. Oh yea I allmost forgot this thing will stop on a dime with the new brakes.

[dj250r]

sweet
did you do anything to the rear ?
Dwayne

[wvspeedfreak]

Looks good.I like it!!

[dirttrack71]

We are running a front shock from a 300ex on the rear. It is just like riding a 300ex without power.

[dirttrack71]

Well he raced today and finished 1 and 1. The racing was awesome. He was running side by side with a 2006 TRX90. It is clearly faster in stock form but the handeling made all the difference between 1st and 2nd. Now what to do to the motor? In the class he will be running we cant change pipes but can overbore. What if I went with a 107 kit, K&N, jetting, and a CDI box?

[smokinwrench]

Originally posted by dirttrack71
It works great but not without some extra support that I had to design and fabricate myself.

I think I'm going to get one of these. What is the bracket you had to fabricate?

Does the extra wieght up front make the front end dive when jumping? Can the front end even come off the ground with this kit? Any bad effects from this kit?

Thanks

[dirttrack71]

I didnt notice any front end dive. It is a 100% better in my opinion. The little bumps on the stock setup would beat the heck out of you. When my son was bounced off his quad at speed last year my wife said no more of that. The extra weight is a small sacrifice. The other day at the races he was coming up short on a double and the suspension ate it up with no problem. Last year he would have been thrown off.

[Pappy]

cleaned this thread back up, removed the BS and sales pitch


dirttrack71, keep us posted on how it all works out for ya, i didnt mean for my personal observations to lead to a 4 pages cry baby fest over this versus that!

Yep!sorry it turned ugly 'that was not what I posted my reply for . So let them know how this works so maybe others can know to.:blah:

[smokinwrench]

I should be getting my kit any day now. It will be a little while before I get all the 300ex parts bought up. We are not serious racer type people, so I don't see my boy getting tons of air with his quad. It would just be nice to get soem better suspension for dune riding.

[chapmanmd]

What 300ex parts do you need? I have a pile of good stuff off of our 04

[DSP Dave]

Hey Guys,
I Have found and bought all the parts to do this conversion on my sons TRX90. The only thing I am lacking is one more front shock off of a TRX300 if anyone has one for sale let me know.
Also I would be interested to hear how this upgrade is working for the guys that have done it.
Thanks

[smokinwrench]

I just sent the kit and a arms off to the powder coater this morning. I have everything bought and ready to install. I am using a blaster front shock on the rear, I have takin a die grinder with a carbide bit to it to shock tension ring. I ate out about a 1/4 inch of area to give it less recoil. I even bought 300ex rear hubs I hope they will fit the stock axle.

[DSP Dave]

smokinwrench
Thanks for the info, let me know if the rear hubs work thats a good idea!!

[chapmanmd]

Unfortunately, the 300ex rear hubs wont fit the 90 axle. Sorry to be the bearer of bad news...

If youre just looking for a 4/110 bolt pattern on your TRX90 and you dont want to go all out for custom billet hubs or converting your entire rear end to disk brakes from a 300/400 Honda or Banshee, then use the Eton Viper 90 rear hubs. They'll bolt right on to the stock or Durablue axle and give you the 4/110 bolt pattern.

I know that Robb's Racing and Hetrick Racing both have WAY COOL rear swingarm/axle/disk brake setups that are definitely sweet.

Good Luck!!!

[dj250r]

im still collecting parts for this TRX build im still lookin for a set of arms i have the hubs spindles and brakes
but as far as rear hubs you can use Kasea hubs and it will widen out the rear a little
Dwayne

[chapmanmd]

Crap Dwayne!!!

I forgot all about you on those arms.

I apologize and will get them out.

[DSP Dave]

I found the shock I was looking for, I had to buy a pair but I got a good deal. So if anyone else is doing this conversion and needs one more front 300ex shock(which is what the kit calls for on the rear)let me know because I will have one left over. Also anyone considering doing this kit just to let you know he claims on his website to have found all the parts to do the conversion for around $350-$400. I have been hunting down these parts on ebay for a month now and have finally found them all and got them at a pretty good deal, but I am going to have about $850-$900 in this conversion and that doesn't include the wheels and tires or shipping of all these parts! Don't get me wrong I am not complaining I think this is going to be a great upgrade for the TRX90 and well worth the money, I am just letting people know what it ended up costing me so they will know if they are considering doing this.
Thanks!

[smokinwrench]

I must be having better luck finding cheap parts.

front holeshots douglas blue labels: $87 shipped
a arms, spindles, calipers, hubs, $190 shipped
tie rods, master cylinder, brake lines, 300ex rear hubs, $155 shipped

I'm sure I will still need a few odds and ends. I know I need brake pads.

I hope to get it all assembled by the end of the month.

[DSP Dave]

Here is where I am so far:

Tie rods W/ends=$30.00 +$13.00 shipping

pair of 300ex front shocks=$36.00+$18.54 shipping

left brake caliper=$24.50
right brake caliper=$29.00
master cylinder w/brake lines=$20.50
shipping=$13.95

upper and lower a-arms=$124.99
spindles=$24.99
hubs=$44.99
pair of 300ex front shocks=$159.99
rotors=$44.99
spindle nuts=$6.99
shipping=$52.00

dual a-arm conversion kit=$159.99
rear wheel conversion kit=$49.99
shipping=$30.00

I already had brand new wheels off a 400ex =$0.00

Total=$883.91

A couple of the items I paid too much for but they were brand new take offs, so I know they will be good. I am sure there will be some odds and ends that I have forgotten.

Smokinwrench
man you got some great deals on that stuff, did you get it off ebay?

[smokinwrench]

I got most of it right off this site.

I got a killer deal on the a arms, shocks, brakes, spindles, calipers, hubs.

Live2Ride300 on this site told me he had everything else I needed. His website and prices are great. Super fast shipping.



Not to mention all the parts are getting powder coated for the right price also.

[DSP Dave]

Man just checked out that site and he has some great deals!!
Thanks,

[WOLFPACK]

Originally posted by dirttrack71
Well he raced today and finished 1 and 1. The racing was awesome. He was running side by side with a 2006 TRX90. It is clearly faster in stock form but the handeling made all the difference between 1st and 2nd. Now what to do to the motor? In the class he will be running we cant change pipes but can overbore. What if I went with a 107 kit, K&N, jetting, and a CDI box? Over the winter we built a 125 cylinder ( Actually 122.6) and found we could take it to a 138 but chose to stay at the 125 area. This wasn't to terribly expensive. The advantage of putting it all in the cylinder is the bottom end holds together better.

[dj250r]

Originally posted by chapmanmd
Crap Dwayne!!!

I forgot all about you on those arms.

I apologize and will get them out.
lol
dont sweat it im in no big hurry:D
Dwayne

[dj250r]

what do you do to get the 125cc or so all in the top end or for that matter 138cc building the wife a bike to play on
she liked it stock but said it needed more of a kick to it :)
Dwayne

[SeanOO13]

how much for the 300ex shock?:confused: :devil:

[DSP Dave]

$50.00 plus shipping for the shock
Thanks,

[SeanOO13]

whre do i get the shock?:chinese:

[DSP Dave]

Just send me an e-mail with your address and I will send it out!
Thanks,

[WOLFPACK]

Originally posted by dj250r
what do you do to get the 125cc or so all in the top end or for that matter 138cc building the wife a bike to play on
she liked it stock but said it needed more of a kick to it :)
Dwayne It involves sleeving and boring the cases. You don't want to spend this kind of money if it is only for play. You would be much better off getting a Liflan or some other china motor. We do this because of the ATVA rules. You can find those motors all over EBAY or at Beatrice.

[dj250r]

ok now
what kind of money are you talkin
?
i strip the motor down to the cases have it bored to except the new cylinder?
and stroke it to 54 mm
so what are you in it
case boring,cylinder ,head crank?
This aint my 1st rodeo lol:D
Dwayne

[SeanOO13]

dose the stock 300 front shock fit on the stock swinger of a trx 90 if so i am interested in it cause i am doing a build now for my brother thanxs

[DSP Dave]

It does work with the stock swingarm but you have to use the brackets that come with the front end conversion(or make your own). It bolts up in the top shock mount but at the bottom it sets back on the axel, this makes the ride height the same as the front.
Go to www.diamondjcustoms.com and download the manual for the trx90 dual a-arm conversion kit and there is pictures of how all this works.
Thanks,

[SeanOO13]

cool. :D know i need your e-mall:) :p so i can get the shock
:D :) :blah:

[DSP Dave]

seanoo13
it's dsp-builders@earthlink.net

thanks,

[DSP Dave]

Got the conversion done and it is awsome! makes a whole new machine out of theTRX90!

Before pictures:

[DSP Dave]

Before pictures:

[DSP Dave]

Before pictures: side

[DSP Dave]

After pictures: front

[DSP Dave]

After pictures: back

[DSP Dave]

After pictures: side

[SeanOO13]

my mom sead i could not get the shok:( :mad: :grr: :scary:

[dj250r]

looks sweet
cant wait till i get ours donew
Dwayne

[smokinwrench]

That looks great. I should have all my parts from the powder coater next weekend.

[DSP Dave]

Thanks guys!
It was a fun project and very simple to do. there are a few things that I had to do to make it work on the 2006 trx90 but all in all a very simple and fun project and my boy loves it!! Like someone said earlier it's like riding a 300ex with no power. It's alot of fun, I rode it for an hour when I finished it just seeing how everything is going to hold together and nothing moved or loosened. It definitely is a big improvement over stock and could probably even be better with some aftermarket shocks. It looks like a mini me of a 450r!

[smokinwrench]

Originally posted by DSP Dave
there are a few things that I had to do to make it work on the 2006 trx90

Can you tell us what you had to do to make it work on the 06. I have been wondering about enough fender clearance for the upper brackets. I want to have everything I will need to do the conversion, so I can do it all in one day.

[DSP Dave]

The only thing I really had to modify was the fender bracket. I had to cut the corner off and move it back 5/8 of an inch,drill anew hole and remount it. I then used a 5/8 spacer and an 1 1/4 inch bolt to reattach the fender to the bracket.

[smokinwrench]

DSP Dave did you just cut off the stock brake lever mount? If you bougth new bars what bend are they?

[DSP Dave]

I just used the stock Bars and cut off the lever mount. I was going to buy some new bars but I couldn't find any that would still allow me to use the cover that holds the keyswitch.
Dave

[smokinwrench]

Hey DSP Dave, I've got another question for ya. Yeah I finally got everything and started assembly this evening.

What setting did you put your rear shock at? I have moved it a couple times. The lowest setting cuases the shock to hit the battery box holder when about half compressed. If I move the shock up 1 bolt hole the shock gets in the way of the brackets. I have also left the shock in the lowest setting and moved the bracket up one hole on the mount, but that seems ot raise the rear of the quad. I'm just curious what you done.

Thanks
Josh

[DSP Dave]

I have mine on the lowest setting also and yes it does hit the battery box but it doesn't seem to hurt anything. I have jumped on it and bottemed it out and nothing has broke as of yet!

Thanks'
Dave

[smokinwrench]

I have had my front end completed for a couple weeks now. Finally got the rear widened out tonight, it is still just a bit narrower then the front.

It is a 100% improvment over the stock setup. I am 100% happy with it. I did have to add a bracket on the front he was hittign bigger jumps and bending the brackets in.

[Pappy]

We converted to a Robbs Racing suspension with Elka shocks. 20 hours on it so far, not one complaint, not even a loose bolt! :D

The travel is incredible, no issues with anything hitting, rubbing or doing anything one would expect. Full brakes sure help alot, but the complete package is what we were after, and we found it:cool:

[Pappy]

46 inches wide with 4-1 rims, I dont think you could flip it if you tried

[Pappy]

A Robbs swing arm and Elka out back work insanly well, although I can see why a titanium axle is prefered. Weight bias is not bad with this set up, but we will be testing with 18 inch snow hogs on reinforced rims to achieve better balance in the air.

[Pappy]

Now I wish I had one of them 16 hp 125 engines:p

[smokinwrench]

What is the price tag on those a arms? Can I use all my 300ex front end with them and also use the 300ex front shocks?

[Pappy]

I would have to check to see what we paid for them, they were not cheap, but usually something that works never is.


We used all 400ex parts upfront as they are a touch lighter then 300ex parts and usually in better condition, and 450R brake components in the rear. I do not see why 300EX parts would not work in the front tho.

[cdevito]

Hey I'm gonna buy the same kit for my son's. He upgreded from a 50 to the 90. I'm just not sure which width to ask for--the 41/2 or 6 in. and which rear spacers to get. Which one's did you use and what is the size of your rear tires and rims? thanks

[echorock]

hey dus the kit just come with the brackets and you need to buy the 300ex parts?or does the kit come with all the parts you need(any anser will help)thanks

[WOLFPACK]

The kit only comes with the brackets. The rest you'll have to purchase/ You can use 300EX or 400EX parts.

[echorock]

how much did the entire front end cost including you buying the parts and ordering the brackets.i also need to know where you got the 300ex parts like i mean what website did u get it from.

[smokinwrench]

I have this kit on my boys 06 trx90. I bought all of the parts on this site and ebay. It took me awhile to get everythign I needed, because I was bargain hunting.

With every part this includes widening the rear. I also got new rear rims and complete news front wheels and tires. I have right around $700 in it and that includes shipping. It is 100% better then the factory setup.

If we were serious into racing I would buy the used set up from Pappy in a heart beat, I just can't justify the cost of it for 3-4 races per year.

[Arctic Cat Dad]

I've been looking around also the dual a-arms for the Honda. We are starting to build on Mikeys 06 Honda. With the high speed and conditions it will see in the GNCC's the dual arms are the way to go. I like the Hetrick set up with Fox Float shocks. Rich says the Fox's are the way to go with this set up. The only downfall is the around 2 grand it cost.

I have some questions about this set up you folks have. How wide does it make the front. How much extra weight did you gain. Because weight robs alot of HP. I'm wanting the lightest setup I can find.Also how tuff are the supports brackets . Do they stay tight after a ruff ride for a long time.

I will say 1 thing this setup looks nice.

[smokinwrench]

Originally posted by Arctic Cat Dad


I have some questions about this set up you folks have. How wide does it make the front. How much extra weight did you gain. Because weight robs alot of HP. I'm wanting the lightest setup I can find.Also how tuff are the supports brackets . Do they stay tight after a ruff ride for a long time.

I just measured mine and took some pictures for ya. Mine is 45.5 inches wide. Yes it did add some weight, not sure how much I can set the front end on a bathroom scale if you'd like me to then compare it to your stock machine. I will say the added suspension is well worth the addition of the wieght. The brackets stay tight. I did add the center bracket because the supports were bending together because of my boy jumping. Since I added the center bracket nothign has come loose or moved and I would guess we have 30 hours on it now. My boy rides with 2-3 other kids 6-8 years old and he rides the hardest out of them, but nothign compared to you full time race guys. He will get a 2-3 feet of air under the quad on just normal weekend riding.

I work for Caterpillar so the kit isn't the quality I would like it to be. I went and got my own grade 5 bolts. YOu will have to add a bunch of washers for spacers. I would love to find a nice used set of aftermarket a arms.

I think you can go with 400ex or 450 spindles and that will save more weight.

http://img138.imageshack.us/img138/6108/dscf04191mr.jpg
http://img89.imageshack.us/img89/3339/dscf04201bd.jpg
http://img138.imageshack.us/img138/6881/dscf04217af.jpg
http://img138.imageshack.us/img138/8571/dscf04227zz.jpg
http://img138.imageshack.us/img138/2592/dscf04233ky.jpg

[WOLFPACK]

I've decided to part out the 400EX. I've been saying i'm going to get to fixing it for the past 8 months but just can't find the time.

I have the complete front end with brakes (master cylinder included), arms and spindles. Basically everything you'd need for your dual a-arm kit.

I believe $250. plus shipping for everything is a fair price. First come first serve!

Shane

[Arctic Cat Dad]

Smokinwrench, Thanks for the quick reply. Thanks for the great pictures, I was wanting to look at this setup up close. I'm gonna use 450r parts anyway,because there lighter and I can get them from some local racers who would help us. The 45.5" is too wide for the tight woods sections. Does any1 know of any1 who might make a dual setup that is just a little narrower then 45". I would like to find 1 around 41 or 42 inches. I know 3 or 4 inches doesn't sound like much but in woods racing it might as well be a foot! To be honest the stock width on the Honda is Perfect for tight woods racing,but when you throw in the 125cc engine on it it's way to much HP for the stock suspension.

[smokinwrench]

Can you just buy some of those nice +3 single a arms with elka or works shocks then get one of those long travel swing arms?

Why do you have to have a dual a arm set up? I know the dual is better but why is it a must have? Everyone that is serious about youth racing seems to have it.

[KWIK CHIX RACIN]

Originally posted by Arctic Cat Dad
Smokinwrench, Thanks for the quick reply. Thanks for the great pictures, I was wanting to look at this setup up close. I'm gonna use 450r parts anyway,because there lighter and I can get them from some local racers who would help us. The 45.5" is too wide for the tight woods sections. Does any1 know of any1 who might make a dual setup that is just a little narrower then 45". I would like to find 1 around 41 or 42 inches. I know 3 or 4 inches doesn't sound like much but in woods racing it might as well be a foot! To be honest the stock width on the Honda is Perfect for tight woods racing,but when you throw in the 125cc engine on it it's way to much HP for the stock suspension.
Call Laz at GT THUNDER. He did the front end setup for Jesi's Honda and it works gereat in GNCC. It is 43 inches wide.
GT THUNDER Phone number is 330-674-7122

[Arctic Cat Dad]

Well I did think about a good set of single arms. But the dual is the way to go. These kids are flying at a very high rate of speed thru some of the most EXTREME conditions for 1 hr. Mikey keeps it pinned the whole way and rides a quad way over the edge. And if he has the heart and talent to do so I will give him the best equipment I can get for him.This kid wants to win another National Championship and go for the overall and you have to have a combination of the best rider and equipment.

Were gonna get a Typhoon also but I don't know if it's gonna be the machine to beat. I like the Honda! And I'm 1 who takes racing very serious! He wants to put a Honda on the podium.

[ROBBSRACING]

We have an XC version of our TRX 90 duals also !

[PTMracing]

That dual A-arm set up idea is awesome!!!! Now.........when are Honda, Suzuki, Yamaha, and Kawasaki going to realize that this not only works better but is safe as well. Geeeze!!! It just seems like they are so slow......oh.......wait a minute........they let the "little man" think of it first, then build it....I see;) Kinda like the 450 machines.:D You go Robbs Racing. I hope you sell a million of these things in the mean time!!!!!!!!!!!

[Valder]

Originally posted by smokinwrench
Can you just buy some of those nice +3 single a arms with elka or works shocks then get one of those long travel swing arms?



That is what I was thinking of doing on my kids Desert Cat 90. Just getting the +3 single As, shocks and a longer swing arm. He is no racer and just rides around the fields and woods. So this would do for me as I want is a bit wider for stability.

Though that conversion looks good!

[boortz]

My boy this week installed a rear adjustable gas charged shock from a 96 KX80 on his TRX 90 and it seems to work great. it gave him some more rear travel and a lot smoother landing on the jumps. It only took him about 30 mins to do this mod.

boortz

[4strokepower]

:devil: looks bad *** man what is the average cost for that kit????

[WhiteYFZ]

looksl ike a cool setupp

[911]

Originally posted by smokinwrench
Can you just buy some of those nice +3 single a arms with elka or works shocks then get one of those long travel swing arms?

Why do you have to have a dual a arm set up? I know the dual is better but why is it a must have? Everyone that is serious about youth racing seems to have it. i have seen the +3 a-arms on a trx 90 w/ 300ex elkas and yes it is as wide and smooth as you would think BUT..... the handeling is awfull , as the wheel goes through the travel you get massive bump stear that pull the front end all over the place. so to ge the travel safely the dual setup is a must;) i'm doing it right now

[easydoesitmikey]

I'm thinking about doing this on my son's Honda 90