hybrid project

[xtremefullbore]

I've been running through thoughts of putting a KTM 520 motor in my 2004 400ex, right now I dont have a full system exhuast so I will need that too which a good Yoshimura Tri-Oval pro series is around 615.00 but what I want to know is how much will this KTM motor project all together cost all together and how long will it take me, I was thinking probably 10 hours of good work because me and my dad put a new motor in a 1969 fastback mustang in last month and it took 11 hours to put it in..

[deathman53]

your looking at about 5-6'g's by the time you are done, cutting, welding, making intake tubes, and most importantly MAKE SURE YOU LINE UP THE MOTOR WITH THE REAR SPROCKET.

[GPracer2500]

10 hours...:p

Unless you've done one before I don't see a chance in hell of that happening. Designing and fabbing engine mounts, radiator mounts, intake, exhaust, and probably a hundred things I've never even thought of....

I've never built a hybrid, so maybe I'm off-base here; but they sure seem like more work than meets the eye.

[†2005 400ex†]

From what i have read, the problem isnt with everything you plan out, its with the stuff that goes wrong while your doing it that takes the most time.:eek:

[xtremefullbore]

well my dad is a farm equipment and truck mechanic and I am a parts salesman at a local dealer and Im 17 and my dad is 47, Im pretty sure we can do this pretty fast... and the 5-6 g's sounds a little overestimated, I was told by my boss on the phone he said he believes it can be a 2500-3500 job depending on the parts and how nice evertything is...

[slvrlakerdr08]

yea but thats prolly not counting all the little things you might want or have to buy

[theTman]

trust me
10 hours you might be able to get the frame rails cut and welded....

if you want to do it right you will take the time...not just rush it

no only do you need to do that....you are going to need full suspension in order to have the quad handle the motor, also fully gusset the frame....

[matt250r21]

It takes a long time, trust me I have built 2 YZ 426 to 250R frame hybrids, and helped a buddy do a CRF 450 hybrid. It takes forever to do it right and also costs twice what you think it will.

[ss440ex]

I have done a few yz/400ex conversions.
Now that I have it down and the kits pre made up...
Its still around 30-40hours.

Getting it completed in a weeks time is a little rough.