i'm doing the EXR hybrid!! (400ex/250r)

[j450rking]

ok so i found out alittle bit more about putting the r engine in a ex frame and from what i have been told there is no welding or frame cutting at all it's just making motor mounts and some small stuff with the exhaust so i'll be doing a full right up on it.

[accidentprone89]

hey man i built a 2001 400ex with a 89 trx 250R engine its a little more then that but ill be morer then happy to help you through it it wasa the best quad ive ever built / road im in the process of building anouther

[j450rking]

well actualy i have about an hours worth of work left on it so i'm going to start break in today. for a hybrid it was pretty easy. i didn't have to mod anything for the intake i just spun the intake tube from the airbox and ran it to the left of the shock. i didn't have to mod the exhaust bc my esr trx5 that i got has a bend in the small pipe that go's from the engine and i just had to use a spacer to space out the can bc of the bend in the 1'' peace of the exhaust makes it go out about 2 1/2'' and i just used the stock 400ex motor mount spacers. the motor mounts i used the stock 250r rear and moved the left side bushing in the swingarm to the right and cut the one that was in the right side to fit and put it in the left bc the left side needed more of a spacer than the original bushing. the front mounts i just used the stock ex ones and cut a chunk out of them to clear the engine cases. and the radiator i made some small steal brackets and mounted it to the oil tank and oil cooler tabs. i also wired in the stock 400ex light switch so i can use the starter button for a horn (it's a nice thing to have) and thats pretty much all i did as far as fab besides the small brackets i made fot the overflow bottle and i mounted it about were the battery was. i'll post pics later

[j450rking]

HERE ARE THE PICS!!!

[j450rking]

other side

[j450rking]

carb location

[j450rking]

intake route

[j450rking]

exhaust spacers

[j450rking]

as you can tell i like big ground wires:D here are the motor mounts for the front

[j450rking]

what sucks is i have it all reddy to start and i filled it with coolant and bam it all cam out the weep hole so i had to get a mech seal and it will have to wait to start till next week some time.

[Rootar]

how much clearance do you have around the front of the pipe, that frame rail, and your arms? step back a few feet and get some good side shots in the sunlight today maybe it wont look as dirty, come one man build up rule number one clean everything AS you put it together :o lol drop that frame skid and clean her up.

lit ooks like it fits together pretty good, i would take a grinder to those mounts and smooth them out where you cut into them other wise thats a pretty good stress riser in those little sharp angles and it will want to crack them right there.

[j450rking]

the front of the pipe is abot a half inch away but it wont hit. it will be clean when i have my hose back on. the monts are vary smooth now. and i am going to polish the skid bc you can see alot of it now

[born2ride14]

wayy cool man way kool

[j450rking]

YEAH IT IS. i am going to see if i can get a video when i have it done.

[j450rking]

here are some pics of it almost done

[j450rking]

right side

[j450rking]

here are some pics of my kicker exstender so my size 13 will clear the exhaust.

[j450rking]

and here are some pics of the kick lever. i used a grinder to make it have that dimond looking cut and to make the part you put your foot on better to grip and then i used super high gloss clear powdercoat to make sure she dosn't rust and make it shiny

[j450rking]

..

[j450rking]

as you can see i cut a small notch in the rear plasic so the lever wouldn't be pushed out by it.

[2muchquad]

Cool build,how does she run?You may want to drop a tooth on your counter shaft sprocket to turn those 10in rear wheels.You wont get much bottom end from your oil burner,should rip though when it "comes on the pipe".I like it;)

[j450rking]

it runs damn good and starts on the first kick but i can't run it too much with the mech seal leaking. i realized that i don't have much torque with the 14 tooth i was dumn and got it bc i'm use to 4 strokes. i am going to get a 13 and see how it is and hope i don't have to go much lower. it sounds great too i would get a video up on here but i have dial up so that aint hapenen untill i get to my grandmas (she has dsl:( ) and by then i'll have a riding video. i have to see if i can find a scale or somthing so i can see how much it weighs. i think it's around 350lb wet i lifted the front end and it didn't hurt my back! i weighed most of the parts i took off and most i put on and it droped like 60lbs just the engine itself was 100lbs from the ex and the r engine is 60lb and then the battery was like 8-10lbs and a buch of other crap like all the wireing and crap. i think the only thing from the R that was heavyer was the exhaust by a pound and a half.

[2muchquad]

Yeah im running 13/38 gearing right now on my 250r hybrid but i just picked up a 40tooth rear and i'll give that a try.It rips in the mid and up but i would like to be able to get up out of the hole and on the pipe quicker,i toast my buddy with his banshee on short drags because i have to let off because i can wind out 5th gear,he has a 6 speed:(

[Nac's22]

j450rking- did you ever adress the center motor mount like i mentioned in your other thread about this? how does the kicker extender work and you give more pics of that? looks like i could potentially slip but i dont know what you did. other then that it looks like it came out awesome! have fun with it man and get some pics of it rippin up dirt!

[LT250RMan]

Nice build man.

[j450rking]

i never did the center mount but i might later when i have a chance to ride it more. the kicker was easy if you can weld all i did was take a 84 250r kicker and weld it to the 85 up kick lever. the 84 kick spline is too small to fit the shaft and i didn't know so i got one of those first and then i got the 87 kicker and it was scraping on the pipe and hanging up on the brake pedal so i welded the kicker splines together and powder coated them and then i took the grinder to the lever and made it so it would grip my fooot better.

[j450rking]

ok so i have been riding the EXR for a while now and it's really really good. the motor mounts are still strong and with just the front and rear mounts and all of my brackets are holding up good. the only problum i have had was the stator coming loose off of it's mount but i took it apart and tightend it and it's the best quad i have ever had the pleasure of riding. even with the maxxis razrs tracktion can be some what of a problum :D t he balance is vary good for jumping even better then the stock 400ex and the handling is better with the smaller and lighter engine. the only thing i don't like is having to unbolt the engine and everything and move it forward to take off the clutch cover but it's not a big deal as i can do it in about an hour. i toped it out at 73mph and it pulls power wheelies in 5th gear:D. i think this is most likly the easyest hybrid to do i have seen and dosn't cost all that much if you shop around and do all the work yourself. in total with the stock carb it cost me about $1100.

i would say this is a huge improvement and is worth every penny and i would say unless you don't like 2 strokes then do it!


this is the engine setup i have right now

87 long rod 250r engine with a wiseco 265 piston with cometic gaskets

tusk clutch plates and heavy duty springs

38mm air striker carb

esr trx5 exhaust

and soon to come a pro design cool head with a bit higher comp.

let me know if you guys want to see some more pics or anything
:macho :macho :macho :macho :macho :macho :D

[born2ride14]

Ya lets see some good pics of it without a rag on the front :p

[j450rking]

lol yeah i had open wireing and it was raining so i covered it. here is a couple from today.

[j450rking]

left side

[j450rking]

right side

[RaceReflections]

Looks good.. Great build..

[Langbolt]

J450RKING,

Nice build!!!

Do you have any issues with chain tension ?

Is it loose when it's not loaded and tight when you're sitting on it ? Or vise versa ?

This is something I thought might happen with having the countershaft sprocket in that location.

Is the Carb completely in the Manifold ?

When I tried fitting a 250R in a 400EX chassis the carb bell hit the frame......Or is it because you're using 400EX front motor mounts too ?

I fabricated my own and maybe had the motor a bit lower at the front.

Maybe I will have to pull my 400EX Chassis out of storage and play some more.....

:devil:

[j450rking]

i had the carb fully in the manifold. i would try the higher front motor mounts and that should solve that issue. and i never had a problum with the chain all i had to do was take a link out but thats it.

[jcs003]

did you do anything special with thr rear mount other than what you wrote?

[j450rking]

no i just shaved the one bushing and switched them.

[jcs003]

j450rking, how did you do the left/front, (shifter side) motor mount?

thanks john

[j450rking]

i just used the stock 400ex motor mounts and bent them to fit and i also had to shave about 1/2-3/4'' out of the mount to clear the side case.

[jcs003]

i got the right one to fit perfect. looks like i have to bend the left one in the opposite direction. thanks, you have been alot of help.

[j450rking]

oh you know what i used the front left on the right and right on the left as the bends were closer that way and i tweaked them from there.

[jcs003]

i have another question. for the radiator how did you mount it? i am having issues with pipe and stearing stem clearence. pics would help.

thanks again,

john

[j450rking]

i don't have aany pics of it anymore but i just cut and bent thick aluminum ( L ) brackets and used the oil tank and oil cooler mounts. or you could zip tie it but it would't be as strong.