650ex finally finished (well, almost)

[tayyo789]

so ive been building my hybrid for 2 years now, and i finally got to take it on its maiden voyage. i only have action shots for now, but someday when i actually get all the bugs worked out i'll take some real pictures. but for now here she is. its the blue framed one with the carbon plastics

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6387-1.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6387-1.jpg" border="0" alt="Photobucket"></a>

[tayyo789]

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6399.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6399.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6422.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6422.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6429.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6429.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6433.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6433.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6434.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6434.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6459.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6459.jpg" border="0" alt="Photobucket"></a>

<a href="http://s244.photobucket.com/albums/gg18/katieyo/?action=view&current=IMG_6464.jpg" target="_blank"><img src="http://i244.photobucket.com/albums/gg18/katieyo/IMG_6464.jpg" border="0" alt="Photobucket"></a>

[tayyo789]

all i have left is to get my new carb dialed in and it needs another swingarm. im actually having some issues finding more places that will make me a +6 for a 400ex with 450r chain slide mounts. if you guys know of a place that would do that it would be much appreciated.

[dehner47]

have you spoken to lonestar? there all about making desert bikes. i'm sure they will make you whatever your mind can come up with.

[250Renvy]

Mike at HRE can build one for you I'm sure. Very reasonable prices compared to others as well. You can choose between round tube or square tube.

He also does flip top subframe conversions if you need if for the kicker.

www.HREatv.com

Check my sig for pics of some of the stuff he's built me.

[tayyo789]

im not very fond of lonestars prices, but hre seems like it would work, unless i can find someone closer to the west coast. i dont need anything special as far as appearance goes, because i am going to do my own powdercoating so its a gauranteed match for color, and i build my own chain sliders. i just need the 450r slider mounts for my sliders. i would also like a slider in the rear of the swingarm as well. one of those ones that are often seen on mx bikes by tm designs. the one i have now is a +2 and i can pull the front end up at 1/4 throttle coming down banshee hill. kinda dangerous if you ask me

[tayyo789]

and as far as the kickstart goes, i have everything worked out now, except for my brake lever, but i have some ideas for it. the problem with that is that the kickstart on the xr650 is soo long, that it swings down and hits the lever right after it comes off the caliper. im thinking about flipping the lever inside of the frame and coming out in front of the footpeg

[boosted3g]

Have you tried using a shorter kicker or off another bike like a crf.

[audioworks04]

have you tried a kicker extention? Sounds like it might sound most of your problems until you kick hits your peg, then like boosted said a shorter kicker maybe in order. Had alot of kicker/brake lever issues with my CRF450 ATC conversion.

[tayyo789]

i like the setup i have now, and i actually built the kickstart. my old one broke so i had to build one with only a couple hours til dunefest lol. but it works great and i like the travel of it. plus the brake lever fab will make it so i have one more custom piece to talk about

[tayyo789]

im going to be going to the dunes sometime in the next month. i usually go to winchester bay. if anybody else is going pm the weekend and maybe i'll see you there. im also going to glamis for christmas if anybody is interested

[quadpornstar]

Hey, we're heading to winchester or Coos sometime in the next month as well. Also heading to Glamis for Thanksgiving. You from Medford? My girlfriend is from Medford. She is getting rid of her Raptor 350 because she just bought a trx450r. Small world.

Anywho. the xr looks good, hopefully you get all the bugs worked out. :D

[tayyo789]

ya im from "methford". born and raised. but now im in corvallis for school :/

do you know what weekend your going to the coast?

[tayyo789]

Stumbled across some pics from somewhere mid-build
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=l_f05df065d9e14e2c8a2a3e1fbb2db390.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/l_f05df065d9e14e2c8a2a3e1fbb2db390.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=l_e81b2bdb16e7460c92635bb74c2b9a2b.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/l_e81b2bdb16e7460c92635bb74c2b9a2b.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=l_8cb4a31fa5be4689bd1cbdc5f5ae7c9e.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/l_8cb4a31fa5be4689bd1cbdc5f5ae7c9e.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=l_8b3d4a0a7b484536acc48a6320935423.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/l_8b3d4a0a7b484536acc48a6320935423.jpg" border="0" alt="Photobucket"></a>

[Pipeless416]

this is my dream hybrid.

[tayyo789]

this motor dwarfs the 400 frame. it feels like your'e riding a motor with wheels. not too bad for my senior project :D

[tayyo789]

headed to hauser over thanksgiving. gunna be there tuesday through saturday. pm me if anybody is going to be there, i'll be riding the hybrid

[tayyo789]

make that tuesday through sunday

[tayyo789]

well im home from the latest trip. heres some pics of me on some hills, and some of the bike sitting in camp. for some reason all the blue on it looks really light colored. i assure its darker blue in person, which makes it look way better. oh how i need a bigger swingarm:devil:

<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7430.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7430.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7431.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7431.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7597.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7597.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7599.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7599.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7601.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7601.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7616.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7616.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7640.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7640.jpg" border="0" alt="Photobucket"></a>
I enjoy muddin', wrenchin', duning, and the cliche long wheelies on the beach at sunset....<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7662.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7662.jpg" border="0" alt="Photobucket"></a>

[J.Brown121]

that thing is bad*****

[tayyo789]

thanks. it took a lot of time, a lot of work, and A LOT of $$, but is completely worth all of it. I now have one of the only hybrids on this site that is not for an mx track, and I love it. This machine is a straight dune machine, ready to challenge any 450, and every raptor that thinks they can outrun me :devil:

[Big_Guy_Green]

Ok I have a LOT of questions about this build! lol

I'll start with just a few

1: It looks like the body work and gas tank got lifted for clearance, is that right?

2: Did you do some modification to the lower frame between the engine and a-arms?

3: What modification did it take to clear the head of the motor?

[tayyo789]

1)Yes, I raised the gas tank, and built custom brackets for it and my front fenders to space them upwards about 3/4".

2)I cut out the frame rail that comes back at an angle from near the a arms, and cut a few inches off, and welded it back in, so that i could use stock 400 front engine mounts.

3)Clearing the head was an issue, because this motor is so tall, i had to build custom brackets on the top frame rail to be able to utilize the top motor mount. In the end, to make everything fit over the now 2 inch taller motor, i had to heat the gas tank, after draining it of course, and used a piede of 1 & 1/2" pipe to press on it to form it around the motor, carb and cables.

Any other questions I am glad to answer

[EXRacer247]

First of all, I am salivating over this bike. I'm kind of a sucker for mean 400ex's. I ride the oregon dunes usually twice a year and if I ever see you down there I'm going to have to shake your hand.
But I wanted to know about those a-arms. are those the +2 standard travel or....? and how do you like them, I was considering buying a set.

[tayyo789]

they are +2 +1 fullflight standard travel arms. i got them for a steal off ebay. i like having the heim joints at a lower cost so thats why i went with that brand

[XR200R]

i remeber mike at HRE telling me about this when i was at the shop getting stuff built.

its cool i got to see what it looked like other then just the frame at the shop.

[tayyo789]

ive never dealt with HRE before. i built the frame in my garage

[XR200R]

hmm, then theres another guy floating around out there with a HRE 650r/400ex hybrid

[tayyo789]

It doesnt suprise me. After the dirtwheels article, a lot of hybrid builders wanted one. And I dont blame them, this thing is sweet:D

[tayyo789]

Update:
well, i got a new swingarm, i went with a +5, and have some sprockets on their way. with glamis next week, im going to go pick up a bumper in the next few days. pics will follow once i get everything on

[tayyo789]

well im back from glamis. we ended up going to pismo for a few days as well. swingarm works great, but still no bumper. heres some pics from the trip. theres quite a few:

<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7733.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7733.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7742.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7742.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7767.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7767.jpg" border="0" alt="Photobucket"></a>
some fun on china wall:
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7776.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7776.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7779.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7779.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7795.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7795.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7800.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7800.jpg" border="0" alt="Photobucket"></a>
some of the bike:
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7857.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7857.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7859.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7859.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7861.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7861.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7905.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7905.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7907.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7907.jpg" border="0" alt="Photobucket"></a>
and the drags at pismo:
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_8129.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_8129.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_8095.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_8095.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_8060.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_8060.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_8004.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_8004.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7984.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7984.jpg" border="0" alt="Photobucket"></a>
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=IMG_7941.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/IMG_7941.jpg" border="0" alt="Photobucket"></a>

[tayyo789]

finally got a bumper. my local shop had some left over pro aluminums, and i got a great deal on this one:
<a href="http://s170.photobucket.com/albums/u276/ramco17/?action=view&current=PA-11-100BLG.jpg" target="_blank"><img src="http://i170.photobucket.com/albums/u276/ramco17/PA-11-100BLG.jpg" border="0" alt="Photobucket"></a>
i dont have any pics of it mounted because i need to put bigger bolts in since this frame came with 3 broken off bumper bolts in it that i had to drill out.

[tayyo789]

headed over to the oregon coast for presidents weekend. any takers out there?

[coryatver]

Originally posted by tayyo789
headed over to the oregon coast for presidents weekend. any takers out there?

race any modded 700xx? I figure it would be pretty close seeing how they have almost the same motor

[tayyo789]

i hvent raced one yet, but i dont see it being any competition. i raced a raptor that had the big 3 and he was about 6 to 7 bike lengths behind at around 150 yards. this bikes scary fast. and it weighs less than my 416:macho

[tayyo789]

im back from my weekend at the coast, and while i was there i took my bike to the dyno.
in the end, i didnt get numbers that were particularly high, but i have an extremely flat curve at around 51 horsepower and 45 ft/lbs. at 1500 rpm is makes 42 ft/lbs!
not very impressive peak numbers, but very usable power. i now have another motor on its way that will be the serious beast. i have a 680 kit picked out along with some other goodies:D

[mooseracerX]

Nice wheeler. I was just wondering if that PWR is off of a 450r? I have one I'm putting in my CRF hybrid and yours looks a lot more straight up and down than mine, If I put it more straight up the cap hits so I was wondering if you did anything special.

[tayyo789]

i built all the brackets, and the radiator was custom made for this bike. we gave pwr the dimensions and they built it to size

[Thumpin440ex]

What exactly needed to be modified to get that motor bolted to that frame?? Bad *** for sure.. Good work..:)



John

[tayyo789]

well the only normal mount is the swingarm, and the only piece that didnt need customizing was the shifter. its a lot of work is all i can say

[tayyo789]

Well, I lost QOTM, but QuadJunkies Raptor 250 is worthy of winning.
I'm heading to Christmas Valley in 2 weeks if anyone's going to be there

[quadpornstar]

I think we might be going to Coos or Winchester on Easter. You riding that weekend?

[tayyo789]

Maybe. If I do that would be where I go. I am not sure yet though. It all depends on my school schedule

[tayyo789]

Im thinking of changing the blue parts to red...any opinions?

[camaromitch]

I think that any color frame under that black body is going to look killer, although with that motor you could probably paint it pink and not lose any fans.

[tayyo789]

I decided to stick with blue. Im going to save the red for my next hybrid

[tayyo789]

I now have an extra motor (stock) and bare set of cases waiting for me when I get home from school. So I'm going to find out how much these motors can take as far as mods go. Most likely it will be drag ready by dunefest. This thing will be a beast. :devil:

[tayyo789]

Wow, its been over a year without any updates, I think some of you are due one after all this time. So here's what I've been up to:
I've got my stroker crank sitting in my garage, a 680 cylinder ready to go, and a big ol' head from Bo White over at club700xx coming back in the mail next week. I have a 700xx cylinder I'm still toying with every once in a while, but no set plans for at the moment.
Let's see, what else....I got a new cam from Web this winter, but I've only been able to run it once, and the clutch couldn't handle it:devil:
I'm hoping to go out next weekend and finally run it with the new clutch in and finally the right pilot jet in, so it might actually start this time.
Basically, the thing still runs great, but of course I'm getting bored of the power so there's going to be more to come!

[camaromitch]

Good to hear! Keep 'em comin'

[tayyo789]

Thanks, I came home tonight to find a new swingarm in my garage as well. Hopefully a +8 can do the job a little better

[tayyo789]

This new swingarm I got is TOP NOTCH. It's from Stellar Machine and Performance, and I cannot stress the crafstmanship on this piece. It is beautiful. Very lightweight, arched, 8 inches over stock.
Here's what it looks like:
<a href="http://www.flickr.com/photos/63425761@N08/5764184512/" title="254340_221725357855297_100000535031068_881093_1836 941_n by tayyo789, on Flickr"><img src="http://farm3.static.flickr.com/2778/5764184512_e1b4c08b98.jpg" width="500" height="375" alt="254340_221725357855297_100000535031068_881093_1836 941_n"></a>
<a href="http://www.flickr.com/photos/63425761@N08/5763635857/" title="250710_221725577855275_100000535031068_881095_3970 384_n by tayyo789, on Flickr"><img src="http://farm3.static.flickr.com/2470/5763635857_f7aa391a3c.jpg" width="500" height="375" alt="250710_221725577855275_100000535031068_881095_3970 384_n"></a>

[MisterGraphic]

That looks awesome, I even like the "raw" finish! :)

Are you keeping it that way or powder-coating it?

[tayyo789]

I'm still trying to decide whether to powder coat it or not. I like the look I have now, but this would look sweet with my carbon plastics as well

[tayyo789]

UPDATE:
Finally got all the pieces to put the big motor together.
680cc from the big bore, and a few more from the +4 crank.
Sent the head off, got some big valves and a real nice port job.
Moving up from a 40mm carb to either a 44 or 46. I have a 48, but want to keep some of the low end and snappy throttle response.
The only piece I need now is the cam. If there are any of you XX guys that know of any gnarly ones, let me know.

[JOHNDOE83]

thats a sweet swingarm!!!

I got my +7 from ace fabrication, its very well built also but isnt very light and its not arched.

Nice build!

[Thumpin440ex]

Awesome build.. Could you PM what you gave for the swing arm?? Thanks



John

[tayyo789]

Honestly, the swingarm was a birthday present so I don't know how much it was. Here's a link to the Products page of his site: http://www.stellarmachineandperformance.com/Top_Selling_Porducts.htm
You have to call for prices, since every one he makes is unique and custom built for your application

[MXin700R]

Theres a guy over on the XX forums thats running a 48 lectron conversion and it hauls the mail. Dont put a 44 on it for sure, 450s have carbs that size.

[tayyo789]

This motor actually runs good with a smaller carb. Right now it's only got a 40 and i really like it. It's extremely snappy and has very good throttle response. I'm not drag racing very often, and I don't have long hills to climb so I really don't need the top end of a 48. I have a few, that I run on a ds650, and I've tried a 46 on the xr, and didn't really like it. It pulled hard on top but took forever to get there

[tayyo789]

Kinda forgot about this thread, I figured I'd at least update what I'm doing with it next. In a couple weeks, I'm going to start assembling the big motor, and maybe doing a rebuild, change some colors up, etc. When it's together it'll be about a 716, with just about everything done to it to get my blood pumping. Over the years I've had this thing it's been nothing but problems, issues, headaches, late nights, and frustration. But every time I get on it, it reminds me why I do this to myself. I will never regret going the hybrid route, I can't imagine a production bike being as much a part of me as this project has become, and is evolving to be.
Anyways, I scrounged up some pictures from miscellaneous points in time since I last updated this thread, and here they are:

Starting with some proof that I do ride it
1718103067

Still cleans up nice though
1718103068

Here's two after that new swingarm
1718103069
1718103070

And the top half of what is to come
1718103071

[tayyo789]

And just for fun, I'll show you the reason why my baby hasn't been getting enough attention. The OTHER hybrid
1718103072

[tayyo789]

Don't want to make a new thread, but I'm looking for a way to get the HRC cam chain setup. I guess they're next to impossible to find after Honda quit making the kit. It had a thicker cam chain, new sprockets, tensioner, and guides. I hear a few companies had some left but then they stopped producing the lower sprocket. And without every piece, I'm left using a stock chain kit on an engine making nearly twice the power of a stock bike. To me that just spells disaster waiting to happen. Maybe any 700XX guys know anything?