Restore & update 1996 Honda 300EX for wife's Bday

[ridersonline]

Restore & update 1996 Honda 300EX for Yolanda's (wife) Bday

Turns out like many things Honda... these things NEVER change much. So all the new style parts bolt on. The goal is to take this old, low hour quad thats been growing rust in my back yard into something fun that looks like my TRX450ER. I shouldn't admit it but she recently bought a matching helmet and riding outfit too.

For an inexpensive suspension upgrade the 400EX front end is a straight bolt on. Ebay to the rescue. I've actually had the suspension in the garage for years. I'm also using some new take off parts from my TRX450ER to add to her update as well. Scored a complete NEW takeoff '06-09 450R exhaust system that I'll be modding to fit. Then a simple Stage 1 cam. And lastly, all these Frankenstein parts will of course require that I finally invest in an O2 meter to properly jet the little beast. (What a round about way to get an O2 system into my tool box... LOL)

Should be fun.

Before pics:

http://ridersonline.org/images/jsb/trx300ex_rebuild_before.gif

.......................more to come.

[ridersonline]

The Tear Down:

http://ridersonline.org/images/jsb/trx300ex_rebuild_teardown.gif

..................more to come.

[IRISH-RACER-14]

nice seat. where did u buy it

[ridersonline]

Most of the parts are here now. UPS dropped off the plastics today. Just waiting on the exhaust & CRF450 perch and lever (ebay) and the JB Racing shock mount & then the rest is on me.

Gonna use a Yamaha ebrake lever on the side rear of subframe. Works real nice cause you can grab it when loading into a truck. Then the reverse cable gets attached the CRF450 mini HOTSTART lever cleaning up the bars a LOT.

http://ridersonline.org/images/jsb/trx300ex_rebuild_parts.gif

[IRISH-RACER-14]

Originally posted by ridersonline
Most of the parts are here now. UPS dropped off the plastics today. Just waiting on the exhaust & CRF450 perch and lever (ebay) and the JB Racing shock mount & then the rest is on me.

Gonna use a Yamaha ebrake lever on the side rear of subframe. Works real nice cause you can grab it when loading into a truck. Then the reverse cable gets attached the CRF450 mini HOTSTART lever cleaning up the bars a LOT.



i used crf450x moose lever with hotstart and removed the e-brake because its never working and causes the pads to wear incorrect

[IRISH-RACER-14]

what hood are you using with the 450r front fenders? you seemed to spend alot of money on that thing. what header pipe is that?

[ridersonline]

A little side by side action:

http://ridersonline.org/images/jsb/trx300ex_rebuild_target.gif

[ridersonline]

Cleaned up the bike and new arms. Got it mostly mounted today. Need to clean up some threads on one of the ball joints before I can sinch it down. Still waiting on shock relocator so she is sitting on the 300ex shocks for the moment. Width front and back is now approx 44 inches. This is the way Honda should have built this thing in the first place.

http://ridersonline.org/images/jsb/trx300ex_frontend.gif

[ridersonline]

I was going nuts to see the final so I mocked up the fenders. The front is drooping about an inch or so... but you get the idea.

http://ridersonline.org/images/jsb/trx300ex_mock090410

[ridersonline]

Big Boy shocks are on the build now. JB ATV Racing shock relocator bracket arrived today. I can't say enough about the simple clean bracket Jody builds. The laser cut pieces... nice welds... good looking powder coat... quality hardware... and perfect fit make me happy I did my homework ! I am even getting over the price. He makes two brackets that integrate with either generation plastics so tell him what you are running.

If you order this thing please tell Jody you heard about it from Jeff in CA - on my build thread.

JB ATV Racing - (814)922-3523
http://www.jbatvracing.com/2010/trx300ex.html

http://ridersonline.org/images/jsb/trx300ex_relocator.gif

[thomasgangross]

first off, the bike is looking great! i cant wait to see the 450r head pipe fit on there, we all want to know what the plastics are, looks like 450r front and back, and 300ex tank cover

[IRISH-RACER-14]

Originally posted by thomasgangross
first off, the bike is looking great! i cant wait to see the 450r head pipe fit on there, we all want to know what the plastics are, looks like 450r front and back, and 300ex tank cover

i think its a rear 300ex fender. will the 450r hood fit?

[ridersonline]

The body is all 08 300EX from the tank cover back. The entire front body is 08 450R. The 450R front only joins the rear at two spots on the tank cover and they line up 90%. Close enough to not be noticeable.

300EX front end is stubby... looks like a kiddy bike... and has too many funky pieces underneath. The 300EX fenders and shrouds are one piece... $150 more expensive... require an additional $50-100 worth of mounting hardware.

The 450R front end just looks and fits the bike better visually. The 450R also has replaceable fenders and costs $150 less than the 300EX front end.

The 450R front fender brackets/head light mount fits around the JB ATV Racing shock relocator perfectly. My work to produce a bracket kit for the conversion should be a cake walk. I might even make up a few kits for others when it's done.

[250ex_dan]

thye exuast didn't fit.?

[ridersonline]

Any 300EX exhaust fits fine. Mine just happens to be an old, loud & rusty FMF that I wanted to replace. So I bought a complete new take off 08 TRX450R exhaust for $50 on ebay. So I will need to mod it to fit the 300ex. The stock 450R head pipe is a nice stainless piece. It is the same size tubing as the 300EX performance header so flow will be right.

You guys gotta know that 450R parts are CHEAP cause there are so many of these things getting parted out.

[ridersonline]

I mocked up the exhaust and headlight today. Things are lining up GREAT ! The head pipe will be moving toward the rear about 2 inches. Silencer should stay pretty close to the photo. I need to cut and shorten the header with a slip fit joint as it exits the head. Flange needs just a slight bit of dremeling to fit the exhaust bolts. The end of the header only needs to be turned down 3/32" to fit the head. I may not need to do any other customizing on the whole exhaust.

Take a look at where the center headlight bracket lines up. I turned it upside down from how it normally gets used on the 450R frame. I only need to put two small spacers and screw it right to the cross bar.

The fender to headlight braces clear the JB ATV Racing shock mount perfectly. And the two threaded bosses on top of the JB mount will be perfect for my custom fender/headlight supports.

http://ridersonline.org/images/jsb/trx300ex_mock090810.gif

[IRISH-RACER-14]

it would have been easier to use the 300ex front fenders,stay and the 450r headlight!is that a 300ex or 450r hood?

[IRISH-RACER-14]

just saying. how well does the 450r pipe mount up? thinking of doing it myself

[250ex_dan]

really nice bike man.!
so is it possible to fit a 450r or 400ex liht on an 08 honda 250ex.?

[ridersonline]

Originally posted by 250ex_dan
really nice bike man.!
so is it possible to fit a 450r or 400ex liht on an 08 honda 250ex.?

The 07+ 300EX uses the same light as the 06+ 450R

The 08+ 400EX uses the same light as the 04-05 450R

The 250X is the same frame as 300EX. But I have no clue what the 250EX is all about. I know you can mount anything to anything with a little talent and creativity.

[250ex_dan]

LOL
n the exhuast most likely won't fit will it.?

[ridersonline]

Originally posted by 250ex_dan
LOL
n the exhuast most likely won't fit will it.?

Well it is not a direct bolt on... LOL

[thomasgangross]

so are you doing the same for my BDAY!!!!

[IRISH-RACER-14]

is there going to be any issues of the 450r pipe hitting the 300ex rear fender?

[250ex_dan]

is it possible to get my 250ex exhuast customized so that the pipe can come out looking UP like the 450r's.?
i don't like how the 250's come straight out.
i was thinking of making a differnt head pipe that curves and gives it an angle and to make a braket that goes all the way down so that exhuast can be fitted right.?

good idea.?

[IRISH-RACER-14]

Originally posted by 250ex_dan
is it possible to get my 250ex exhuast customized so that the pipe can come out looking UP like the 450r's.?
i don't like how the 250's come straight out.
i was thinking of making a differnt head pipe that curves and gives it an angle and to make a braket that goes all the way down so that exhuast can be fitted right.?

good idea.?



go with the less hassle option and buy a 450r!

[ridersonline]

Originally posted by 250ex_dan
is it possible to get my 250ex exhuast customized so that the pipe can come out looking UP like the 450r's.? Everyone has varying levels of tools and skills. I own a 450R and had the stock head pipe laying around. They are good quality stainless steel. So I could evaluate what it would take to use it... and if it was appropriate size from a motor requirement stand point.

While shopping ebay for a heat shield for my head pipe I found a complete exhaust for $45... head pipe, silencer & heat shield included. No brainer !

If you can imagine it... and have the ability to make it real... then do it !

[250ex_dan]

well right now i don't have the resources(money...ect)but thats for the info:)
its been on my mind on howm i can do it and if its possible.
ive been looking at it and it might be possible.
i might as well just go to a shop around here and get mine custom(or buy one from scratch) and put it back on.


...will it be able to create any power gains.?
....most likely will require to be rejetted right.?

[dman66]

So you inspired me to think about a 450r exhaust on my 250x,so found a complete exhaust and bought it cheap and new.So did you finish the exhaust?and how did it turn out? can the exhaust pipe be mig welded when fitting together? NICE JOB on the quad. You give some inspiration to others,that don't want to be followers.Not trying to butter you up, just saying what a nice job on that quad!!!! Did you fit this quad with a 450r swinger?