400EX KTM520EXC Hybrid

[DragonGunner]

Built this a few yrs. ago before KTM finally got around to making a quad. Was inspired by Daryl Raths build. This was built on my 400EX. More Pics. an info. to come....???...having problems with posting pics....not sure whats going wrong...?

[97Rocks]

Im interested in your build... check out mine (KTM laeger build) on this forum. looking forward to pics by the way! -Rick

[DragonGunner]

Any questions??? Lonstar swingarm +1.25 cut on chain side to fit better, Jansen radiator, it has a aluminum coolant tank that we made for the water pump to go up to under the front plastic....it has a 18lb pressure cap..it then flows down to the radiator that has a 30lb cap, the overflow comes out of the extra coolant tank an flows back to the rseivoir from a yfz450. Radiator shrouds are from yfz450, just a little filing. Carb jetted 200 main, 52 slow jet on a 2004 trx450r, adapator runs back to stock air box...front motor mounts are still 400EX fabricated to refit. Its electric an kickstart, kickstart fabricated to work with our extention. KTM motor from 2002 complete upper topend rebuild, got it off ebay like most stuff. Its gearing was 14/38 with 18" tires it has the same gear ratio..seems to be anyway as my nephews built Banshee,(Bored, Ported, 2 in 1 carb an Toomey Pipes) along with top speed...but its a bit faster on take off an wins at 300 yd. drags....it now has 15/38 gearing an seems to be smoother an not as fast of shifting so this thing rips. Roll Design a-arms an trx450r elka's up front with built dual spring 400EX shock on back....this is the most comfortable quad I've been on.

[RATPACK Z400]

looks good !

[DragonGunner]

It has a trx450r CT Racing exhaust mated to the KTM header pipes. The frame was cut above the water pump an a solid piece of steel rod was fabricated an slid into the frame tube then brought back into the other end....cuts were made at an angle for more weld area making it stronger. The 400EX top motor mounst an spacers added still runs across the frame just above the motor for added strength. I think someone from Rath's told suggested I make strong motor mounts for the bottom of the frame an so we did. Gearing at 14/38 with 18" tires seems to be about the same gear ratio of my nephews built Banshee, his with 20" tires is slightly faster once we are in 6th gear, but I get him in 300 yd. drags....it now sports 15/38 gearing an I'm not shifting all the time an seems to be ideal gearing so I know my top end will get him now....I'm guessing somewhere over 90mph, probably more with taller tires. Motor came off ebay from a 2002, tope end rebuild an this quad handles great, been in several harescrambles an MX grand Prix type racing an after several years is holding up great.

[Brad77]

That looks sharp ! I built my KTM 400ex hybrid around 03. It has held up great and its still very fun to ride.

[DragonGunner]

pic.

[DragonGunner]

The White Brothers seat cover is going on 9yrs, an still in great shape. The counter sprocket has a spacer behind it an the rear sprocket has spacers on the inside, not very thick but it did the trick to get the chain lined up. The Lonestar swingarm that I already had looks like the only one, after modifing a little bit that would of worked.

[jcs003]

this is awesome! KTM seems to put out alot of power and they also seem to be some of the most reliable engines. husky's also are big power motors with great reliability. i would like to see an husky hybrid.

[DragonGunner]

Yes they do seem reliable...an produce power like crazy an seems to keep building power....the one thing I didn't like about the 400EX motors is that they would sign off an then drop. Hill climbing is much more comfortable with the KTM....the other plus is that the 400EX motor seems to weigh around 90lbs an this motor wieghs closer to 60lbs....when I
picked it up I thought....Wow!!!!

[SpasticR450]

Dude I want. If was mine id make blue and trim the rear plastic.

[DragonGunner]

Found some more photos...this helps show the coolant tank made, water pumps up to it then it drains back down to the radiator.


http://i829.photobucket.com/albums/zz219/61chalk/securedownload-4.jpg (http://s829.photobucket.com/user/61chalk/media/securedownload-4.jpg.html)

[DragonGunner]

TRX450R carb....note the 2 nuts welded to the frame, this is for the CDI to be bolted on.

http://i829.photobucket.com/albums/zz219/61chalk/securedownload-7.jpg (http://s829.photobucket.com/user/61chalk/media/securedownload-7.jpg.html)

[2001400exrida]

do ya really think it'll eat drag banshees? that's a slick hybrid, haven't seen one like this before, props for the ingenuity.

[DragonGunner]

do ya really think it'll eat drag banshees? that's a slick hybrid, haven't seen one like this before, props for the ingenuity.


Naaa....that sig line is for laughs and for the guys wound up to tight like guy on the 400EX forum thats claims he's a engine builder and thinks a anything over a 185 main in a EX will wash the rings out....lol. My nephew is a sick Banshee rider that likes dragging at the Dunes in MI, and like I said, this dirtbike KTM motor beats him.


..<a href="http://s829.photobucket.com/user/61chalk/media/100_0136_zpsb8df0703.jpg.html" target="_blank"><img src="http://i829.photobucket.com/albums/zz219/61chalk/100_0136_zpsb8df0703.jpg" border="0" alt=" photo 100_0136_zpsb8df0703.jpg"/></a>