2011 Indy Show XC2 Pro-Am GNCC 450R Build

[Dave400ex]

The 2011 Indy Show build is under way. For the 4th straight year it will be featured in the Maier plastic booth. I want to thank Jeff Lewis and everyone at Maier for allowing me to do this! Also a big thank you to all the companies that are helping with the build.

I'll do my best to keep this updated along the way. The show begins February 18th.

Below is a list of products we are using for the show.

Maier Plastic - Front Fenders, Radiator Scoops and Rear Fender
Moto-Xperts - Head Porting, Tranny Mod, Cam, Exhaust, Air Filter, Grab Bar, Sprocket Guard, Rear Rotor Guard, Full Chassis Skid
Lonestar - DC-4 XC A-Arms, DC-6 Linkage, Steering Stem, Axle, Anti-Fade, Parking Brake Block Off
Axis - Shocks
DWT - 4+1 Single Beadlock Fronts and 9x9 4+5 Dual Beadlock Rears, Tires, Mud Plugs, Lug Nuts
Quadtech - Plastic Hi-Pro Hood Scoop and Hump Seat Cover
Rath Racing - XC Bumper and Monster Peg Nerfs with Heel Guards
Streamline Brakes - Brake Lines, Billet Holders, Blade Brake Rotors, Clutch and Throttle Cable
PowerMadd - Hand Guards, Mounts, and Wraps
Spider Grips - A3 Grips
ASV Inventions - C5 Pro Model Perch with Hotstart, C5 Brake Lever and Rotator Clamp
IMS Products - Natural Dry Break Tank
Precision Racing Products - Pro Steering Stabilizer and Shock & Vibe Bar Clamps
CV4 - Radiator Hoses
Rekluse - Basket, Clutch, Black Clutch Cover
ORP - Rotor and Radiator Guards
Easton - EXP 1-1/8 Bars

We started with a new 08 ER. The frame was gusseted and TIG welded by my cousin using a Rath gusset kit.

[Dave400ex]

Engine In

[Dave400ex]

Other Side

[Dave400ex]

Overview

[Dave400ex]

Swingarm and Link On

[Dave400ex]

Grab Bar, Exhaust, Carb, and Wiring/Cables going on.

[Dave400ex]

Engine with more stuff installed.

[Dave400ex]

Another view

[Dave400ex]

A-Arms hanging

[Dave400ex]

This is where we stopped last night. We'll start back up again next weekend.

[400man]

so is this bike going to be kick and electric start??

[Dave400ex]

Yes it will have both electric and kick.

[antwanrttg]

Always great builds ... can't wait to see it pan out.

[wild250rman]

what type of finish is the powder coat?

[Dave400ex]

It is a black mini texture.

[IOWAracer]

24v setup? 04-05 carb?

[Dave400ex]

It will have a dual battery setup. Sticking with the stock carb for now.

[antwanrttg]

Just found out who the "XC2" rider is for this beast. I really hope to see this thing on the podiums this year!

[fastredrider44]

Originally posted by antwanrttg
Just found out who the "XC2" rider is for this beast. I really hope to see this thing on the podiums this year!

Do tell. I was wondering.

[hondaxcracer]

Originally posted by fastredrider44
Do tell. I was wondering.


me guest is that it is parker jones

[Dave400ex]

The quad will be ridden by #18 Parker Jones for 2011.

[Dave400ex]

More progress. Starting on the Front End.

[Dave400ex]

Precision Clamps and Easton Bars going on.

[Dave400ex]

Rear End going together.

[Dave400ex]

Airbox and wiring getting wrapped up.

[Dave400ex]

Full Shot

[Dave400ex]

Front end ready to bolt on shocks and Precision installed. Ockerman rock guards and Streamline Blade rotors on.

[Dave400ex]

:)

[Dave400ex]

Here is where we finished for the weekend. I put the calipers and rear master cylinder together today so I can get all the brake parts installed. Hoping to have it done a week from today.

[patrickj75]

Are those OEM front hubs?

[Dave400ex]

Originally posted by patrickj75
Are those OEM front hubs?

Yep stock 05.

[quad2xtreme]

another great build Dave.

I am not seeing any frame gussets.

[DnB_racing]

were are you going to put you second battery, and what type of battery box? and what are you setting the compression at

i have both kick and 24v and i set my compression above 62 and it seams to work good for both, but im still experimenting trying to get the perfect combination

[Dave400ex]

Thanks Jon. You can see the gussets better on the first page. They are hard to see. With them being TIG welded they blend in and the powder help covers them. We used the Rath gusset kit and added the Walsh subframe gussets.

The second battery will be up front in a custom made battery box. He has ran it this way for a couple years now. I am not sure what the compression will be set at. That is up to Parker and Toby at Moto-Xperts. He has had several 24v and kicker setups so they might have a specific setting. I've ran the kicker only quads so I am not sure about all these electric start settings.

[DnB_racing]

Originally posted by Dave400ex
Thanks Jon. You can see the gussets better on the first page. They are hard to see. With them being TIG welded they blend in and the powder help covers them. We used the Rath gusset kit and added the Walsh subframe gussets.

The second battery will be up front in a custom made battery box. He has ran it this way for a couple years now. I am not sure what the compression will be set at. That is up to Parker and Toby at Moto-Xperts. He has had several 24v and kicker setups so they might have a specific setting. I've ran the kicker only quads so I am not sure about all these electric start settings. Im running mine under hood also but im only tie wrapping it... when you get the box could you please show some pics? and if you could find out about the compression they use I would really appreciate it, mine starts all right with the kick but I think more compression would be better, but im just hit or miss at this point!!

[Latemodel32]

Looking sweet :D

[Dave400ex]

More progress

[Dave400ex]

Rear end

[Dave400ex]

Front end

[Dave400ex]

Tank On

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Wider view of rear

[Dave400ex]

Angle

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Plastic on

[Dave400ex]

Front with plastic on

[Dave400ex]

Other side of engine

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Top view

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Rear

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Higher side shot

[Dave400ex]

Another angle

[rmfhobson]

Looking good, where are the front shocks??

[Dave400ex]

Last one for now. All that is left are the shocks and custom graphics to be installed this week.

[upah1]

Originally posted by DnB_racing
were are you going to put you second battery, and what type of battery box? and what are you setting the compression at

i have both kick and 24v and i set my compression above 62 and it seams to work good for both, but im still experimenting trying to get the perfect combination

this could be a stupid ? but what 'compression' are you guys referring to here?

[DnB_racing]

Originally posted by upah1
this could be a stupid ? but what 'compression' are you guys referring to here? no question is stupid only stupid answers.. so here you go,lol

when you set your valve clearance for exhaust there are two adjustments one for actual valve lash and one for the starting decompressor,

the starter and battery are kinda underrated and wont turn the motor over with high compression as well as stock, by adjusting the decompression arm a little loser then specked out for factory battery and starter you add more starting compression, making it harder to turn the motor over with the starter.. but with the duel bats you can run a higher starting compression and allows quicker starts with the kicker

[cp689]

as usual dave another stellar build

[upah1]

Originally posted by DnB_racing
no question is stupid only stupid answers.. so here you go,lol

when you set your valve clearance for exhaust there are two adjustments one for actual valve lash and one for the starting decompressor,

the starter and battery are kinda underrated and wont turn the motor over with high compression as well as stock, by adjusting the decompression arm a little loser then specked out for factory battery and starter you add more starting compression, making it harder to turn the motor over with the starter.. but with the duel bats you can run a higher starting compression and allows quicker starts with the kicker

gotcha, thanks. I forgot about that adjustable decomp mechanism on the kickers and 06-07 e-starts. i've had 2 08's and they changed the decomp on the e-start 08's to a non-adjustable pin.

[rpfeifer11]

Why would you go from the fcr to the 04/05 carb? I always see people doing the opposite?

[braybray08]

Originally posted by rpfeifer11
Why would you go from the fcr to the 04/05 carb? I always see people doing the opposite?

I'll answer for Dave, the 04-05 has a smoother response and during a 2+hour race thats what you want. The FCR is snappy and could make you a little more power but the rider fatigue caused from snappier power outweighs the increased power in this situation.

[rpfeifer11]

Makes sense to me. I guess you don't really need tons of power in the woods.

[DnB_racing]

Originally posted by upah1
gotcha, thanks. I forgot about that adjustable decomp mechanism on the kickers and 06-07 e-starts. i've had 2 08's and they changed the decomp on the e-start 08's to a non-adjustable pin. actually he is using an 08 for this build, Dave are you using a 08 cam and holder???

[fastredrider44]

Originally posted by rpfeifer11
Makes sense to me. I guess you don't really need tons of power in the woods.

An XC1 or XC2 rider does need power, just not snap that wears you out. The 04-05 carb also seems to make a little more pull up top.

[Dave400ex]

Originally posted by braybray08
I'll answer for Dave, the 04-05 has a smoother response and during a 2+hour race thats what you want. The FCR is snappy and could make you a little more power but the rider fatigue caused from snappier power outweighs the increased power in this situation.

Correct. The 04-05 also seems to be easier to keep jetted correctly and not as finicky.

[Dave400ex]

Originally posted by DnB_racing
actually he is using an 08 for this build, Dave are you using a 08 cam and holder???

Good question, I am not sure. I don't know all the ins and outs of the engine build. I will try to find out.

[Dave400ex]

Pictures from the show

[Dave400ex]

:)

[Dave400ex]

:D

[Dave400ex]

Front

[Dave400ex]

Close up of side

[Dave400ex]

The rider

[leev26]

Great looking build Dave! Loving the attention to detail, makes a huge difference.

[gpd005]

check the air box for a tic tac box!!!! LOL

The bike looked great, nice job guys!

[Dave400ex]

Originally posted by leev26
Great looking build Dave! Loving the attention to detail, makes a huge difference.

Thanks Lee. The attention to detail is what sets them apart. I am so particular about every little thing. Parker got to find that out while we were building it!

[Dave400ex]

Originally posted by gpd005
check the air box for a tic tac box!!!! LOL

The bike looked great, nice job guys!

Thanks Garon. That was a nice throw with the tic tac box. The 400 was looking pretty darn good as well!

[SHIFTx450]

sick bike man, nice job

[fastredrider44]

I really like the sprocket gaurd. I'm not sure I have seen anyone powder one yet. Bike looks great!

[Dave400ex]

With GNCC rounds 1 and 2 in the books, Parker is currently 3rd in Pro-Am class points and #15 in the top 20 overall. After a rough Florida, Georgia went great with a 2nd place podium finish and the holeshot!

I'll get some pictures up when I get them. We did a photo shoot with both Harlen and Pappy.

[Dave400ex]

Pictures from Pappy

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14. Thanks Pap!