CR80/400ex hybrid possibility?

[JOHNDOE83]

Got a cr80 motor and a empty 400ex frame.

I wanted a light weight mx/dirt road type "fun" quad that wasnt 300lbs and came up with the idea of a 2 stroke 80 full size quad.

In this pic I was just testing some things out.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00475_zps7dc538e7.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00475_zps7dc538e7.jpg.html)

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00476_zpsac11437d.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00476_zpsac11437d.jpg.html)

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00476_zps3b7c7cdf.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00476_zps3b7c7cdf.jpg.html)


One thing I see thats gonna be easy is the spacer for the motor to swingarm bolt, the swinger bolt in the pic is actually from a cr80 and is the exact size of the 400ex swinger bolt, so its just one less thing to have to do.

Actually this is the bolt from the rear tire, but this and the cr swinger bolt are the same diameter as the 400ex bolt they are just shorter then a EX swinger bolt.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00477_zps5f59d53e.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00477_zps5f59d53e.jpg.html)



Im going with 18in rear tires, zuma knobby scooter tires for the front, lower sitting shocks that are more suited for speed then jumping, under 225lbs total weight, 450r swinger, +4 rear axle, wider offset front rims "not to drastic".

Should be a fun ride when its done :devil:

My only questions are.

Is it better to go with a front sproket for the cr motor that uses the stock 420 chain and go with a custom 420 rear sproket for the 400e?

Or is it best to go with a 520 custom front sproket that fits the cr motor for the heavier duty chain?

Do I even need the heavier chain?

It is possible to run the 520 on the 420 sproket, but you know how thats gonna end up at some point.

[chronicsmoke]

one guy did a ds450/cr80 swap, he'd be your best to answer the chain/sprocket question.

Looks like it will be a fun little project

[JOHNDOE83]

A lil progress.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00526_zps507f499f.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00526_zps507f499f.jpg.html)

[JOHNDOE83]

Im having the swingarm bushing made and it should be ready for pick up.

Spending most of this weekend trying to make motor mounts and doing as much prep as possible before I get to the point where I need to order custom sprokets.

[JOHNDOE83]

I picked up the bushing today from the machine shop, gonna head to home depot later and buy the steel for the motor mounts. :muscle:

[JOHNDOE83]

Last time when I built the cr250 hybrid, I neglected to take photos of the swinger bushing I had made, this time I made sure to get a few pics of the bushing/spacer.

This is a stock cr80 motor case bushing and 2 right side 400ex swing arm pivot bolt bushings, one 400ex bushing was turned down to the size of the cr80 motor bushing. A cr80 motor bushing has a bolt hole thats to small to fit a 400ex swingarm bolt through, but a 400ex swingarm bushing has enough meat to be shaved to the right size.

from left to right 400ex shaved bushing/spacer, cr80 bushing, stock ex spacer.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00736_zpsae69b295.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00736_zpsae69b295.jpg.html)

from left to right cr80, 400ex shaved, 400ex stock

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00734_zps11e64d2b.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00734_zps11e64d2b.jpg.html)

you can tell which is which by now

http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00733_zps17ebedcf.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00733_zps17ebedcf.jpg.html)

[JOHNDOE83]

I got the motor mounts made and also made some spacers for the mounts, now I need new carrier bearings before I can continue with the build. I actually have a few things I could still do but like all projects I try to go piece by piece incase something arises that wont let the build happen I can stop early and save a few bucks.

This build looks like its gonna be easy tho......:blah:

Ill post pics when the suns out again.