Cr80/400ex hybrid build

[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?

[Logan #34's Dad]

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?

Go with a 428 chain... They make front sprockets already..ebay. Then call Rebel Gears (877-851-2504) and tell them you need a 50T 400ex with a 428 conversion.
I've turned two CanAm DS450's into 85cc Honda's for my son.

[JOHNDOE83]

Go with a 428 chain... They make front sprockets already..ebay. Then call Rebel Gears (877-851-2504) and tell them you need a 50T 400ex with a 428 conversion.
I've turned two CanAm DS450's into 85cc Honda's for my son.


GREAT advice!!!!

Will deffinetly call rebel, was gonna call sidewinder but since I have a reccomendation from someone thats used it, I will go with rebel.

And since you have experience with a build like this, I will also go with the 50t.

That was my next concern was what the gear ratio would change, id hate to pay for a sproket to be built then find out it didnt have enough teeth or to many.

Thanks for the help! :muscle:

[JOHNDOE83]

Well I was wrong about the swinger bolt, turns out the 400ex is a hair bigger. Im hoping to solve this with some thin piping and worst case ill have a bushing made like I did for the cr250r/400ex hybrid.

Im trying to determine whether to use the cr pipe, a trx250r pipe, or a shifter kart shorty pipe. Im gonna try the cr pipe but if to much modding is needed I will entertain other options.

Heres a lil bit of progress.

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

[Baxter]

Looks fun, Always wanted to fit a CR125r engine in a 400ex chassis for the same reasons as you.

[JOHNDOE83]

I just recently found out a cr80 rear sproket has the same bolt pattern as the 400ex, the bolt hole is slightly smaller is the only difference.

It can actually be drilled out bigger and maintain the countersink for the sproket to be lined up correctly!

Poject going slow but im still at it...lol.

Im actually trying to fit the cr80 rear swingarm on the 400ex for a off road reverse trike.

Im gonna call it the Honda Scorpion 80r....lol.