TRX650ex, yes I did it

[STILLinFRONT]

I have just completed my project. Stuffing a XR650L motor into a 400ex frame.
The L motor has electric start off of the dual sport bike.
I had to cut off the motor mounts, and relocate them:

Make new mounts

gusset the frame

modify a 400ex exhaust

I do my own powdercoating

Install Hot cam

Finally done!!


I rode it all weekend, I do need to change sprockets, 1st gear was like 25mph, it would not pull 5th

[yfz450admirer]

Your quad looks great! That engine looks like it was made for that machine. How much did it cost to pick up a 650 engine? Did you fabricate the exhaust? Good choice on the rear tires.

[STILLinFRONT]

It was realy hard to fit it in, I have no clearance anywhere, I even had to reshape the gas tank.
It got the motor, carb, cdi, and reg. after I powdercoated a friends quad frame.
I took a stock 400ex exhaust, cut one side off, cut both headers 1 inch shorter, repositoned it, then welded it back up.
My intention was for it to look just like a 400, until we raced!

[Zingnut]

Very slick and very Impressive!!!

[beak7707]

That is a sweet quad. How is the power, how do you think it will run when you get it geared right?

[Tommy 17]

how did u reshape the gastank????


very nice conversion thou...

[sled_ed 300ex]

thats awesome !!
realy nice work its even clean it almost looks like the 400 motor !!

im realy impressed it looks great!!

[exrider360]

very nice job it looks stock. did you alreayd tell everyrone you ride with your doing it if you didnt dont tell them and smoke them

[Jawzy]

Aw man you beat me to it... I still haven't found a motor. I found a bunch or 650R's. But I dont want water cooled or a kick start.

It kinda looked like it was going to be a bolt on fit to me but I guess not. What did you have to modify on the fuel tank??

[STILLinFRONT]

The gearing was way too tall, but it easliy pick to front end off the ground. It is much faster than a stock 400, It sounds sweet. It has a very deep sound, but not much louder than a 400.
To reshape the gas tank you need a haeat gun, spray water bottle, and a teflon coated spoon.
After I drain the gas and vented the tank, I filled it with a gallon of water.
I just heated the tank slowly, pushed with the spoon, and sprayed water to cool it off, then released pressure.
It will only move 1/4 inch at a time. You need to do it slowly.
If you heat it too much, or push too hard you will tear the tank. If the tank looks "wet" you heated it too much.
My tank had no leaks when I was done