TRX250R.ORG
General => Projects => Topic started by: Turftamer on November 22, 2013, 09:32:10 PM
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I picked this quad up about 2 years ago. It was very clean and ran pretty good. There were a few small issues. The drain plug threads were cracked and required silicone to be cleaned out and re-applied every oil change. The case saver mounts were damaged, but functional. Compression was OK but not great and there were also a few cracks in the frame. The previous owner cracked the original swingarm and bent the shock. His son had a 2006 TRX450R he was upgrading the suspension on, so he decided to try the 450R swingarm conversion with the stock take off parts. I actually think handled rather well compared to my limited experience. The only problem was, in order to get the sprockets to line up, he had to shift the engine over to the right 3/4". This created a bunch of fitment issues with the carb and exhaust. He also had to modify the linkage mount, rear motor mount, lower motor mounts and headstay (which eventually broke in half). I think this was the cause of the majority of the frame cracks. I rode it for about a year like this before I decided to do a complete rebuild.
(http://i1333.photobucket.com/albums/w635/turftamer/IMAG0094_zpse8e4be5a.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/IMAG0095_zps742646f3.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/IMAG0096_zps2fc6e1a9.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/IMAG0097_zps57c01c3e.jpg)
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I decided to completely strip the bike down and either fix or replace any problems I could find. I relocated the engine mounts to the stock positions, repaired all the cracks and added Pumashines gusset kit. I wanted to put an aftermarket swingarm back on to fix the alignment issues and retain the handling, but since the linkage mounts had been heavily modified, I decided I would have to either re-use the 450R swingarm or replace the frame. My wallet actually made the choice for me.
(http://i1333.photobucket.com/albums/w635/turftamer/STH70226_zps9229ede7.jpg)
I sent the frame and several major components out for powdercoating.
(http://i1333.photobucket.com/albums/w635/turftamer/PCframe2_zps22c34b9a.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/PCframe1_zps16914352.jpg)
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I tore down the engine and sent the cylinder to Neil for porting, boring, and fitting of a new piston. While the cylinder was away I had the cases repaired and powder coated by BDT. I found a few tranny gears that had some wear, but luckily I had some spares.
(http://i1333.photobucket.com/albums/w635/turftamer/STH70223_zps3337deb7.jpg)
When everything came back I started sanding and polishing everything, mostly by hand.
(http://i1333.photobucket.com/albums/w635/turftamer/20130429_181701_zpsb4e57dd8.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20130429_181716_zps26d4affc.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20130522_225528_zps30ff6cee.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20130522_225555_zpse49e905c.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20130529_211604_zps5999489c.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20130713_140335_zpsfec4f351.jpg)
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Here's how the swingarm linkage mounts were modified. I thought about trying to cut it out to use a 250R swinger but figured it just wasn't worth the effort.
(http://i1333.photobucket.com/albums/w635/turftamer/20131017_195539_zpsdf4fd8ef.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131017_195614_zps964306e2.jpg)
Upper shock mount adapter bracket.
(http://i1333.photobucket.com/albums/w635/turftamer/20131017_195728_zps19f98220.jpg)
For some reason I had to grind down the swingarm to fit between the frame again. Maybe thickness of the PC added to some distortion from the welding created an issue.
(http://i1333.photobucket.com/albums/w635/turftamer/20131017_191639_zps1d776c41.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/20131017_191611_zps6ef831c8.jpg)
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Motors back together and in the frame.
(http://i1333.photobucket.com/albums/w635/turftamer/20131022_194616_zps4989ade4.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131022_194649_zpsb9bc1aa7.jpg)
Rear shock and linkage installed.
(http://i1333.photobucket.com/albums/w635/turftamer/20131023_213128_zpsa39e36ff.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131023_213159_zps6f2eac5f.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131023_212751_zps2401a12d.jpg)
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In order to relocate the engine back to the stock position and remedy the sprocket alignment issue, I had the rear sprocket hub machined and a spacer made to take up the space on the other side.
(http://i1333.photobucket.com/albums/w635/turftamer/20131110_173732_zpsb8fa95f4.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131110_173633_zpsa4899c93.jpg)
New chain, Pumashine case saver, and PC sprocket cover.
(http://i1333.photobucket.com/albums/w635/turftamer/20131110_190102_zpsccc3b16b.jpg)
I removed the blue anodizing from the Nacs kicker with the intentions of polishing it.
(http://i1333.photobucket.com/albums/w635/turftamer/20131110_190151_zpsf9591b60.jpg)
Vacuum testing cylinder.
(http://i1333.photobucket.com/albums/w635/turftamer/20131109_180018_zps5a27a415.jpg)
More pics to come!
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Nice build man, and your polish work looks great man as well. I lime your attention to detail and your eye for shiny parts. Keep up the great work man.
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Your build is looking pretty sweet. I can tell you have been working your fingers to the bone. Doing a stock cylinder by hand has got to very time consuming. I got tired after my first one. Keep at it and it will definitely be a show quality bike.
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Thanks guys. As soon as I started sanding on the cylinder I thought "This was a HUGE mistake", but I'm very happy how it turned out.
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Very cool build, I like the 450r rear end!!
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I picked up a CT midrange pipe due to recommendation from Neil to compliment the porting. Well, it didn't fit quite right with my Pro Circuit silencer.
(http://i1333.photobucket.com/albums/w635/turftamer/20131125_184436_zpsd46a26ce.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131125_184629_zps0815938c.jpg)
After a little heating and bending and cutting and grinding, I finally got everything to fit together a little better.
(http://i1333.photobucket.com/albums/w635/turftamer/exhaustmockup_zpse13e9a5e.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/exhaustmockup2_zps6d39176a.jpg)
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Looks like your silencer mod worked pretty good. Its good to know I am not the only one with those kinds of problems.
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Looks like your silencer mod worked pretty good. Its good to know I am not the only one with those kinds of problems.
I actually had to cut and bend the pipe to fit, the silencer I left alone. I had to shorten the stinger by about .700" and open up the bend a little. Now I just need some hangers ;).
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I pickpCT midrange pipe duen o recommendation from Neil to compliment the porting. Well, it didn't fit quite right with my Pro Circuit silencer.
(http://i1333.photobucket.com/albums/w635/turftamer/20131125_184436_zpsd46a26ce.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/20131125_184629_zps0815938c.jpg)
After a little heating and bending and cutting and grinding, I fiannaly got everything to fit together a little better.
(http://i1333.photobucket.com/albums/w635/turftamer/exhaustmockup_zpse13e9a5e.jpg)(http://i1333.photobucket.com/albums/w635/turftamer/exhaustmockup2_zps6d39176a.jpg)[/QUnOTE]
Is that a Lrd black silencer laying on the floor in the last pic.
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[/QUOTE]Is that a Lrd black silencer laying on the floor in the last pic.[/QUOTE]
Nah, it's the same red one that came with the bike.
(http://i1333.photobucket.com/albums/w635/turftamer/IMAG0094_zpse8e4be5a.jpg)
I was using for mock up.
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Beautiful job! Cani ask what red pc you used? Is it a close oem match?
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Beautiful job! Cani ask what red pc you used? Is it a close oem match?
Thanks! The color was "Very Red" from Prismatic Powders. I think it's close to OEM, but I don't have anything to compare to. Primarily, I just wanted to match my plastic.
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Nice looking build!
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Got the shocks cleaned up and re-assembled.
(http://i1333.photobucket.com/albums/w635/turftamer/20131204_172503_zps6c72fe71.jpg)
Started bolting up the front-end. One of the stainless shock mounting bolts seized up and now I have to cut it out. :mad-new:
(http://i1333.photobucket.com/albums/w635/turftamer/20131204_172352_zps0bc4e906.jpg)
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Looks great
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This is a very clean build. I like it a lot!
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DONT CUT IT WITH A GRINDER!!! Go to sears and get the nut cracker it will save your powder.
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DONT CUT IT WITH A GRINDER!!! Go to sears and get the nut cracker it will save your powder.
Thanks, I didn't think about that! I actually have one at work. Probably give it a try Monday night.
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very nice job. the polishing is done well.
whats the reason for the upper shock relocation bracket?
john
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very nice job. the polishing is done well.
whats the reason for the upper shock relocation bracket?
john
To be honest, I think it was just a result of the shock being too short. The previous owner did most of the modification and I think it was simply a matter of using what he had available. I'm sure it's not the best setup, but for the type of riding I do (mostly trail), it works just fine.
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I promised myself I'd get it on the floor by Sunday night - mission accomplished!
(http://i1333.photobucket.com/albums/w635/turftamer/20140112_190244_zps7xd5a9uq.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/20140112_190216_zpsybzmolau.jpg)
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To be honest, I think it was just a result of the shock being too short. The previous owner did most of the modification and I think it was simply a matter of using what he had available. I'm sure it's not the best setup, but for the type of riding I do (mostly trail), it works just fine.
I think they could have to do with using the trx450 rear end. I bought a complete 06 setup and it seems like I'll need to mess with the linkage and shock mounting location to get the geometry as close to the original Honda design as possible. I could and might be completly wrong but that's my guess...
NICE BUILD!
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I think they could have to do with using the trx450 rear end. I bought a complete 06 setup and it seems like I'll need to mess with the linkage and shock mounting location to get the geometry as close to the original Honda design as possible. I could and might be completly wrong but that's my guess...
NICE BUILD!
Thanks. I'm almost positive you're correct. The rear shock overall length is about 16". I'm not sure what a 450R shock length is, but I think this is the complete rear setup the previous owner took off his son's 450. A longer shock might help, but I think the lower linkage to frame mount would still need modification.
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That thing looked pretty good before. Now it really looks nice. Great job on the rebuild!
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Well, I finally filled with oil, coolant, and fuel! Damn thing fired up on the first kick (actually caught me a little by surprise. LOL!) and idled smooth. The only problem, center case gasket leaks. So, back out it came. Right now the motor's split apart and I'm cursing the cheap gasket maker I used during assembly as I carefully scrape it off, trying not to gouge the mating surface or scratch the powder coat. On a brighter note, I got some cool bling in the mail from Pumashine. Thanks a bunch Tony!! :cool:
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140429_182941_zpsvomoguxg.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140429_183911_zpscbs6clck.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140429_183932_zpssomhkepv.jpg)
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Big steps this weekend... Got the motor back together, sealed up tight, and re-installed in the frame; Installed my new CR ignition; and modified my Streamline hydraulic clutch to use my ASV shorty levers.
(http://i1333.photobucket.com/albums/w635/turftamer/20140518_104055_zps046sdqg6.jpg)
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Oh man, pulling the motor apart just for the center gasket! What we go through to have a little piece of mind. Those rezi clamps are looking good!
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Oh man, pulling the motor apart just for the center gasket! What we go through to have a little piece of mind. Those rezi clamps are looking good!
It was actually leaking pretty bad. After all the time I've put into this, I couldn't stand the thought of dirt and dust caking up all over the bottom end. Also, the resi clamps work great. I think I have your entire catalog installed on this bike. :lol:
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man thats a nice bike. awesome detail in everything!! and dont feel bad ive taken my cases apart over 30 times. been thru 5 center case gaskets!! fml
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IT'S FINALLY DONE!! Just have throw on the skid plate, do some carb tuning, and I should be ready to hit the trails. Thank you all for the support!
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140526_133405_zpsf66f9044.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140526_133419_zps07c54c12.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140526_133447_zps012aac0b.jpg)
(http://i1333.photobucket.com/albums/w635/turftamer/Mobile%20Uploads/20140526_133431_zpsba2b4574.jpg)
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Wow nice job! I like how you kept everthing red,black and shiny.
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Very nice man
Oh yeah, he's not kidding. Your build is super sweet!
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Very nice indeed.