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View Full Version : 2004 TRX250EX conversion - w/ vid



atctim
02-21-2010, 01:40 AM
So this was what I started with:

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs386.snc3/23610_324433942944_607307944_3687461_1029983_n.jpg

OK - so I wanted to get this thing done this weekend - and it looks like I should be able to. As of last night - I got it tore down to the bare frame for final welding and gusseting. Here it was as of Friday night:
http://hphotos-snc3.fbcdn.net/hs215.snc3/22246_332223812944_607307944_3711184_2272999_n.jpg

Upon tear down I was extremely surprised at how nice this machine was. Every bolt once cracked loose was un-threaded with my fingers. Here in western PA Honda bikes with drum brakes go through hell. When I got into these I was surprised to see that the factory seals had kept all the mud and water out for the past 6 years as this is a 2004 model. Here are two pictures of the drum brakes. Keep in mind - this is how it looked when I opened them up - no cleaning required here:
http://hphotos-snc3.fbcdn.net/hs215.snc3/22246_332223792944_607307944_3711182_7446472_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs295.ash1/22246_332223797944_607307944_3711183_4330833_n.jpg

My cousin welded and gusseted it up for me. Here it the frame once final welded:
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs215.snc3/22246_332223837944_607307944_3711186_141572_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs235.snc3/22246_332223852944_607307944_3711188_1612966_n.jpg

And some paint:
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs235.snc3/22246_332223857944_607307944_3711189_4805864_n.jpg

and finally some assembly pictures:
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs215.snc3/22246_332223867944_607307944_3711190_4548856_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-ash1/hs295.ash1/22246_332223877944_607307944_3711191_7835682_n.jpg

and as she sits now:
http://photos-g.ak.fbcdn.net/hphotos-ak-ash1/hs295.ash1/22246_332223897944_607307944_3711194_1489810_n.jpg
http://hphotos-snc3.fbcdn.net/hs215.snc3/22246_332223907944_607307944_3711195_3179578_n.jpg

I should finish this bike up tomorrow night if all goes well.

So far so good - no problems and everything fitment wise is spot on. The more of these you do the easier they get. This being #3 - they should only get better and better.

audioworks04
02-21-2010, 04:15 AM
I think that this conversion looks much much better than your previous ex conversion. What forks are those, and why not use 85/86 250r forks? I understand not using inverts due to price and the lower speed and existing suspension of the 250ex oem. My family has an 05 250ex and it is a wheelie monster from the factory, how hard is this one to ride aggressively with the even lighter front end.

MonroeMike
02-21-2010, 08:02 AM
Very nice work.

atctim
02-21-2010, 10:51 AM
Audio works. I used 200X front suspension. I feel that it most fits this bike compared to the rear suspension of it. Honestly - 250R forks would be over-kill on this little trail bike.

The first EX we built was wheelie happy - but not uncontrollably by any means, like you mentioned - Kind of like the quad. I am able to ride it aggressively on trails all day long. I honestly wish I could ride this thing exclusively on trails.

Now this new one is 1.5 " longer as we stretched it a little bit to try to compensate -

iceman atc
02-21-2010, 11:26 AM
Nice job Tim!

Kintore
02-22-2010, 09:30 AM
cant wait to ride it buddy! looks AWESOME!

Billy Golightly
02-22-2010, 09:42 AM
That thing looks awesome Tim, NICE work! Love the simplicity of it.

atctim
02-22-2010, 09:51 AM
thanks guys - just waiting on a front wheel and a new set of bars. Will update hopefully tonight once those parts get on. Pretty much finished it all up last night except the above mentioned parts! It really is a nice looking trike!


Love the simplicity of it.

Simplicity is really what has driven this design to where it is now. I know it is very non traditional - but I can have a basically new trike by building one for about the same money as restoring a trike - and about 1/16th of the work. We will have approx 12-15 man hours in this build. Not much considering.

torker
02-22-2010, 10:06 AM
Hey there Tim: Congrats on this project, THE QUICKEST OF THEM ALL!!!!! And it looks absolutely great. Like Billy said, I love the simplicity on this. Were there any challenges at all on this one? I think I can get a "FREE" TRX 250X that would be great for this. Is that the stock fuel tank? This looks awesome.
Did I say quick as hell? Man, that was quick.

TORKER.

OZQUAD44
02-22-2010, 11:12 AM
ATCs never went away, they just rugged up for the winter.

Looks like the sun is shinning in your shed!

P.S. It think it's going to need some wheel spacers, looks a little top heavy?

atctim
02-22-2010, 12:02 PM
To Torker and Ozquad:

Torker - the only challenges is getting the rake right - which is not all that challenging. We have this one set identical to the 200X since that is the front end we are using. Another small challenge is getting the clearance for the fork tubes when the steering is cocked completely (and making it look right when this happens). This one really surprised me how good it looks. When we originally looked at it with the quad front fenders we did not think we would ever get it to look good - but with a dremel and lots of patience - I love how the shrouds look. One last challenge (for me anyway) is the actual welding / fabricating. My cousin Jake is a welder by trait and is very good and efficient at what he does. I think he went from tack welded to completed in about 1.5 hours. This includes final welding, gusset building, grinding and everything. He also has a plasma cutter which is key for fast and efficient gusset cutting. Also - it should be noted he has a pipe bender that makes fabricating the lower section of frame a snap.

Ozquad - It really can not be seen too good in the pictures - but there are 1 3/4" wheel spacers on each side for a total or +3.5" width. As it sits - it has about the same width and length as a stock 350X. The 250EX is narrow by nature so wheel spacers are a must. I have searched high and low and can not find any manufacturer that makes a plus length axle for the 250EX. Our first 250EX conversion has 3" spacers on each size for a +6" and I personally find it a bit too wide - but since it is the wife's main ride - I keep it that way for added stability. this one seems about perfect. It does sit a bit higher than a traditional trike - but our other one does not feel tippy or top heavy when riding it. Also - alot of the "top heavy" looks is from the low bars in the picture. We are putting a much higher rise bar on it and this will put it into perspective a little better I think.

Since we are building this one to sell, we went ahead and welded the VIN plate from the quad to the steering neck. This should make for a better sell since we have the title for this bike and it can be registered without any hassle.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs235.snc3/22246_332223852944_607307944_3711188_1612966_n.jpg

atctim
02-22-2010, 10:56 PM
OK - the build is done. We test rode it and it handles great. I am still waiting for my new bars which are a higher rise bar as these are too low. This build went very well and I am very happy with results.

Here is me and my cousin Jake - the builders / test riders

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs391.snc3/23817_336128757944_607307944_3731749_5999515_n.jpg

Completed bike
http://hphotos-snc3.fbcdn.net/hs371.snc3/23817_336128777944_607307944_3731750_356230_n.jpg

http://hphotos-snc3.fbcdn.net/hs391.snc3/23817_336128787944_607307944_3731751_493516_n.jpg

audioworks04
02-23-2010, 12:13 AM
Looks good especially the tank, it flows just right with everything.

MonroeMike
02-23-2010, 08:48 AM
That was quick, looks great.

OZQUAD44
02-23-2010, 10:40 AM
Unbelievable, nice work boys.


Next quest to ask is this, is it worth more as a three wheeler?

rdlsz24
02-23-2010, 10:45 AM
Nice work. This was the second one you did right? The last one was red??

Rob

Mondexbrute
02-23-2010, 11:25 AM
How much? Looks like it needs taller handlebars.

atctim
02-23-2010, 11:48 AM
$2000 - it is getting taller handlebars - they will be in and installed tonight!

This is actually our 3rd conversion - 1st was a 450R - then an 06 250EX - black and red - now this one. All 3 can be seen here:

http://www.venustel.com/~tkeister/customs.htm


Unbelievable, nice work boys.


Next quest to ask is this, is it worth more as a three wheeler?

Wouldn't it have to be?????? Cost of quad + labor + trike parts and last but not least - COOLNESS FACTOR!


BTW - this trike comes with a PA title.

Mondexbrute
02-23-2010, 01:38 PM
thats awsome! $2000 is a good deal I think! Ever thought about turning a bigger 2x4 into a trike, like a Honda Foreman, Rancher, or something like that?

atctim
02-23-2010, 02:13 PM
Mondexbrute - I have given some thought to doing a bigger machine - but trying to turn a 4X4 into a 3X3 is futile! Many have talked about it and lots of ideas have been kicked around, but it has never been done. I've heard all ideas from a string of drive shafts - to a Rokon style motorcycle drive train to a 2nd motor on the front rack. My opinion is that it would be too much trouble than what it is worth. The only feasible way to do it in my eyes would be to run a hydraulic pump off the front drive shaft to a remote hydraulic motor that powers the front wheel. But then speed control would be the factor.

I personally want to turn the Honda 420 Rancher into my own personal trail 3 wheeler. It is the larger utility quad Honda makes in a 2WD. Someday I will make this happen!

Mondexbrute
02-23-2010, 05:02 PM
Oh I was reffering to a larger cc 2wd Like the 420 Rancher you mentioned! Check out my build " Big Camo 250es Project" , I guess its the next best thing for riding down south in the swamps!

oldskool83
02-23-2010, 05:22 PM
Looks pretty cool, is it just me or do the bars look super low?

SYKO
02-23-2010, 07:57 PM
what is the overall length of the machine? it looks loooooong... and narrow... well I know the rears are narrow and some spacers and offset wheels can cure that but compared to a 200x or 250r what are the overall wheelbase differences?

Mondexbrute
02-23-2010, 08:32 PM
How does it ride? If you can you should post a video clip!

atctim
02-23-2010, 09:32 PM
I will post up video tomorrow if it is not raining out.

Syko: I think the looks may be deceiving.

2004 250EX conversion - wheelbase = 51 1/2" and it is 45 " wide.

Compare this to other machines.

1985 200X - wheelbase = 47.6" and 41.3" wide

1985 250R - wheelbase = 51" and 44"

1985 350X - wheelbase = 50" and 43.9" wide.

So by comparison dimensionally - it is most like a 3rd gen ATC250R being just 1/2" longer wheelbase and a full 1" wider.
Some based on a comparison - it really is not that long compared to it's width. I will get some pics of it tomorow along with some other trikes as a comparison.

jason85atc250r
02-23-2010, 09:48 PM
Atc tim it looks good. Makes me tempted to have you do the 92 250x i have + i have a extra 350x front end sitting around

By the way if you are going to do any more of them i have tons of 83-85 200x front end parts sitting around.

Tim my buddy has a 2wd rancher he is trying to sell. he got it at a bank repo auction online. he bought it by mistake he thought it was a 4x4 he bought 3 ranchers total. I'll ask what he wants.

how much for the front wheels from the quad? The ones on "rex" are getting really beat up the one looks square on the outside.

atctim
02-23-2010, 09:52 PM
Jason - sounds cool. I'll keep that in mind about the parts, and I appreciate it. Jake and I have thought about doing a 250X or 300EX. Let us know if you are serious about it.

jason85atc250r
02-23-2010, 10:02 PM
i'll let you know about it depending what i decide. The 250x/300ex front suspension sucks for a person thats 250+ my 350x rides way better.

SYKO
02-23-2010, 11:26 PM
well I guess it is deceiving then for some reason it just looks realllllly loooonnngggg and narrow... oh well no biggie! I like it though!

audioworks04
02-24-2010, 12:25 AM
There is a company out there that makes conversion kits to make dirtbikes all wheel drive, so it would be possible to make a 3x3, but probably not feasible. They do this with a chain drive off the counter sprocket, up to the frame, then another set of sprocket to make it follow the frame then somehow changes to a set of telescoping drive-shafts down the forks, or something to that effect.
http://www.christini.com/

atctim
02-24-2010, 09:26 AM
OK - this video came out really really bad. I will try to get a better one tonight when I get home. At least this will give you and idea of what is up with this new trike.


http://www.youtube.com/watch?v=qlQQh5Kgqkk

oldskool83
02-24-2010, 01:00 PM
a 300ex conversion would be awesome, i been thinking about this since i bought a 300ex for my g/f in nov.

fabiodriven
02-05-2013, 10:12 AM
Tim, I've always been a big fan of this conversion. I think you guys did a great job on this bike. Feel like putting up a couple more pics? I've been getting into the SX's pretty big lately and I've been thinking a lot about this conversion.

atctim
02-05-2013, 10:18 AM
John, I'm not sure I have any more pictures of them. I=Trike had one a while ago, but he doesn't have it any more. The other one went with my ex-wife. Honestly, this conversion is the most fun to ride all around trike. Great in the woods and decent power for what they are. I have always wanted to build another one for myself - but have not come across a cheap enough 250EX yet.

fabiodriven
02-07-2013, 02:06 PM
Awesome Tim, thanks for the reply. I'm just thinking down the road I'm going to have to build something like this. We've been wheelin' the hell outta these SX's and ES's in the mountains and these machines are not getting any younger. An update will be in order at some time.

fabiodriven
02-07-2013, 02:24 PM
Speaking of the mountains, if you ever wanted to come scale a mountain with us sometime feel free. It's a really good time. We'll find a bike for you to use if you couldn't bring one. Not everyone gets offered a bike to use, but the guys we know do.

mooseknuckle
03-15-2013, 08:00 AM
WOW! Amazing job Tim! I can see I'll be stashing $$ away, I HAVE to get one of these sweet trikes!