2004 TRX250EX conversion - w/ vid

[atctim]

So this was what I started with:



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:


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:



My cousin welded and gusseted it up for me. Here it the frame once final welded:



And some paint:


and finally some assembly pictures:



and as she sits now:



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]

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]

Very nice work.

[atctim]

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]

Nice job Tim!

[Kintore]

cant wait to ride it buddy! looks AWESOME!

[Billy Golightly]

That thing looks awesome Tim, NICE work! Love the simplicity of it.

[atctim]

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]

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]

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]

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.

[atctim]

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



Completed bike

[audioworks04]

Looks good especially the tank, it flows just right with everything.

[MonroeMike]

That was quick, looks great.

[OZQUAD44]

Unbelievable, nice work boys.


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