350X 400EX Transplant Build!

[BOB MARLIN]

The advantages for me are as follows:
-Electric start
-Reverse
-Lighter engine (don't know the exact numbers but I do believe it's lighter)
-More aftermarket support/parts availability

Other than that I don't know what to tell ya. It's something that I've wanted to do for a while. The overall idea is to end up with a more modernized 350x. A 450 hybrid would be cool but a bit out of reach for me plus I really like the 350x so a modernized version of it really appeals to me.

That's a good enough list to justify it. For me it was the e start I was after, the oil tank was the killer of the project though. I've seen a few ex conversions (pictures) and the oil tanks seem to be the problem . Maybe under the seat somewhere or along the side under the rear fenders would work, but all the ones I've seen are mounted out front like the quad and look hideous, and vulnerable.

So I elected to go the 450 hybrid rout.

[Ol Deuce]

WHAT AGREAT UPGRADE............that push button start and reverse are a great way to fly ! Great job!! Ol Deuce

[Matt85'350x]

That's a good enough list to justify it. For me it was the e start I was after, the oil tank was the killer of the project though. I've seen a few ex conversions (pictures) and the oil tanks seem to be the problem . Maybe under the seat somewhere or along the side under the rear fenders would work, but all the ones I've seen are mounted out front like the quad and look hideous, and vulnerable.

So I elected to go the 450 hybrid rout.

You read my mind! To me the solution to the oil tank is in the motorcycle world. There are hundreds of ready-made tanks made for motorcycles that could be used for this project. No reason to make a custom tank. Right now I'm leaning toward having the tank hang off the side of the rear of the frame. If I did that I'd get something like this: http://www.ebay.com/itm/Basic-Round-...H8oCFQ&vxp=mtr


Or this: http://www.ebay.com/itm/CHOPPER-BOBB...Bq0PtA&vxp=mtr



If I decide that it needs to be between the carb and swingarm, this might work (gotta check the measurements). I measured around 3 inches being available but the mounting plugs might get in the way. http://www.ebay.com/itm/3-in-Custom-...9W112x&vxp=mtr



I'm leaning towards hanging the tank off the side because I'd gain some oil capacity which I believe will help with cooling. Besides that I see no reason to hide the mechanical things, I think it'd look good. I used to love Indian Larry's builds because he would always showcase the mechanical parts of the bike-one time he had the oil filter hanging right out the side of the bike! I'm no Indian Larry, but I don't see anything wrong with a tank hanging off the side of the trike.

[Matt85'350x]

So far this the scariest part of the build. In order to mount the rear of the engine, I actually had to drill the cases. This mounting hole does not go all the way through. No idea why, but it doesn't. When I looked at the case halves on Ebay, there's nothing there to put at risk, it's just not all the way through. After I realized this I went back and re-read "Top Notch 350x" build and he mentioned that you have to drill the hole out. So I held my breath, said a prayer, and drilled it out:









It drilled really easy. Didn't see any oil come out, so I think I'm good!

[RIDE-RED 250r]

This is fantastic!! Nice work thus far Sir!

The oil tank: ever give any thought to running some sort of pod filter that would allow room for the tank where the air box is?? Myself I would be a little concerned mounting the tank outside the frame under the rear fender. Seems like it could sustain some damage from flying debris and whatnot there so close to the rear wheel with nothing to protect it. Particularly in the cases where a descent sized tree branch gets tossed by the rear wheel. As much as those hurt to get hit by, I would suspect it could damage an oil line

[userj8670]

Sorry for the ignorance but why do you need an oil tank? Do you not put oil in the crankcase?

[Matt85'350x]

This is fantastic!! Nice work thus far Sir!

The oil tank: ever give any thought to running some sort of pod filter that would allow room for the tank where the air box is?? Myself I would be a little concerned mounting the tank outside the frame under the rear fender. Seems like it could sustain some damage from flying debris and whatnot there so close to the rear wheel with nothing to protect it. Particularly in the cases where a descent sized tree branch gets tossed by the rear wheel. As much as those hurt to get hit by, I would suspect it could damage an oil line

The same thought crossed my mind but I didn't think of a pod filter. Definitely an idea but would prevent me from running in the mud right?

[Matt85'350x]

Sorry for the ignorance but why do you need an oil tank? Do you not put oil in the crankcase?

The 400ex has an external oil tank. The oil is pumped into the engine. Not the only engine to do this.

[RIDE-RED 250r]

The same thought crossed my mind but I didn't think of a pod filter. Definitely an idea but would prevent me from running in the mud right?

It's true that running a pod does require a bit more care in wet and muddy situations, but I wouldn't think you would have to avoid the mud 100%. I would just be a little more careful, avoid hitting deep water holes and getting it buried up to the seat. An Outerwears can help a bit in this regard.

If you look for mud to play in alot, then a pod probably won't suit you.

[DohcBikes]

If I were building a trike with a dry sump motor, I'd thoroughly clean and close up the backbone and the downtube of the frame and use it for the tank.

[bkm]

If I were building a trike with a dry sump motor, I'd thoroughly clean and close up the backbone and the downtube of the frame and use it for the tank.

You beat me to it as I was thinking the same thing. The XR400 is basically the same engine and uses the frame as the oil tank.

[BOB MARLIN]

Now you guys are seeing why I kept talking myself out of the EX conversion and went strait to the 450.

[Matt85'350x]

Now you guys are seeing why I kept talking myself out of the EX conversion and went strait to the 450.

I knew what I was getting into when I started this. Not too interested in using the frame. Don't know that it could hold enough oil. This isn't an impossible issue-it will be overcome.

[Matt85'350x]

It's true that running a pod does require a bit more care in wet and muddy situations, but I wouldn't think you would have to avoid the mud 100%. I would just be a little more careful, avoid hitting deep water holes and getting it buried up to the seat. An Outerwears can help a bit in this regard.

If you look for mud to play in alot, then a pod probably won't suit you.

I never go looking for mud but it seems to find me. When this is done I'll probably just not ride if it's muddy. I've got a lot planned for this build, it's not just the engine. Frame will end up getting sent to HRE to get gusseted and fitted for one of their swing arms. I've got some low pros for the rear and new plastics everywhere else. Also got an aussieduner white light for the front.

[DohcBikes]

It will hold plenty of oil. Why aren't you interested in using the frame? Its the obvious answer. In my opinion. Aren't you going to run a cooler?