350X 400EX Transplant Build!

[Matt85'350x]

Did a few little things. Decided I'd work on the electrical. Anyone know what this nub is about on the switch assembly? It's a brand new OEM part, does the quad have bars with a hole in them? I don't understand.

It was preventing me from mouning it to the bars so a little dremel work and voila



Also got my new grab bar from PRM. Those suckers only sent me 3 bolts?



Got home late from church tonight or I would have had time to modify the skid plate for my oil lines. You'll see what I nean hopefully tomorrow. I need to cut it here.



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[x-rider]

I just did the same on my x.

[Matt85'350x]

I just did the same on my x.

Put a 400ex engine in it? Have any pictures?

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[x-rider]

Cut the nub off my electrical switch. Lol.

[Matt85'350x]

Cut the nub off my electrical switch. Lol.

Lol. Misunderstanding there. Why does it have it?

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[Dirtcrasher]

Some OEM bars have a hole in them.....

[x-rider]

Probably for a hole so it doesn't shift. Guessing.

[Red Rider]

Probably for a hole so it doesn't shift. Guessing.

Exactly. It also keeps it from spinning around.

[RIDE-RED 250r]

3 bolts for the grab bar is correct if I recall.


Looking good!

[Matt85'350x]

Made some progress tonight. Got the slot cut in the skid plate so now the oil fittings and lines will clear. Cutting that was a lot on the little dremel but with patience and letting it cool down a few times I got it done. Still need to finish grinding it but wanted to do a test fit. Looks to work and I think it's a classy mod, not too hideous. I'll dress it up and it'll look nice.




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[Matt85'350x]

Had a few minutes tonight. Decided to see how close a 350x exhaust comes to bolting up since the headers between the 2 fit right on. Full exhaust almost bolts right up but ends up being about 3/8 too short


Just was trying to figure out the path of least resistance. If the 350x exhaust worked out perfectly I'd run it for testing, I'll experiment more with the 400ex exhaust.

Did figure out the CDI mounting. Just use the CDI sleeve from the 350x and rotate it around on the 400 CDI. Then just slide it where the coil went on the x.



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[Matt85'350x]

More progress tonight on the electrical. Took top notch's idea of where to mount the coil. Just need to bend the hook near the oil cooler back. Then use the mount that normally just has a wire clamp on it. A longer screw is needed and I used 2 nuts to make up for the gap between the coil and the frame...easier to just see in the pictures.


The spark plug wire doesn't have any extra length where it is but it works. The wire harness heat shrink has to be removed so that the coil wire isn't so far back. It was hard for me to cut back the heat shrink since I bought a brand new wire harness. The wire for the coil comes from the CDI which works out with where I mounted the coil and CDI.

Had to remove the tape and shrink to get the reverse and neutral connections to the engine loose. My goal is to not to have to cut the wiring harness. So far it's working out.



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[6spdls1z28]

Looks good keep up the good work.

[Matt85'350x]

Still working on the electrical. Need to mount all of the components so I know where to route the lines. Made a plate for the key and indicator lights but it didn't quite work out because of the triple trees




This is where it hits



Decided to remake the plate but move the key and lights to the opposite side of the bars. Then I'll get bars without a cross brace



At least the actual holes work as intended, just a few tweaks on the drawing and I'll have it



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[RIDE-RED 250r]

Hmm..... Any possibly way you could shim the plate away from the triple??? What about using long studs instead of bolts for the handlebar clamps, then using spacers on the studs to shim the plate away?