Well I've started collecting parts for this project, so figured I'd get a thread going. I have some crazy ideas for this build, but I'll have to see how things work out. It's a budget built so probably won't end up too pretty, but it's a functional build to get a little more out of the 250sx and more tuned for my riding style and terrian (sand, swamps, mud, tight wooded trails, etc).
Here's what I'm starting with. Also missed the trashed fenders in the photo. 85 250sx frame, grab bar, tank, and some ITP steel rims I got off the guy. I'll have to get a photo of the 350D, it's ride-able but pretty trashed and the engine noise has stopped me from enjoying it as is. Since I fear the worse and the crank needs fixed/replaced I have some interesting mix up of parts I want to try, if they work, I'll have a very unique shaft drive machine, if not, then just at typical 350D shoe horned into the 250sx frame. I'm unclear, but some people say the engine bolts right in, more people say it's nothing the same. I'll find out once I get the engine pulled. Engine mounts shouldn't be a big deal to build but making it so the engine can go in/out of the frame might be a challenge lol.
Anyway, few photos of where I'm at. I'm keeping an eye out for a parts 250sx since I have a feeling I'll need some misc parts but most will be from the 350D. If all goes to plan, I'm converting the engine to kick start only, no battery, I'll keep the voltage regulator/rectifier for lights (maybe LED). Name of the game is to make this thing pretty light since shaft drive naturally is heavier than chain drive. End goal is effectively an atc350x except it's shaft drive which is why I'm targeting the 350D engine which has more or less the 350x top end design.
Frame looks pretty straight, I haven't looked over it for broken bolts and such, foot pegs bent up a bit but should be easy enough to fix later.
Tank clearly was repaired at some point in time, hopefully it is usable, not too worried about it being ugly. Guy put a bunch of oil inside of the tank to prevent rust.... used engine oil. Couldn't see how bad the rust was, should have asked for some gas and flushed it out. I'm not sure on what tire and tire size I'll be running, he had the rims for pretty cheap so figured I'd grab them encase I needed an extra set, I don't have much for SX parts on hand.
I do plan on building a custom harness for this machine once I get everything else figured out.
Always open to ideas and suggestions or other people's experience. I have the 350D on hand, I know the 300/300fw engine is easier and done more often, but that's a 2 valve engine, I want the 4 valve 350x style =). I'm currently not planning anything like big bore kits or anything like that. Wouldn't mind running a bit higher compression piston than factory, I'll be running ethanol free 90 octane in it.
I've heard the XR400 exhaust header works on the 350x engine, anyone have more details on that setup? I heard there's some slight head mods needed to make it work.
I like a quite/stock sounding exhaust, thinking about a TRX400EX exhaust, good or bad idea? Mounting and bending a little is no big deal. The other option is a DG for a 350x, but not really into the super loud exhaust.
Planning to use the TRX400EX carb and will try to use the stock air box (I think I have one around). I don't normally go in super deep mud, but I want to connect the carb up to the frame rail "snorkel" that's factory to keep atleast stock levels of ability for water.
Clearly the 350D engine is full time 4x4. I'm not sure how the offset compares to the 250sx, but maybe I can swap the output shaft over from a 250sx into the 350d engine? If not I should be able to figure out something to "delete" the front drive shaft one way or another.
Any suggestions on cheap but pretty good rear shock? I'm pretty sure I have a spare one from a 350x and should have one from a trx250x. Probably not going to be jumping this thing too much, maybe that will evolve later though.
Hopefully this is a fun thread and the build should be pretty interesting.