Crossfire 400r Irs

[fan4chevy]

I will post some images. Mine are being pretty modified. Spoilers, seats, plastic, safety netting, doors, larger cc engines, 4 point racing harnesses, hammerhead plastic, windshields.

[BEEFKING69]

You should be fine putting bigger front tires on those. I prefer the kenda front max. 20-7-8 will be a good bit taller than what you have now

[fan4chevy]

I think I can fit that 20-7-8. What model tires you like on front and back?

One thing I am considering doing though is to upgrade the front suspension to a Yamaha Raptor. I feel this would be way better than the stock ones I have. However, I also want to have a 50" front wheel width so I can get on the 50" max trails.

If I go much bigger on tires, I think I will have some rubbing issues bringing in each side by 1.5". Pretty tight leg room as it is.

[BEEFKING69]

Originally Posted by T@BD

Something else i wanted to ask you was about those knuckles your building for your crossfire....can they be made to work with stock a-arms and spindles? I need to replace all 4 of my balljoints and those look very interesting.

[fan4chevy]

I wish I had a high, low, neutral reverse gearbox with the independent rear suspension like you have.

[BEEFKING69]

Stock no bigger than 23s.....ITP mudlites and kenda bearclaws are really good and ive had a set of 22-12.50-10 super swampers that i liked. On this build ill be running 26-12-12 GBC dirtdevils as i got them for basically free....They will be mounted on a pair of 12 inch carter gtr rims.

[fan4chevy]

what will you be running on this build in the fronts? I am guessing your talking about 26-12-12 rear.

[BEEFKING69]

Yeah i love my High/Low and the IRS is night and day.....if you find a HH250ss for cheap buy it and motor swap it or just cut it in half for the IRS like i did.....Dont remove the sway bar like i did tho. The 400 is 2 speed automatic.....it has a torque converter like a car and the 2 speeds is basically High/Low. Technically 1st was for city cruising and 2nd was for highway cruising. Yes 26 rear and 21 or 22-7-10 on the front. The raptor front end will be alot better as long as you can graft it on right.

[fan4chevy]

so you feel the irs was worth the swap?

[BEEFKING69]

Absolutely. I would honestly take a garage kept running/driving HH250ss and cut it in half just to put it on my other crossfire and my buddy who owns my old crossfire (the sym 250 swaped one in this thread) wants irs on his.

[fan4chevy]

The one thing I think though is that the straight axle does have advantage of less wearable parts. No worry about axle boots tearing, bearings wearing, etc. Especially when considering we are usually near dirt, water, sand.

[BEEFKING69]

Yep....Ive had to replace my cv boots multiple times. And now i need to replace the center axle bearings and cant get the cv axles off...infact ive done snatched both cv axles apart trying to get them off and still cant get the inner cups off the center shaft.

[fan4chevy]

So with that said, I have kind of talked myself more away of independent just for the dependability.

I could be wrong. However, I would imagine that an awesome pair of shocks on a straight axle would be better than mediocre shocks on an independent rear and an awesome pair of cushioned seats.

Speaking of seats, mine now sit up about 4-5 inches higher and it feels real cool.

The one thing though about independent is better ground clearance.

This is my inspiration buggy:

[BEEFKING69]

A good pair of shocks (banshee front shocks on the rear) and seats will make a world of difference. Ive had very little problems out of my irs up till now but i havent taken care of it what so ever. The hh250ss needed center bearings when i got it almost 2 years ago and i didnt feel like tearing it apart to change them and ive put a few hundred miles on those bad bearings since ive had it. Boots have been an issue because i used thin stretch boots so i could put them on without having to take the cv axles apart. Both of my rear shock are completely blown out and it still is way better than a stock swingarm.

[fan4chevy]

Not sure if they fit yours. However, there are boots that are in half that you screw together so that you don't have to pull the shafts out. I used them before on a car. Was an awesome quick solution.

I am considering the Yamaha raptor shocks because they are very easy to find and have excellent review.

[BEEFKING69]

I havent seen those before and on shocks just make sure they are 13-14 inches eye to eye.

[fan4chevy]

I think on my rear shocks I will go longer and weld new location. I would like to force a bit of lift on the back.

This is my inspiration buggy attached

[BEEFKING69]

That will work also and that buggy is sweet. Youll have to see how the suspension travles with those having that dog bone links. Best way is to unhook the shocks and jack it up under the body to see how the links affect the travel.

[fan4chevy]

If needed, I think I can modify the lengths of the dog bone links. One way or another I would like to raise the body up about 2" or so and get a much more aggressive travel. Besides the front suspension on my buggy is so weak looking.

[BEEFKING69]

I want to lift the back of mine a little bit but i dont know how much i can before the cv axles bind. I may not even need to once i get the 26s on and the polaris predator 500 shocks.

[BEEFKING69]

Next project once i get this drivable again is to get it street legal

[fan4chevy]

I drive mine on the streets. Registered and insured. Problem is, POWER! Mine hits 25mph right now with upgraded gy6 parts.

[BEEFKING69]

What kind of sorcery did you pull to get them legal? and they should run 35 bone stock

[fan4chevy]

I wish they could do 35. If they could have then I would have been decently happy. Having the 3 of them, not one could hit over 25 with performance clutch, a12 cam, 12g sliders, hipo variator bell, performance cdi, straight through muffler and jetted. I am about 2300 elevation though.

For getting them street legal, at first dmv by phone said, we don't even give offroad stickers for them. However, that dmv agent was wrong. I went to dmv and got the limited use plates which means can not go on hwy. However, as is, they really are not much fun on pavement. After the new seats I put in and hopefully more power will change that though.

[BEEFKING69]

Something aint right somewhere....slowest buggys ive ever had was yerfdog spiderbox's and they would run28-30 stock. Im basically at sea level but that shoudnt matter. Ill be getting actual car tags for mine if everything works out.

[fan4chevy]

I am not sure but I have ran our cars behind them and 2 of them have been between 22-25mph.

I don't think you will be able to get car tags anywhere in USA. Not even Rzrs can. If you can get them legalized, your not suppose to be able to go on any street that has a speed limit above 45mph.

Even in my area you can not cross even a state hway unless it is in an area below 45mph. Rzrs also fall under this.

[BEEFKING69]

One thing to check is ur brakes and parking brake....ive had problems with brakes dragging and numerous problems with the parking brake adjuster bolt self tightening.Theres several tagged rzrs running around.....a few are tagged as motorcycles and some are tagged as custom built trucks. Theres also a HH250ss in Michigan thats tagged as a roadster and a carter gtr 300 in south fl tagged as a car.

[fan4chevy]

I can turn the tires by hand and they don't appear to have any drag. The funny thing too is that bot are about the same speed.

If they are getting rzrs on state and federal hwys, I am shocked. Thy would have to have dot approved seats.

Our state is super lenient and as mentioned we are limited to streets, no hwys. If you state has them full access, wow that is real cool.

The coolest thing would be to do a 500cc or 600cc motorcycle engine. I have seen some super fast buggies with them.

[fan4chevy]

By the way,

Looking at your project is real cool. You should really consider a ninja engine. They are just awesome: https://www.youtube.com/watch?v=4_62fcas6rk

[BEEFKING69]

They are jumping through loopholes and gray areas....Seats dont matter but they gotta have dot tires and windshields etc and some or non interstate use tags.....some have also went the route youre talking about that limit them to 45 under roads.

Anothger thing to check is to jack it up and pull the cvt covers off and see if the belt is coming all the way to the top of the rear pulley.

I mainly went with the cb400 because i got the whole running bike for free and it only had 8800 miles on it plus i had read a couple of write ups on using it on the other forums.

[fan4chevy]

Interesting they can get them on hwys. I think even if I could get the buggy to 50-70 I just would not want to go that fast in these. 45 even in a rzr is pretty fast.

I know the front variator pulley does not go to top. Probably about 1/2" from top.

Your cb400 I would bet would hit 70mph. It is a crazy 59hp.

[BEEFKING69]

Its expensive and time consuming from what ive seen and you have to get an outa state title and have it transferred in some cases. It not going to the top sounds like rollers or sliders are not in right. Im estimating 85mph in high but im going to gear it down to around 65 and yeah the front ends have to be in perfect alighnment or they go all over the place above 40mph. Mine and my buddys both ran 50 smooth and straight after front end work but before they was all over the place.

[fan4chevy]

could be dangerous if not steady straight at them speeds.

I checked many times and the sliders are for sure in correctly. Could be the new belts though not long enough as they should be.

[BEEFKING69]

Yeah they are sketchy lol. what size belts you got?

[fan4chevy]

743-20-30

[BEEFKING69]

Thats definitely the right size.....maybe its the performance variator?

[fan4chevy]

not sure. Do they always go all the way up?

[BEEFKING69]

Mine lack a couple of mm from going all the way to the top

[fan4chevy]

hmmm. I will check it out more this week. Man these buggies are so addictive. Can't wait to see yours done.

[BEEFKING69]

Yeah they are and fairly cheap addiction compared to name brand stuff......although this one has gotten outa hand pretty quick since the 400 swap started mostly cause im ina hurry so everything falls apart at once lol. I know im ready for this to be done also so i can get some video of it in action.

[fan4chevy]

What has been the difficult part to the build that I should be aware of when doing engine swapping?

Still seems reverse would be a kicker.

[BEEFKING69]

On mine its been figuring out how to keep reverse....On my buddys it was figuring out how to mount the 250 to the swing arm....What to cut and where to cut and how to get enough clearance for the swingarm to have room to piviot without the motor hitting anything.

[fan4chevy]

I too really want reverse and see that as being the hard part in engine swapping. However, I thought long and hard and figure that POWER is so much more important than reverse that is rarely used. Yes convenient and wonderful. However, not worth the sacrifice of POWER!

Nonetheless, I am still in desire to figure out reverse.

[BEEFKING69]

Reverse is an absolute must for me if im going to ride it anywhere other than the dirt roads to town and back. Hopefully this shaft that travis is building me will take care of that. Ive already got the sprocket and bearings and have my gear ratio figured out. Still gotta order chain and im clueless on how im going to do chain tensioners.

[fan4chevy]

Why not just do the chain tension like they do on many atv engines including the gy6 buggy where there is a threaded bolt that pushes the engine up and down for tension?

My area has a lot of hills and rough terrain. I got very frustrated trailering our buggies to the woods to find out I had to keep turning around due to lack of power. Especially as we ride two per buggy.

[BEEFKING69]

Ill have two chains.....One from motor to jackshaft and one from jackshaft to axle. Be impossible to get both tight with one adjustment. I never had to much problems with two people in any of my modded buggys altho it was bad on clutches but stock ones or a pig.

[fan4chevy]

where I was riding had a lot of hills. I was lucky to hit 5mph in both of the buggies. GY6 150 that is.

Is the jackshaft for the Reverse gear box?

Are you using the round external Reverse gear box that is on gy6 150's?

[BEEFKING69]

I still think something is wrong with your cvt....or either you got some hella steep hills. Yes jackshaft is for the reverse box and it will be a stock external box from a 150.

[fan4chevy]

I get fairly slow take off and need a real run at a hill that is about 15' high.

[BEEFKING69]

Here is the list of mods...

Crossfire 150

26mm carb
Uni filter
glasspack type muffler
60mm jug with HC piston
Big port head with SS valves and titanium springs
A-12 cam
135 main
38 pilot
12g sliders
yellow clutch springs
yellow contra
custom oil cooler
Iridium spark plug
Stock coil/cdi

Would run almost 50mph on flat ground and climb any hill i ever looked at

[fan4chevy]

Mine is:
Stock bore and head
Uni Redneck
128 jet
Pilot jet not changed
12g sliders
1500 Springs throughout
Beljing Clutch Bell
NCY green clutch
Ball Bearing Contra Spring Base
Straight through exhaust 1-1/8" pipe
115mm Variator Faceplate
Irridium spark plug
Orange coil
performance cdi
New performance chain
A12 cam

[BEEFKING69]

Ive never had any luck with orange coils or performance cdis on 150s. I tried a couple on that crossfire and it ran like dog ****. Also never tried the roller spring base but always wanted to. Id try putting the stock cdi back on and see if it makes a difference.

[fan4chevy]

I will try going back to the stock coil and cdi. Just went with the flow where so many said it was a must to have these for improvement.

The bearing Contra spring base is pretty cool. Just takes the binding out of it.

Thanks

[fan4chevy]

Where is a good place to find 530 chain gears. I think I will need one with 27 splines.

[BEEFKING69]

Cdi is most likley gonna be the culprit if anything. Best bet on sprockets will be from motorcycle or atv.

http://www.jtsprockets.com/catalogue/ This is where i found sprockets that fit the carter gtr 250 motor. Very time consuming as you have to just go down each manufacture/type/and capacity till you find something that will work if theres even anything with the same spline count and diameter.

[BEEFKING69]

Update.....Going with 2 vm-30 carbs off polaris trail blazers and got the new intake manifolds to adapt them to the 400 and got a GM two post coil and new wire and boots. Should have motor mounted and maybe some wiring done this weekend. Gotta find a 2-1 throttle cable long enough for the buggy.

[fan4chevy]

So close aren't you?

[BEEFKING69]

Close enough i can taste it lol......been wayyyy to long since this buggy has seen action.

[Fabtastic1986]

Could you post some more pic. I'm in the middle of a 500cc ninja swap on my crossfire. I'm trying to get some feedback on mine. If you get a minute I would like your opinion on my thread. Its crossfire with 500 Vulcan motor

[fan4chevy]

I think I am going to have an enormous task trying to fit a chain drive. My drive shaft was not meant for a chain gear so I have to figure out how I am going to make it work. The shaft is 27 spline with 29.5-29.7mm diameter.

I thought of using an oem wheel hub that fits it and see if there is a way to attach a chain gear to it with a 30mm diameter center.

[BEEFKING69]

Fabtastic1986.....Phone is broke and the tablet takes crap pics.....but if theres something inparticular you want pics of let me know and ill see what i can do and ill go check out your thread.

fan4chevy.....can you get some pics of the motor and shaft? what model/make scooter is it from?

[Fabtastic1986]

Beefking69......I would like to see some in depth pics of your IRS setup. I built my own trailing arms but the are pretty big. I would like to shrink them down a bit. Mounting is what I would like to see.

[BEEFKING69]

Ok ill try and get some today of my 250 and of my moon buggy 150cc cause its got irs also

[Fabtastic1986]

Awesome thanks.

[BEEFKING69]

If you want to see my 250 ones before I get some pics just Google hammerhead 250ss trailing arms as the back of my crossfire is hh250ss rear section. The moon buggy 150 trailing arms are different

[BEEFKING69]

Tried to get some pics of the moon buggy arms but after i looked at them on the tablet you cant really tell anything about them. Got some of the hh arms just gotta get them uploaded.

[BEEFKING69]

Update...Made some progress on getting these stupid cv cups off the center axle. Most likley going to have motion pro build me a 2-1 throttle cable.

[fan4chevy]

awesome. Keep the images coming.

[BEEFKING69]

I belive i have my chain tensioners figured out....I think im going to try what Donnie did. 5/8 idler sprocket with 5/8 adjusting nut welded to frame and some all thread.



Bonus pic...Decided to pull the motor out and fire it up.

[fan4chevy]

you are getting really far on it.

[BEEFKING69]

The first pic isnt mine its just to show what i plan on doing. Honestly it should have been dont long ago lol

[fan4chevy]

It is a good idea.

[BEEFKING69]

Update....FINALLY got the cv cups off the center shaft.....Literally had to wrap a chain around both ends and then hook one chain to a tree and the other chain to my truck and snatch it apart and then swap ends and do it again. Got sprocket and brake rotor swapped around and old bearings out but now i cant find my new bearings so have to wait till tuesday to get more bearings.

[BEEFKING69]

Got the carrier back together with the sprocket and brake rotor swapped around. Also going with a twin piston caliper. Got the tires and rims back on temporally.

[fan4chevy]

awesome tires.

[fan4chevy]

anything new happening?

[BEEFKING69]

Will be starting on it again soon....Got the motor pretty much mounted and then it got to cold to really do much but its warmed up now. Travis should have my shaft finished soon...had some setbacks on getting it how we want it. I need to build a 2-1 throttle cable order chain and do some wiring.

Do you still have those 500cc motors? The guy helping me build mine is intrested in one if you do.

[BEEFKING69]

Weather has started to warm up so ill be able to work on this again finally and Travis at BD has finished my reverse shaft so now im just waiting for it to come in the mail.

Biggest things left to do is build a custom 2-1 throttle cable and make a wiring harness and get exhaust done. Found out that Honda 400ex spindles fit the crossfires just gotta swap left for right and right for left so thats got my front brakes taken care of as the carter gtr 250 hubs and rotors should fit the 400ex spindles.

[BEEFKING69]

Got reverse shaft today and did a quick mockup.....gotta get some new chain and a mounting plate made. Weather has gotten cold and ****ty again

[BEEFKING69]

Also got 2 new sprockets for the sym 250 swapped crossfire (The yellow/black one). Got a 12T (JTF1265) output sprocket that fit the gtr 250 motor and had a custom aluminum 41T 520 made by rebel gears to replace the 39T 530 sprocket.

[BEEFKING69]

Got bored and decided to put my 26-12-12 dirt devils on the crossfire.

[SYCARMS]

Like those rims.

[BEEFKING69]

Thx Ive got the matching 10 inch fronts and all 4 center caps also.

[BEEFKING69]

This is what happens when you dont change brake pads......

Brake caliper came around with the rotor and knocked a hole in the bottom of the radiator....

New radiator and location along with X bars behind the seats......

Doin away with rear brakes temporally and installing front brakes......

Hit a snag....The original spindles have the caliper mounts but are slightly thicker and the flat spot between the mounts is not cut as deep as the crossfire 150r spindles so im either going to have to use the 150r spindles or grind the originals down a couple of MM to clear the body of the caliper.

[plee911]

Nice work wish I had that much ambition lol.

[BEEFKING69]

Now if only i could get my 400cc swap finished lol. So igot front brakes on the crossfire but hit another snag...I ground down the original spindle just a couple MM so the caliper body would clear and then put the hub 150r hub on and then trioed to put the caliper back on and it wouldnt go....turns out the bracket was hitting the rotor bolts????? So i scratched my head a minute and then realized the inner step on the original spindle was roughly 2-4 mm shorter than the 150r spindle which allowed the hub to sit closer to the caliper mount.

So due to time i ended up just putting the 150r spindles on the 150 but i could get a couple of washers and put on the original spindle and used them.