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  #1  
Old 05-24-2017, 07:03 AM
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Default Crossfire 400r Irs

This weekend we killed 3 buggys in ina 30 minute time span. My buddys crossfire ate a tree with the driver front wheel and broke it completely off and folded the shock in half and then not long after that i hit his son head on at about 35mph coming around a turn ( he had lost something out of his buggy and turned around to go get it) and it pretty much totaled my HH 250 and tore his HH GL 150 up pretty bad No body was seriously hurt just some bruises. But his buggy just needs 2 new a-arms and a wheel and my 250 it completely destroyed both a-arms the shock and all mounting tabs for the a-arms and strut.

So im bout to go out side and cut the HH 250 in half behind the seats and we are just going to weld the HH rear to the crossfire 150r and then after our trip to the offroad park we are going to put the 400cc on. Id like some input on building a jackshaft tho. I need to find some universal indicator lights for H/L/N/R cause i kinda got used to having them but then again idk if its worth the trouble since im planning on putting the 400cc twin on within the next month.

Another question i had was if i need both radiators or if i can get buy with the main one? And im goin to need a pair of swing arms sooner than later as these are already starting to twist.

Will try to get better pics tomorrow. The wheel base is longer than id like but its just mocked up..ish atm so itll be a couple inches shorter once its actually put together. Also looking for a pair of rear Carter GTR 250/300 rims or would like to know the offset of them so i get a set from ITP. Im eventually going 22/7/10 on the front and 23-24/11/12 on the rear.









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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 06:10 AM.
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  #2  
Old 05-25-2017, 10:52 AM
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wow, at least u and the kid are ok that's the important part.
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Hammer head Single seater know as herbie
under construction

Aluminum fuel tank, aluminum wheels, custom fuel/cargo rack, entire rewire, trail tech vapor, ported big valve head, a12camshaft, 12 gram sliders, straight intake, kirkey wide seat, front end extension. 4 point harness, welded cage. Hammerhead exhaust.



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welded cage, engine build, new wiring harness/electric box, spun aluminum fuel tank.
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  #3  
Old 05-25-2017, 12:41 PM
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Good to hear everyone is OK. You have your work cut out for you.
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  #4  
Old 05-25-2017, 02:02 PM
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Here are a couple of retakes. And one of the little HH 150 i hit which has been mostly fixed and one of the other crossfire. The HH 250 rear just about fits perfect under the crossfire's rack. Hopefully we should have the frames welded together this afternoon and then all thats left is to move the wiring and shifter over to the crossfire and remount the brake master cylinder.











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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 06:26 AM.
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  #5  
Old 05-26-2017, 03:02 AM
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Making some progress......Hope we got everything level and square. Should have it ready to test drive tomorrow.









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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 06:33 AM.
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  #6  
Old 05-26-2017, 10:50 AM
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nice work, its always nice having a spare frame for parts or situations like u ran into.
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Hammer head Single seater know as herbie
under construction

Aluminum fuel tank, aluminum wheels, custom fuel/cargo rack, entire rewire, trail tech vapor, ported big valve head, a12camshaft, 12 gram sliders, straight intake, kirkey wide seat, front end extension. 4 point harness, welded cage. Hammerhead exhaust.



Blade Single Seater Restore
welded cage, engine build, new wiring harness/electric box, spun aluminum fuel tank.
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  #7  
Old 05-26-2017, 03:20 PM
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Thx. Ive had that crossfire for a couple of years now just for this purpose and I originally bought the HH 250 just to cut the rear end off but then when i got it home it just needed a clutch and carb put back on and the frame was in such good shape i just couldnt bring my self to cut it up so ive been riding the hell out of it and then this happened so that gave me a reason the cut it up. I think i paid 150 for the crossfire and 350 for the HH and ive got a yard full of buggys for parts and still cant find what i need half the time lol
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #8  
Old 05-27-2017, 02:58 AM
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Heres a couple with the cage back on. Still gotta weld the bottom of the frame up and modify the 3 mounts behind the seats. We are going to weld the cage solid at all mounting points and put an x brace in the roof of it and fix the rack area where it can be taken off separate like the HH 250s rack. Gotta get shifter mounted and hooked up and get some custom wiring done....Atm i just have the entire HH dash and harness layed out in the floor for testing. Im really shocked at how the HH 250 rear fits so good under the crossfire rack.....It almost seems like its sposed to be there. P.S. it looks better in person and it wasnt quiet aligned in this pic.

Id like some suggestions/ideals on building a custom dash and possibly a center console. Im getting a tach and id like to have H/L/N/R indicator lights along with Fan and Temp lights im going to keep the power outlet and turn signal switch and horn button i believe. Head light switch is going to be setup so low beam turns on the 2 led cubes in the bull bar and high beam will turn those on plus roof lights when i figure out what i wanna mount up there.

Discuss....



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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 06:37 AM.
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  #9  
Old 05-27-2017, 11:13 AM
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Looking like a buggy again.
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  #10  
Old 05-29-2017, 07:24 AM
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Update.....Its now on its own 4 wheels and is solid. Gotta get wiring done and shifter mounted and brake master cylinder mounted. Master cylinder will be mounted directly in front of driver seat as theres no where behind to mount it. Shifter will be mounted as expected and battery will be mounted in the center in front of the motor. Also added a couple of goodies to my buddys sons buggy and got me a new toy to put on.







__________________
Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 07:09 AM.
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  #11  
Old 05-29-2017, 01:42 PM
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I finally had to chop it to a smaller panel with my eps install, but I always liked the basic dash i made from a piece of aluminum diamond plate. Welded some tabs with holes to the cross tube ahead of the steering column, mounted whatever i wanted in it and bolted it in place. A filler panel in the frame opening ahead of it kept the mud and water off of it.
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  #12  
Old 05-29-2017, 03:59 PM
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You have any pics of it?
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #13  
Old 05-29-2017, 11:33 PM
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the page linked, post 631 about half way down has a picture of it.
http://buggymasters.com/forum/showth...?t=2243&page=7
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  #14  
Old 05-30-2017, 04:33 AM
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Thx buddy thats sorta what im wanting to do. Got shifter installed and temporary wiring/dash installed earlier tonight and took it for spin through the trails and have to say it almost rides like a cadillac and feels alot stronger than the HH did.....idk if its any faster or not yet but it seems like it. I need to get brakes put on next and get some new shocks as the crossfire front shocks are garbage right off the showroom floor and the HH rear shocks are blown out have leaked pretty bad and are just spongy feeling but it still rides way better than any 150cc or the HH250.

Any suggestions on rear shocks would be awesome. Im most likley going with predator 500 on the front. Going to weld the cage at all bolt together joints as i cant stand how every crossfire has that horrible cage rattle and also goin to ad an X brace to the roof and will hopefully have the winch on tomorrow. Trying to decide if i should add two battery's since ill have a winch. Currently i run 230 cca lawnmower battery's in all my buggys.



__________________
Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 07:16 AM.
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  #15  
Old 05-30-2017, 05:42 PM
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You'd probably be good to go with the predator podiums front and rear. i've used 3 pairs of those now in different builds. always down to spring selection to get it dialed in, all else you can tune internally easy enough. I'd chop the pass. grab bar, run a dash panel under that tube across it all and put a panel in the front that also turns upward for 3-4 inches of the front hoop to give some extra splash protection. Once you panel these buggies in, you don't want to go back to open ones if you're hitting mud holes or stream crossings.

Last edited by x-bird; 05-30-2017 at 05:44 PM.
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  #16  
Old 05-31-2017, 02:32 AM
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Hmmm thats a good ideal about the shocks.....should i use predator 500 fronts or rears all they way around? I also like that the way that dash sounds. I absolutely can not stay out the mud and we do have a few crossings and a few trails that you actually drive down the creek bed. Ill be putting a 5 inch sunpro super tach 3 in front of the steering wheel.....really dont want a tach that big but i had one on my old crossfire and its the only one that read over 8000 rpm and had a two clyinder setting. (For future reference any tach with a 2 cylinder setting works on our buggys)

Got some more ride time today and i love it and it still mostly fits through all of our trails even with the added length. It feels so much peppier than the HH250 and high gear is actually usable now in the trails instead of just hard pack. Did a top speed run and it hit 46 mph on flat ground with aired down tires. The HH250 would only hit around 42 and took forever to creep up to that speed and only managed 45 down a long hill once. These are gps speeds btw. Is the crossfire really that much lighter? Really gotta figure out the alignment tho cause it was all over the place from about 35+ just could not keep it straight....HH250 tracked straight as an arrow at any speed. My goal is atleast 50 with the 250 then once i drop the 400 in itll go way faster than id want to drive it.
__________________
Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #17  
Old 06-01-2017, 04:18 AM
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Update.....Did some alignment work and it now drives 100% better.....also hit 51mph with two people today on the same down hill section that the HH250 only hit 45 with just me and drove straight as could be. Relocated small radiator to what i thought was a good spot till i put the seat back in......and its basically covered it :/......Do i really even need the small one? New master cylinder otw along with led tail/brake light strip.

Exhaust hanger broke today and the flex pipe has a gaping hole it so i need opinions on exhaust and mufflers.
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #18  
Old 06-01-2017, 06:31 AM
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shocks ---use fronts, they're podium 500s--all Fox so in the end the source doesn't matter as much as eye-to-eye length and what spring is on it. Again, you may have to pick up some springs to experiment with, usually the quad front springs end up too stiff up front, ok at the rear.

You might want to consider a Trail Tech, speedo, tach, shift lights, temp gauge, trip all in one unit.
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Old 06-01-2017, 01:57 PM
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Ok cool. Ive thought about the trail tech before...any particular model?
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #20  
Old 06-01-2017, 03:24 PM
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75-402 is what I have on my 250. These are all designed for ATV's or cycles. You will have to weld a bracket for the speed sensor.
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  #21  
Old 06-02-2017, 03:32 AM
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Ok ill look in to that. Got master cylinder mount welded on tonight and got the cage tacked at all joints so no more rattles in the cage but now i hear the front motor mount rattling actually its some long bolt thats sposed to have a rubber dampener on it or something. Jersey devil is building me an exhaust. Need carb suggestions cause this carb has never worked like it should.
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #22  
Old 06-03-2017, 11:06 AM
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A stock carb rejetted is all you need.
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Old 06-05-2017, 05:39 AM
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Im beginning to believe its the crap electric choke. is there any way to mod it so thats its permanently off? Heres a couple of pics from saturday.



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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-15-2017 at 07:21 AM.
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  #24  
Old 06-05-2017, 04:18 PM
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Why do you say it is the electric choke?
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  #25  
Old 06-05-2017, 04:48 PM
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It has a very erratic idle after it warms up and constantly smells rich regardless of jet size.
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #26  
Old 06-07-2017, 12:28 PM
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Check to make sure with the engine running that you have power to the enrichment valve. The current to the enrichment circuit has a resistor usually of the neg. side to control a set voltage, so don't expect to see 12 volts at the valve usually anywhere from 9-10 volts. 99% of the time the problem is no voltage to the valve due to bad connection broken wire or bad resistor.
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Old 06-07-2017, 04:31 PM
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Ok thx ill check that today
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #28  
Old 06-08-2017, 07:00 AM
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So im getting a set of Carter GTR wheels and have quickly found out that nobody makes a 23-24x10-11 or 12x12 tire....except theres a swamp fox 23-10x12 but other than that 23 and 24s only come in 8 wide for 12 inch rims so im wondering what i need to do sprocket wise to run 25 inch tires. Also gotta figure out how to get a 4on4 hub on the front of a crossfire.

Also got a new master cylinder with 4 ports with a brake light switch (only needed 2 ports plus switch) and got a led tail/brake light strip along with a 7 inch led bar for a reverse light. Need to find an atv radiator so i can replace both HH radiators with just one bigger one.
__________________
Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #29  
Old 06-09-2017, 12:35 AM
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Nice job man. Seems to me Polaris trail boss or Trail Blazers use a 23" tire. (Pretty sure that's what uses it. It's Polaris something) Maybe look for some being sold on Craigslist.
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Old 06-09-2017, 05:05 AM
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Thx buddy and i have found a few but im looking to get a set of mudlites or vampires or somthing similar. i may go with the swamp fox for now. Update...got winch installed last night. Now to get tail lights and reverse lights installed. I like the looks of the trail tech...is it back lit?
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #31  
Old 06-09-2017, 07:09 AM
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Cool

Kenda Bearclaw's . I bought 23/11/10 's for my King Cobra , in 24" too .
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2011 BMS KING COBRA 150 Sold
YERF DOG SPIDERBOX's Sold
YERF DOG 3203's. Sold
MANCO SILVER FOX. Sold
2009 POLARIS 500 HO SPORTSMAN 4X4
2002 POLARIS 500 HO SPORTSMAN 4X4
2000 POLARIS MAGNUM 2X4
HALF A DOZEN CHEVY 4X4's
NEED-MO-BUGGY
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  #32  
Old 06-09-2017, 12:39 PM
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The carter gtr rims are 12 inch rear. I can find plenty of good tires on 10inch rims
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #33  
Old 06-09-2017, 02:23 PM
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Try rockymountainatv.com or motosport.com.
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  #34  
Old 06-09-2017, 05:34 PM
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I have and also mudthrowers.com and a couple others. I may just get the 23x10-12 swamp foxes for now till i get some sprockets.
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #35  
Old 06-10-2017, 02:08 AM
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Does anyone know what size bearings are on the crossfire 150 front? Or atleast i need the the inner diameter of the front bearings.

What im planning on doing is run the gtr 250 front hubs if i can find some bearings that fit the crossfire spindle and GTR hubs. Ill have to build a set of caliper mounts but that shouldnt be to hard.....Update...found the bearings needed for the GTR hub to fit a Crossfire 150 spindle.....6003rs for the outer and 6004rs for the inner.
__________________
Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 06-10-2017 at 04:13 AM.
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  #36  
Old 06-12-2017, 05:23 PM
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Quote:
Originally Posted by SYCARMS View Post
Check to make sure with the engine running that you have power to the enrichment valve. The current to the enrichment circuit has a resistor usually of the neg. side to control a set voltage, so don't expect to see 12 volts at the valve usually anywhere from 9-10 volts. 99% of the time the problem is no voltage to the valve due to bad connection broken wire or bad resistor.
Found out its defiantly the choke cause when i took it off and took it apart it was just a huge blob of corrosion under the cap where the wires go in. Got it put back together to where its always off for now and have ordered another one. It idles so much better and gained a couple mph also but now i need to rejet the carb but im having problems still with it just dieing like its out of gas. Sometimes the filter is empty when it does it and sometimes the filter is still full when it does it......let it sit a couple of minutes and it cranks right back up.

It has a new 1/4 inch petcock and hose and big filter....does it with or without the gas cap on and ive had the carb off multiple times to check float and needle and run it through the ultrasonic cleaner.
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Crossfire 250r IRS (400cc swap soon)
Crossfire 250r (SYM 250)
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Old 06-13-2017, 06:08 PM
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Got new rear pads in today which are non existent on ebay apparently so i just browsed till i seen some that looked the same and ran across a set for a PGO Bugrider 250 and they match the old ones perfectly. They are Gold Fren AD283 ceramic carbon pads. Also seen several atv pads for around 5 bucks that look like they will fit...gonna start ordering different ones along and see what all fits.

Also ordered a new carb and apparently they are sending a 30mm pumper instead of the stock one.....so any one have any experience with the pumpers on the 250s?
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Old 06-15-2017, 05:01 AM
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87 Honda trx250 rotors are a direct replacement for GTR250 front rotors so i got them on the hubs and now got the hubs on the crossfire.





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Old 06-16-2017, 03:07 AM
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Update.....GTR wheels will be here monday and these outer bearings are not gonna work as planned because they stop on the spindle to soon and allow the hub to slide back and forth a half an inch or so.....I need a 17x37x**mm bearing
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HH250SS..RIP (IRS donor for the crossfire)
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Many other random parts buggys (still never have what im needing tho :/ )

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Old 06-18-2017, 04:11 AM
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Ok so heres what im going to do....I ordered a pair of 20x37x9mm bearings and a pair of 17x20mm bushings so we will see how that works.
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HH250SS..RIP (IRS donor for the crossfire)
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Many other random parts buggys (still never have what im needing tho :/ )
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  #41  
Old 07-04-2017, 12:46 AM
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So it appears that photobucket has just shot its self in the foot and may not be around much longer since they have chosen to disable everyones pics unless you pay 400 a year. Now that all my pics are broke ill try and find another host and reupload them.

I got my bushings in a week or so ago and i believe they will work....I havent had time to mess with them since i dont have any 12 inch tires for the rear yet so no point in putting the front wheels on atm and am having very frustrating electrical gremlins causing intermittent spark and no power to the rear of the wiring harness period so im trying to decide if i wanna keep the 250 or go ahead and start the 400cc swap.
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Crossfire 250r IRS (400cc swap soon)
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HH250SS..RIP (IRS donor for the crossfire)
HH150
Gs Moon buggy 150
Many other random parts buggys (still never have what im needing tho :/ )
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  #42  
Old 07-04-2017, 02:47 PM
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Quote:
Originally Posted by BEEFKING69 View Post
So it appears that photobucket has just shot its self in the foot and may not be around much longer since they have chosen to disable everyones pics unless you pay 400 a year. Now that all my pics are broke ill try and find another host and reupload them.

I got my bushings in a week or so ago and i believe they will work....I havent had time to mess with them since i dont have any 12 inch tires for the rear yet so no point in putting the front wheels on atm and am having very frustrating electrical gremlins causing intermittent spark and no power to the rear of the wiring harness period so im trying to decide if i wanna keep the 250 or go ahead and start the 400cc swap.
I made the switch away from photobucket a few months back. Went to postimage.org it's free and better then photobucket
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Old 07-04-2017, 08:24 PM
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imagur.com also works well and is free
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  #44  
Old 07-10-2017, 11:02 PM
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Thx ill check that out. Need help with this random no spark issue. It just randomly dies like you hit the kill switch.....So far ive bypassed the ignition switch and kill switch...tried a new coil and plug and checked all connections. Only thing i havent tried is cdi as i dont have any of the square plug cdis laying around and idk how to check the pickup coil....as in idk what to look for as far as voltage or what settings on the multimeter to use.
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Old 07-10-2017, 11:27 PM
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If I recall it is a 250 correct?
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Old 07-11-2017, 12:50 AM
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Yes. Atm its a HH250ss rearend motor and complete wiring harness...It will be all custom once i do the 400 swap which will be soon as i ran it really hot last night and now its starting to smoke a little. But i need to get this no spark fixed by sunday cause we are goin back to the off road park. I ordered a new pick up coil and cdi but id still like to know how to diagnose the 250 stators.
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Old 07-11-2017, 12:05 PM
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Ok there are 2 checks , first is the exciter coil which is part of the stator. Not sure of your wire colors but they should be close. Exciter coil with meter in the R x 1 ohm range 50-350 ohm range measured across the bl/r and g wires. Second is the ign. pulse gen which you referred as p/u coil,50-170 ohms measured across the bu/y-g or g/w-bu/y depenging on which colors are used. Hope this helps, if not e-mail or call me 662-301-1563.
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Old 07-11-2017, 12:52 PM
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Awesome thx thats the info i was looking for! Another issue i forgot to mention was over the last couple of weeks the trans has started to whine just like a rear diff in a truck when its low on gear oil. Ive changed the gear oil late last year and it looked good then and ichecked it the other day and its still full and clean looking but the whine is getting louder by the week.
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Old 07-11-2017, 01:58 PM
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Worn gears or bearings will cause the whine. Lucas oil stabilizer will usually work if not too far gone.
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Old 07-12-2017, 02:09 AM
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Thats what i was afraid of how much lucas to to gear oil should i run?.....I dont even know how much gear oil it even holds.....i just squeeze till it starts runing back out.
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Old 07-12-2017, 01:22 PM
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It holds 1000 ML. Read the instructions on the bottle, I believe you can go 100% but check first.
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Old 07-13-2017, 02:37 AM
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Ok thx and Of course it wouldnt fire again tonight so I checked stator and it only has 5 wires....3 Yellow, Green and Blue/yellow. Pick up coil tested at 123 ohm. I noticed a couple of wires loose at the 9p connector so i fixed then and it cranked up and ran for about 2 minutes and died like the key had been cut off so i checked the 9p connector again and wiggled it and it cranked again so i just cut the connector off and spliced all the wires together and it ran for an extended amout of time this time so i guess we will see if its perma fixed this time.
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  #53  
Old 07-15-2017, 07:33 AM
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Got pics fixed....maybe i got them all and in the right order.....although they are freaking huge now :/ and no spark again yesterday so i replaced the cdi and the new cdi went up in smoke the instant i turned the key on....so i took one off of a roketa with the yamaha 300 and put it on and i drove it roughly 15 miles lastnight without a hiccup.
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HH250SS..RIP (IRS donor for the crossfire)
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  #54  
Old 07-17-2017, 08:03 AM
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Bent driver side front spindle and knocked the steering box outa whack.....are the crossfire and dune 150s the same spindle? also looking at steering box optons....was thinking about using a hammerhead style box as all hammerheads and buggys with those types of steering boxes always seemed to steer alot smoother but was wondering if the shorter tierods would affect steering.
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Old 07-17-2017, 11:32 AM
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Could not tell you if the spindles are the same. I know the crossfire I have uses a rack and pinion system just as the HH does. I believe the tie rod adjusters are longer on the crossfire as compared to the HH but the racks I believe are the same.
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Old 07-17-2017, 12:01 PM
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The crossfires use a vw sandrail type rack and all other buggys use a wide larger diameter rack that just seems smoother and better built to me. and yes the crossfire rack is only around 14 inches wide while the others are like 20+ inches wide and most have an offset to them wheres the crossfire is centered.
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Old 07-17-2017, 01:46 PM
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Both racks should still operate the same, the difference will be in the suspension. The crossfire and HH have totally different suspensions. I had always found the crossfire to have the better handling of the two.
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Old 07-17-2017, 05:09 PM
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If I remember correctly, the Dune used 12mm joints and the Crossfire R used 14mm.
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Old 07-18-2017, 06:11 AM
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Yeah the crossfire is my favorite buggy and rides alot better it just dont turn as sharp. And the 150r is 14 at the a-arms but i believe its still 12 at the spindle?
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Old 07-21-2017, 06:05 AM
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400 swap in the very near future as the 250 has started smoking and the gearbox has been whining for a few weeks now.

Need some ideas on building a jackshaft and on gear ratios......also gotta figure out reverse as i refuse to drive a buggy without reverse.

Update i just got a polaris trail boss/blazer 250 and im seriously thinking about using its F/N/R box only issue is it uses 520 chain. I belive the polaris trans ratio is 2.5-1 in forward and 3 or so in reverse. Thats where im stuck tho is what size sprockets to run on the input and output shaft on the trans. Ill be keeping my 39t axle sprocket and would like to go with 25/26-11/12-12s. Also this motor has a torque converter like an auto car trans so there should be less "shock" load on the drivetrain compared to a normal motorcycle motor.....I think anyway. Any and all ideers and suggestions are welcome.



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Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 07-21-2017 at 06:32 AM.
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  #61  
Old 08-02-2017, 04:57 AM
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Update...Keeping the 250 till i get reverse figured out for the 400 because i will not drive any buggy without reverse (still havent got this damn polaris gearbox out the frame)....Got to get the head gasket replaced on mine by friday so we can go to the offroad park saturday.

Will be starting 2 more engine swaps in the next couple of weeks.....The first is going to be a carter GTR 250 on a crossfire 150 and the second will be a honda trx 300ex on a dune 150. Both of those will be on the stock swing arms till i can find two more hammerhead 250ss's to cut in half like we did mine.
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  #62  
Old 08-06-2017, 06:03 AM
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Next Crossfire 250 swap starting this week......Will be using a Carter Gtr 250 on stock crossfire swing arm for now for this swap.......Got some questions.....whats the tooth count on the GTR axle sprocket? does any one know of any 520 4 bolt sprockets with roughly the same tooth count as the GTRs that bolt to the 150 axles? Im going to be running 25 or 26 inch tires on this one also as the GTR came stock with 25s. What is recommended carb upgrade for the GTR? Will be having custom header and muffler made and hoping to get head work done sooner than later.

Should i start a new build thread or just keep it in this one since they are both an ongoing work in progress?
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Old 08-07-2017, 01:37 AM
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Just keep in mind the Carter is no longer, if it has the SYM 250 engine there are no parts available for them.
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Old 08-07-2017, 03:13 AM
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You can get the engine parts from Can-Am as their DS250 uses the SYM 250
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Last edited by BEEFKING69; 08-07-2017 at 03:15 AM.
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Old 08-07-2017, 12:30 PM
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Here is what I know about that engine. There is one of these buggies in the neighborhood which has had 6 owners in the past 5 years. First it was the rear axle, custom made from a place in Florida was 400.00 per axle. Seems no one wants to spend that so they sell it to someone else which they than call me for the axle. The original owner sold it to someone for 1500.00 with a bad axle which he had someone local weld it for much less. Didn't last a week so he sold it. Each time it was sold for a cheaper price. I would then be called to find an axle. The last one to purchase it got it for 200.00. He too called for an axle. Since there are no axles to be found I referred him to the place in Florida. He too did not like the price. Finally 2 years later he sent them the axle for repairs. Buggy run great until he lost a valve and destroyed the head. This was about the time I was told the DS-250 parts would work. The neighbor now asked me if I could get a head. I told him what I had heard. Since he works in Memphis he brought the head to the Can AM dealer for a new one. When the dealer told him the head was 400.00 plus stripped he declined and sought out an ATV bone yard which they said they had one complete and good for 200.00, so he drove 2 hours to purchase. He had brought the old head with him to compare and the used one he bought was identical, so he thought. When he tried to install the head he found that the bolt pattern was different. Prior to all this several years ago I had contacted SYm looking for parts for the Carter 250 and was told that they get calls all the time and from their experience he said, although the engines look identical and built by SYM the Carter SYM was made to Carter specs and were different. So not to dispute what anyone says about this particular engine this is what I have run into with this engine.
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Old 08-07-2017, 04:22 PM
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Thats interesting to know....Now in my experience ive rebuilt 2 GTRs so far and used parts from Can-Am with no problems.....Rings, base gasket, head gasket etc.... Is his a 300? I believe the part numbers for the ds 250 are the same from 06-17
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Old 08-07-2017, 08:05 PM
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It is definitely a 250 for one it says on the buggy and the local dealer who sold them went out of business prior to the 300. I don't know enough about the later model sym carters and cannot say I have even set my eye's on a 300. So I would not know if the heads are alike but won't swap out. As I stated earlier he got one from a boneyard so it could be a 300 head he got. One thing I know for sure is he is not going to spend 400.00 for a bare head.
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Old 08-07-2017, 11:30 PM
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No i highly doubt i would either....to many engine swap options for the price of the head and other bits especially at can-am's prices.....its about 110 bucks just for rings and gaskets with shipping. I dont even know what year either of these 250s are. I know where a 300 is thats tagged and insured here in FL that i may try and get my hands on.
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  #69  
Old 09-04-2017, 07:08 AM
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Work has started on my buddys crossfire 250 swap.....Just rebuilt the sym 250 and now for pics. It sits alot higher than expected but we have just cut the rack out for now and will lower the swing arm today. Will be using stock swing arm for now but will be swapping it to IRS also as soon as i find HH 250ss to cut in half. I need a wiring diagram for the carter 250.









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Old 09-18-2017, 07:06 AM
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Update.....So my crossfire 250 was down to 120 psi compression and i decided to put new rings in it to try and keep me going till i can figure out reverse for the 400 swap and after i put new rings in it the compression only went up to 130 and now it just bellows smoke......I had the cylinder honed and am 99% sure i put the rings in right and made sure i didnt get them bound up while putting the cyclinder back on.....So im kinda at a loss as to what could be wrong unless i got the wrong rings maybe? The CH CN and CF 250s all use the same piston and rings right?

Edit. re rebuilt it and its now at 190+ and doing good other than carb acting up.
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Last edited by BEEFKING69; 10-20-2017 at 04:02 AM.
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Old 09-18-2017, 10:05 AM
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I cannot speak of the CH for it is a different type motor but the CN and CF motors have a 72mm bore. You should have about 175psi with good bore and new rings. These cylinders are not known to wear out.
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Old 09-18-2017, 02:15 PM
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Did u clock the rings correctly ? And did u do a compression test with throttle wide open?
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welded cage, engine build, new wiring harness/electric box, spun aluminum fuel tank.
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  #73  
Old 09-18-2017, 06:05 PM
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I set them the same way the original ones was and it was checked without any carb on. Compression tester should be good as the baja dune 250 reads 200 psi.
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  #74  
Old 09-19-2017, 06:40 AM
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Unfortunately you need to pull the cylinder, piston and rings. Mic the cylinder it should be 72mm or 2.834". A couple thousands over is OK. I have known some people to over hone the cylinder way too much. Next put the top chrome ring in the cylinder first and using the piston square the ring in the cylinder. Remove the piston then measure the ring gap using feeler gauges. Gap should be .015-.016".
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  #75  
Old 09-22-2017, 05:36 AM
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Thx for the info. I may do that if i can talk my self into it or i may just run it till it slings its self apart because im honestly tire of messing with it

Update on the crossfire GTR swap.....Got new cdi from the carter site in canada and it runs different i guess you could say.....By that im mean its 100% drivable now at all rpms but now its slow as dirt.....Slower and weaker than the BBK 150 we took off....It barley runs 44mph where with the other CDI it would run 50.

It has no balls now where as with the other cdi it spit and sputterd till bout half throttle and then felt like you shot nos to it.

Massive off throttle backfire through muffler still and a faint but steady sputter from 1/8th to WOT. Ive tried 4 different carbs 2 PZ30's PZ27 and the stock carb along with jets ranging from 110 to 130. I just cant figure out if its a timing issue or carb issue.

Its got just over 180psi compression valves have been checked and timing marks are in place at TDC.....Im at a loss here.

Anyone have a known good stock carb I can buy?
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  #76  
Old 09-24-2017, 09:14 AM
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I would start by installing the stock cdi and carb after a good cleaning. By good cleaning I mean to totally disassemble the carb let it sit overnight in some Barryman carburetor dip. After soaking in dip remove and rinse under warm water while scrubbing with old tooth brush or like. Using small wire, push through all small orifices then blow out with compressed air than reassemble carb. Keep it all in original stock configuration. 99% of the time if the cdi goes bad you will have no spark.
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  #77  
Old 09-24-2017, 05:24 PM
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Stock cdi is dead :/ First cdi was one from ebay labled as fitting only gtr. This new one is a factory cdi from CarterBrothersParts.com. I know i Chemdipped this carb not to long ago when i was working on another gtr and blew it out good. I cant remember if i ran it through the ultrasonic cleaner or not tho.
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  #78  
Old 09-24-2017, 06:03 PM
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I don't think the site you ordered from is the original carter. If they were they would list their address and phone #. They do show a website under construction but has nothing on it except if you want to be updated on new information you fill out a short form. Well I had done it one year maybe two years ago and have heard nothing back. So it would be safe to sat carter is no longer and the carter parts is just some Chinese Company selling what they say are carter parts. I do know for sure that when I contacted sym they told me that Taiwon told them carter buggy parts would not interchange with sym since they were made to carter specs.
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  #79  
Old 09-24-2017, 08:33 PM
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I think they bought up leftover inventory because they only have 250/300 stuff and alot of it is out of stock. I ordered a cdi from them last year and for a gtr i was fixing up to sell and it worked flawless and the ladys son is still driving it. The one i got from ebay is massive compared to this one. But this motor just feels gutless.
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Old 09-27-2017, 11:57 AM
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When Carter burned down they were in the process of starting to build their buggies in the US. They had just received many containers of parts, supplies and scooters. They had millions invested when the economy crashed and sales pretty much come to a complete halt. Than the fire occurred, everything was destroyed to the point nothing was salvageable. All 3 buildings and everything in them were destroyed. Immediately there were no parts at all except if a dealer had parts on hand.The fire marshal declared the fire as arson and the investigation began on a local and federal level. Since the owner was millions in debt and the insurance was not going to settle the claim suppliers stopped the manufacture and sales of parts and vehicles. Carter still held the copy rights on 90% of their parts so even the large distributors who tried to purchase the parts from China could not purchase them. Since that time suppliers have been trying to find alternatives for parts but since Carter had their own specifications on most parts so that they could not be copied thus forcing you to purchase only their parts none have been available since. The last article I have read from a Alabama news article about 3-4 years ago read that although there has been no evidence he started the fire the insurance is fighting the claim and that it could be a drawn out battle for years to come. I have never read that bankruptcy had been filed but I am certain it has since millions were owed to the banks and suppliers in China.
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  #81  
Old 09-28-2017, 08:55 PM
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Thx for that info man. Thats the best explanation of the situation ive ever read. If you havent already check out the website.

The current situation on the swap is.......

1...Ebay cdi cranks right up but idles bad and runs like crap till about half throttle then feels like a huge bust of power and runs 50 mph.

2... What i believe to be a factory cdi cranks right up and runs damn good other than a slight flutter through out the whole rpm range but feels gutless and only runs just over 40mph.

3...Advanced the timing one tooth on the cam and it feels stronger out the hole but now only hits 39-40.....Tried ebay cdi and it runs alot better through the whole rpm range but still only hitting 39-40.

4...Is it possible that the 39t axle sprocket is just bogging it down that much even on a long stretch of pavement? Still dont account for the 10mph speed loss between CDIs tho.

5...Does anyone know the timing curve on the Syms vs the CNs etc? I could possibly get a programmable unit like the igntech< spelling?
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Many other random parts buggys (still never have what im needing tho :/ )

Last edited by BEEFKING69; 09-28-2017 at 08:58 PM.
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  #82  
Old 10-18-2017, 07:57 AM
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Update on both buggys....My Crossfire is down again due to center axle bearings and I cant get the inner cv cups off so i reckon im just going to have to cut them off and get a new center axle.

The yellow Crossfire is running 50 mph pretty consistently now but is is havin carb issues, Have ordeered new sprockets to play with gearing and believe I also found a source for sym 300 engine parts.
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  #83  
Old 10-20-2017, 04:03 AM
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Update....Got the 400 fired up and running.It is now being put in. 250 is out.







Needs to go up and back for header clearance and i really dont think im going to have room for the polaris tranny. I need a shaft made like Donniearcher did in his build. Here are some pics of his reverse shaft.









I had been talking to him back in january about his build but when i emailed him a few months later about it again his wife informed me that he had passed away .

Is there anyone that could build one for me at a reasonable price?

In the sketch he has 3/4 shaft but i believe he actually used 1inch.
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Last edited by BEEFKING69; 10-20-2017 at 04:11 AM.
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  #84  
Old 10-20-2017, 08:42 AM
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Sorry to hear that he's no long with us. Some of his work was the first stuff i followed. Looking at what he did, was to essentially insert a 150 or 250 cc output shaft for a matching reverse box into the bored end of a piece of common shaft. After dealing with pillow block mounted jackshafts too often, i would recommend revising the design for vertical mount bearings (axle hangars and clamshells). other than that, it's a matter of getting a reverse box and output shaft and finding a local machine shop to give you a good on center bore in the common shaft. then weld it up. most expensive bit is the reverse box parts.

Other method of doing the something along the same lines would be to put the reverse box in line with the engine output shaft and having someone mate a buggy output shaft to a hollow hub with the splined portion of the original bike/quad sprocket inside the hollow hub. That approach would require less area at the jackshaft--to put the reverse box on the jackshaft at the pivot point may require new trailing arm mounts.

Last edited by x-bird; 10-20-2017 at 08:47 AM.
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  #85  
Old 10-21-2017, 04:16 AM
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I have several reverse boxes and output shafts for them already. What kind of problems have you had with pillow blocks? Ive never built a jackshaft or used one for that matter except for older gokarts that already had them. Also im going to need two chain tensioners. I have very little room to stuff all of this and will have two short chains. This is a HH250ss rear end so the jackshaft will be sitting over the center carrier assembly.

I set the carrier back in tonight for mock up purposes (still cant get the cups off) and im going to swap places with the rotor and sprocket plus im going to have to make a caliper mount for my dual piston caliper anyway and swaping them around will give me room to work i hope plus i need the sprocket on the outside anyway.
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HH150
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  #86  
Old 10-24-2017, 11:46 AM
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I had an output shaft made for a crossfire and my cost was 175.00. Machining is not cheap . I called all over trying to find a shop to make one, they all told me the same thing that the main problem is that the spline's are metric and broached cost way too much for them to but for one shaft.
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  #87  
Old 10-24-2017, 06:18 PM
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I dont know if he had it drilled and splines cut in or not....that would be the strongest way tho but im under the impression that the keyed shaft was just bored and the buggy shaft was cut down with 2 inches left and pressed in and welded.
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  #88  
Old 10-24-2017, 07:47 PM
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The above is my thought too.

pillow blocks have long bolt holes that tend to suck fairly thick washers in, allow for the position to shift when tightening the bolts (the top surface is raw casting --pebbly) and generally require a stop/adjuster bolt set-up to keep them from moving over time. Once i started using vertical axle hangar bearing setups all the pillow block adjustment issues i had vanished.

If you can, avoid short chain runs--they get hot faster and higher temps the shorter they are.

if you haven't, you may want to dig through the last 3-4 pages in my build to see the changes i made going from the 250 to the 400--which is when i went with the stub shaft off the engine and switched from pillow blocks to hangers.
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  #89  
Old 10-24-2017, 08:15 PM
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Ill check out your thread and im really not goin to have a choice but to have short chains i dont think.
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  #90  
Old 10-25-2017, 11:21 AM
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The 250 Joyners run pillow blocks with no issues. You can't use the average thin flat washers they must be thick heavy washers.
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  #91  
Old 10-25-2017, 12:25 PM
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Im digging the axle hanger bearings. I My use pillow blocks first since i can get them cheap as dirt cause this has got to be ready done by the middle of december
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  #92  
Old 10-25-2017, 01:07 PM
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Looking forward to the finish. Awesome.
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  #93  
Old 10-28-2017, 04:44 AM
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Update....A friend of mine told me his buddy works in the machine shop at some kind of helicopter shop and said he could build me the shaft so hopefully that will work out.

Currently the to do list is as follows.

1. Replace 3 more balljoints
2. Fix/replace steering rack....where can i get the boots for the rack?
3. Replace front/rear shocks with fox podiums from 03 polaris predator 500
4. Replace both rear cv axles.....Both trailing arms are twisted also but they are just gonna have to wait
5. Custom build headers
6. Figure out what i want to do carb wise... Send the twins off to have them gone through or maybe Dual to single???? What size single to replace two 28mm's? Or maybe fuel injection.
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  #94  
Old 10-28-2017, 12:37 PM
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I should have the boots but need to know if they are the same length and how long.
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  #95  
Old 10-28-2017, 05:08 PM
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I believe they are the same and ill find out what length they are
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  #96  
Old 11-03-2017, 02:46 AM
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Ordered some parts lastnight.

1"x12" Keyed shaft
30t sprocket
pillow bearings
1.5" exhaust pipe
Pulled a reverse box and shaft out of a parts buggy
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  #97  
Old Yesterday, 01:36 AM
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Update......Travis at buggy depot is going to build my reverse shaft. Got exhaust mostly figured out. Also got a complete running/driving big bear 400 for 75 bucks that had 4 like new GBC dirt devil tires so ive got a set of 26-12-12 and 26-10-12. The 26-12-12s will go on the rear. 22-7-10 on the front.
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  #98  
Old Today, 12:37 PM
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Old Today, 12:45 PM
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That is cool that Travis can build you the reverse shaft.

You are able to put some big tires on the front. My buggy can't handle more than I have, which is 8".
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All stock but to be like Buggy 1 with all koso cvt.

Roketa 150
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