2004 300EX quad to trike conversion.

[jeswinehart]

In a attempt to get a much better suspension then the 85 Bigred could ever offer I bought a 300EX that had the traits I want. Electric start + reverse in a not so big of a package being I ain't exactly a large framed fellow.
Never done anything like this before. Basically going be a all bolt on type of build until I know for sure which way I need to go with front end.
Choose 83/84 250R front end. I was very happy with the ride on the 84 250R I had years ago so that influenced my choice to start with.
This build will be one of those "on going" projects, not going be married to this front end (nor the stock 300ex rear shock either ) but like I said, just a starting point.
Honda took many steps backwards in the reverse design as compared to SX + ES machines from years before. You need to use your right hand reaching down on the left side of motor to engage/disengage reverse/forward lever ~ what was they thinking !
The choke lever is so buried I need to squat beside the machine on the left side to even see where the heck I am trying to get one finger onto (to crowded for more then one finger), very awkward at best. I will be hooking up a remote cable to solve that sorry design.
With front end all removed I did find there is 4 hard point threaded holes so I have mounted a 3/4 inch thick alu plate that once goose neck is welded to flat steel plate I will be able to drill and thread 6 to 8 bolt holes to mount steel plate/goose neck (goose neck won't be here till next Friday). I did add 2 nut + bolt to the lower cut off frame area for more added holding power.
Yeah, so just going for function first ~ looks,,, I don't give a hoot. I need better suspension.
Great info in this > http://www.chromedoutmag.com/rake-trail-off-set-frame-geometry/tech-tips/

[ctk]

Cool project, john

[6speedthumper]

Neato! Keep us posted.

[350for350]

Cool idea! You're right about the reverse. The setup was HORRIBLE. I'm not sure what the difference is, but maybe you can use the improved one off of a newer one? These engines were basically bulletproof as long as you're not trying to get big power numbers out of them. They were decent performers stock. Should be an excellent trail trike. Maybe you could find a trike with a Missle kit on it and use the front end for a "reverse trike". Think off road CanAm Spyder.

[bigred22]

i just traded my 300ex a little over a month ago, it's kinda hard to watch you cut that one up, it looked to be in darn nice shape, i agree with the choke lever suckage, and the whole idea behind the reverse set up is to make the rider release the throttle so the engine remains at idle when shifting into reverse, i didn't really care for it either, curious to see how this project turns out..............

[tapper190]

I guess you did cut it up, I thought you were going to wait until the winter, lol.
Great start

[Derrick Adams]

Just out of curiosity, why aren't you just installing that motor into the 350X chassis? I mean it's a bolt in deal and there is lots of aftermarket parts out there still for the 350X. The suspension is pretty nice on them too.

[jeswinehart]

Just out of curiosity, why aren't you just installing that motor into the 350X chassis? I mean it's a bolt in deal and there is lots of aftermarket parts out there still for the 350X. The suspension is pretty nice on them too.

I just found out a couple of days ago that the X + EX motors swap over that easy. If I knew about it beforehand I forgot about it,,,, would not have mattered anyways I suppose.
I did get a bracket made for remote choke cable plus a clamping bolt for the ill placed choke lever.
I definitely have a workable idea about making that shifter a left foot operated affair. Might as well tinker with that for awhile.
Choke cable I will most likely use > http://www.ebay.com/itm/UNIVERSAL-CHOKE-CABLE-LAWN-MOWER-TRACTOR-CARBURETOR-/201138387044?pt=LH_DefaultDomain_0&hash=item2ed4c83864

[Billy Golightly]

I totally forgot about how those frames were shaped - thats actually fairly conducive from a fabrication stand-point to turning into a trike it looks like.

Very interesting project - will keep an eye on this one one John!

[DickyDanger]

Why would you want to put a 300ex motor in a 350x? Besides the obvious electric start and reverse I dont get it. Doesnt the x motor make more power than the 300?

[jeswinehart]

I believe I have seen some sorts of a similar set up on old Harleys :)
With this particular EX I don't think you can shift into reverse until the clutch is engaged.
I don't have but a couple of hours seat time (if that much) on it as a quad but recall trying my hardest to get into reverse and couldn't because I did not have the clutch lever all the way drawn in. Old Bigred habits die hard,,,.
I can feel/hear it hit the stops so that is a good thing. Any final tweaking that may be needed will wait until I get handle bars + clutch perch + lever back in place.
It's okay to laugh since I am even chuckling over this set up but at least it will be hands free operation ~ dose have a small roller bearing for smoothness :)

[big specht]

I think it would be way easyer to just put it in a 350 frame

[jeswinehart]

A 350X don't fit me well enough to have anymore then the 2 I have over the years.

This is the very first sentence I typed when I started this thread > In a attempt to get a much better suspension then the 85 Bigred could ever offer I bought a 300EX that had the traits I want. Electric start + reverse in a not so big of a package being I ain't exactly a large framed fellow

[oldskool83]

I was going to do this years ago and the idea popped into my mind again this summer since I have an endless supply of 300ex/250x parts.

Id like to see what you come up with. I also like the 300ex size as its is a decent go almost everyware run for ever atv.

[jeswinehart]

received the gooseneck and a assortment of other parts during the week and made good progress with the project.
Remote choke cable installed, final length to the top triple tree area to be determined. The bracket I took time to cut and install will definitely be well worth the effort.
Twist grip throttle installed ~ right thumb shot, prefer a twist throttle.
test fitting of the gooseneck kinda went south with a over cutting of angle, nothing that the welder won't be able to overcome, just will cost me a few more dollars I suppose,,,
My idea is to have the steel plate welded to the gooseneck and drill and tap threads into the 1 inch thick alu plate that is bolted to hard points on the front of frame.
I don't want anything permanently welded to frame at this point since all you see is temporary (but a heck of a improvement over how my 85 Bigred rides).

[350for350]

You're making good progress. Keep it up!

[6speedthumper]

Coming along nicely!

[tapper190]

nice John, looks like it will be ready for our September ride.

[jeswinehart]

Got to working with the stock ex quad plastics and they cut + folded over well. Certainly don't look like much work but did take me all morning with lots of staring and thinking time of how/where to cut.
Never did need the heat gun but did use the dremel tool way more then I suspected I would.

[atc300r]

This is a cool project. Cant wait to see it finished.

[6speedthumper]

This makes me want to get an EX engine and a 350x swinger and convert the EX frame I have on the shop floor. Good thing for me is I have a spare 350X frame and front end with a rotted out subframe and engine cradle.

[jeswinehart]

After 4 angle changes I believe I have the angle that I am looking for. Handles quite well now.
Got a thousand little things to button up (lights, front brake, cable tie backs, lots of little things).
The reverse foot operated shift lever works like a charm, same with the cable operated choke.

Work in progress,,,,

[MojaveRider]

Very cool! I'm glad you were able to test ride it to find the best angle. Do you know what the neck angle ended up at compared to a 200X, 350X, or 250R?

[M.Pargiello]

Looks cool! Is it going to be in Baldwin in Oct.?

[oldskool83]

looks like it does not have enough rake. throw on a 350x triple tree. front end should be throw out a good inch or more.

[jeswinehart]

n You might be right oldschool. It certainly feels better then I had it and I did have it wayyyy to much raked. That looked great but would take a very wide berth to turn,,,

[jeswinehart]

I did one more increase in the rake and oldschoolin was right,,, better yet. Fender clears where it probably would have not done so before (borrowed this one last night from Dizasterfun AKA Kevin Shively).
Redone the cables/wire routing from the way I had them routed the last time I took pics so those ain't all bundled up. They cleared every thing before but just look more right this latest way.
Space between front and back axle is 43 1/2 inchs. Got a headlight + brake caliper + hose + fender coming my way.
Going to lock tight the mounting bolts in, change fork oil, engine oil, rear brake pads, chain adjustment and planning on going to Kevins and ride around his 15 acres tomorrow. Rides good around our small back yard.
Miss Korey wants to ride it as dose Kevin and his father Dale (Dale is in town visiting Keving and Corey because of the new baby boy Corey + Kevin had last Saturday)

[6speedthumper]

Looking so much better! How's your arm height? Only asking because your bars look a tad low.

[jeswinehart]

Well the arm height feels all right, the reach seems okay as well. Those bars have been bent from a roll over the fella I got the quad from so they won't be staying on there. I would like to play around with different height bars now that you mention that.
I am sure I will have more feel from the trike tomorrow after getting some real seat time on it. Also looking forward to the input from 3 other experience trike riders have to say about it and what, if any improvements they recommend.

[DohcBikes]

Looking great john, rake looks correct now. Didn't wanna just parrot oldskool but I was hoping you'd try it. Agree with 6speed, dem bars look short...

Fantastic work. These modern trikes are going to pave the way for new possibilities, and yours is starting to look factory built. FYI I had a bummer of a day and your update just made it better, thanks.

[6speedthumper]

DOHC is right. These modern trikes are paving the way for the future of 3 wheelers. I said it once in this thread, and I'm saying it again, this makes me want to use the 300ex frame I have for a trike project. I have a complete 350x front end to put on that bad boy...

Jeswinehart, other then some better, taller bars, I'd install some extended rear wheel hubs and possibly an extended swinger if it's really wheelie happy. For some reason I remember the 300ex being very wheelie happy with that extra front wheel, how is it with the proper front wheel count? lol. Oh yeah, and an exhaust, air filter, high comp big bore, cam, porting... ALL the good stuff! Hahaha!

[MagicJames]

Hey john, long time no talk! Question, what did you do with the front half of that? I'm building a 250x/350x quad for my wife and could use some of the parts you don't need anymore. I might have a few boxes of spare 300ex/250x parts laying around and maybe a supertrapp full exhaust. Give me a call if you still got my number laying around

[jeswinehart]

Sorry James, that front end didn't hang around long,,,, kept getting in my way.
Patrick, you are right about the rear wheels need spaced out a wee bit. I suppose I will put wheel spacers on my shopping list. The handle bars seemed fine to me. Kevin seemed to think they was okay too. In doing some ruff measurements these have 3 inch height and the 350X stock bars have 4 inch rise.
Since you guys have pretty much been correct on your observations I will be on the look out for BigX bars or at least some that are 4 inch rise.
Now as far as a wheelie machine, no not really. I didn't seriously try to bring the front end up but 2nd. to 3rd. gear pretty much pinned it never raised up which is just fine with me. But then again, I don't often hit the gas that hard (anymore).
Kevin thought steering should be a little looser. Got it home and discovered I had really cranked the retaining nut down much more then needed (and never greased the roller bearings either).
Perhaps just a little more rake but I am going to called it good enough for this season. I will need to do some trimming on the stock 83/84 front fender coming in this week, no way it will clear exhaust.
Just for comparison Kevins stock 83/84 250R measures 1 1/2 inches longer center to center front to rear axle. I ain't striving for it to be like a stock R but rather just an interesting comparison.
Mike Pargellio, if it survives next week ends ride near Rose City (camping at Ambrose Lake), it will be up to Baldwin in October.

Thanks guys, john

[6speedthumper]

That's cool, dude. The TUSK extended rear wheel hubs are very nice. I have a set on my sister's 250ex. Will widen it by 3.5" total.

I forget what the rise and pull back is on my ProTapers I put on my 350x. They feel great for me.

[6speedthumper]

Now I remember. They are the ProTaper ATV High bend.

[oldskool83]

should put some smaller rear tires on and pull the forks down to the triples. If you do not have coin for higher bars, just double up a top bar clamp under it and use longer bolts. I used CR hi bars on all my 3wheelers, but cut the bars down inch off per side. Its looking better.

[jeswinehart]

Well for sure the trike fund level has went down some, time for me is the more critical factor. I don't know if these EMGO HANDLEBARS



•Carbon Steel 7/8" replica handlebars

•No pad on crossbar

•OEM Brand: Honda ATC

•Width: 28.5"

•Rise: 4"

•Pullback: 2.75"

•Center Width: 7"

•All bars are knurled

•No paint on throttle side

•Plastic end caps
•
bars will be here in time for this week end, I am more so getty ancy about the head light and other parts coming in from California.
I have a fog light I can slap on there to meet Michigan rules for the few county roads will most likely be on this upcoming weekend.

[DohcBikes]

I have bought and sold dozens of sets of the EMGO ATC bend in several colors. In my opinion they will be just right on your project, looks wise.

[tapper190]

After having the pleasure of riding this little gem, I would say that it is a great build! Has lots of power, great handling, not a wheelie machine at all, everything feels right with it. Great job John!

[rdlsz24]

Looking good. 300ex was my first quad. They are a great size, similar to a 200x but with more power.

Rob

[jeswinehart]

I don't think they are anything close to a first gen 200X IMO,,, this machine actually has power after 3rd. gear + quite a few much better traits.
BUT, like I have said in ealier postings about this 300EX + Honda not using what they learned in past (reverse shift/back up start/choke systems) I believe I have found yet another area they managed to engineer stupid into this machine.
With Honda keeping with the practice of NO grease zirks on any dam thing they recommend to service on a regular basis I needed rear axle bearings on this 10 year old "trike".
What I ran into in taking the axle out I really was in no way prepared for. Everything that was inside the swing arm housing was rusted SO bad I had to use hand held band saw, sawZall, hand grinder to get the axle out and bearings removed. I had to first cut off the disc brake mounting hub to get assembly out of the swing arm housing.
Once I had that in vice proceed to cut/grind/beat the bearing carrier to get to the bearings where I repeated the cut/grind/beat method for bearing removal.
I have had my fair share of 25+ year old bearing replacements with machines I have had since 1985. NONE ever have I had to do this too.
I have never seen inside the carrier (or noticed before) it having holes, 8 of them to be exact. I am positive the swing arm is not water tight so where to drain any moisture ~ into the rear bearing housing. WAY to go Honda. trailprotrailprotrailprotrailprotrailprotrailprotr ailpro's

I will post up what I will do, as I have done in the past on machines, to correct the "stupid hurts" logo Honda is SO proud of.

[jeswinehart]

it took just over 2 and a quarter tubes of grease and a zirk adapter to stuff the swing arm full from inside the carrier.
Double width bearing carrier came with a grease zirk and I used the grease gun zirk adapter to first fill the inside of the new carrier thru where the stopper bolt was originally (bolt no longer needed) and then I filled the cavity around the outside of the carrier that is inside the swing arm housing.
3 tubes of grease total used.
Replacement brake disc hub will be in middle of next week,,,

[Derrick Adams]

Are you concerned that you filled the outer cavity with grease that it will cause your carrier (chain) to come loose?

[jeswinehart]

Well, never even thought about it in the aspect Derrick ! We shall see how well the pinch bolts do their job.

[M.Pargiello]

Don't know if you are still looking into bars, but the Easton EXP's I use are all a CR bend. Don't know what the measurements are exactly, I think you have ridden or sat on it at least. They are really comfortable to me, feels just a tad wide even though it barely fits all my controls/hand guards. Might get the fasst flexx next time, but thats $$$$

[Eric250R]

Great job John ! And out of curiosity have you considered swapping the forks around and trying a leading axle versus a trailing axle instead of adjusting the rake again ?

[jeswinehart]

Not so much swapping forks around but simply turning them outwards. It should not effect the speedo set up I just got on there but defiantly I would loose the front brake,,,, I want to keep that.
Swapping forks around I probably could keep front brake but would loose the correct direction on speedo drive gear that I just done a swap for. I want to keep that as well.

[HoustonAE2]

Any chance of a video with you on trike? Would love to see how it handles.

Awesome build.

[jeswinehart]

Any chance of a video with you on trike? Would love to see how it handles.

Awesome build.

Nope, no videos Allen. I was thinking early on in the build that this would be a good starting point and do suspension upgrades this winter.
I am now leaning towards leaving suspension just the way it is. The cost of inverts on the front + something 600 dollarish rear shock just don't add up for the way I ride (slow),,, it basically rides and handles just fine as is,,, for me.
Not to say suspension upgrade (if you want to say it that way) won't ever happen but not in the plans at this time.
So yeah, if you come across a cracked up 300EX I highly recommend the conversion because it is a silly simple to do IMO.

[fabiodriven]

Great job Johnny! We'll see it in June!

[ctk]

I can speak from riding with john, this trike looks to handle very well. That's handling overall from turning to bumps. Great conversion john, looks like a factory Atc going down the trail.

[jeswinehart]

After many rides and about 300+ miles the front end felt a little loose on my last outing in Baldwin, mi. (the birthday ride).
Front 250R forks needs new seals so while the outside weather is still tolerable I decided to investigate.
What I found was the hard point area for the EX steering shaft bracket has the 4 nuts welded on the inside and they broke free. I had to cut the plate with grinder cause the oem nuts was just spinning They didn't pull thru the thin plate and my 2 additional hardened nuts + bolts I had installed all the way thru the frame kept it all together preventing a major accident.
So now that I know this conversion set up (300ex) is definitely my daily rider I will refab and have the goose neck welded in place.
Bottom line is if you are considering this quad for a conversion don't rely on the 4 bolt steering shaft mounting area for long term.
More to come as this rather slow improvement comes together.
john

[jeswinehart]

This part of it went along better then I anticipated. Probably since I had the rake previously figured out I suppose.
I used the angle of the inserts as my guide and cut away what I needed too from the lower frame tubes. Thankfully I did not need to cut away any of the factory welds + gussets.
Lots of grinding on the C channel to get good fitment for the welder,,, LOTS of grinding.
Oil drained, battery out, electrical stuff zip tied back out of harms way (and unhooked for the most part). I figure they will need to flip it on its back and sides to best get to the inside area for welding. All they will need to do is to remove the triple tree retainer nut and the front end will drop out and be out of their way.

[86125m]

you have the rake just right now its starting to look like a proper factory built 3 wheeler.

[Crazyktmmatt]

How did this turn out?

[jeswinehart]

I am very happy with it. It fits my trail riding requirements very well.

[edizzle89]

reading the thread title i didnt have high hopes for this turning out well, but after reading through the whole thing it ended up amazing man, incredible work.

[camy]

wow that's some nice DIY!!! I really like the idea of taking a little reliable machine like this and take the low cost way instead of TPC 450r 7000 + $ machines

[jeswinehart]

Thanks guys ! It is a real nice daily driver for me. Tinkering around with dash lay out today to better facilitate my new GPS mount.