TRX 300KX -- HondaSaki

ATV - 1997 Honda TRX 300EX
Donor Bike - 1996 Kawasaki KX 250
Total Time to Complete - 10hrs.

  There we were, with Mikey's 300EX and a pooched motor. Bad piston, con rod, cylinder, cam, follower..... It wasn't good. Looking at spending the better part of $1000.00 Cdn to rebuild it. Thing is, that it was already a 383cc kit from 4-stroke Tech, with a modified black box, a White Bros - E series pipe and a race cam, so there wasn't a whole lot left to do to it, and I hate putting good money into something and at the conclusion, only having what you started with.

    So, we searched (not too far) and found a mint 96 KX250....(things that make you go hmmmm......) Let the fun begin.

    Below is a series of shots with explanations, that we took during the conversion process. Let me say that the finished product is impressive. We drag raced it against two slightly modified Raptors and the outcome was a draw. The Raptors both have pipes (1 GYTR, 1 White Bros E Series) Both Raptors have jet kits, and modified air boxes. The KX motor is stock. I'm pretty convinced this bike will take a stock Raptor - we have one of those too, but the pilot was unavailable for testing at this time.

At present we have no lighting coil, but will salvage one off a KDX 250 to retain the EX's factory lighting.

The goal of the project was to not only install the KX250 motor into the 300EX frame, but to noy damage the EX in case we ever wanted to go back (???). With the exception of a cut breather tube and a couple of brackets welded to the frame for the rads, all EX tabs, mounts and parts were not harmed during this installation.

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        The EX is stripped and powerwashed.  












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        Mikey (left) and Baby Man strip the KX.
   












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        The 250 sitting on blocks inside the EX frame.











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        Chain alignment and swingarm geometry set and checked,
        custom engine brackets fabricated.











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With just a slight tweak in the vise on the 1st bend in the pipe, and with the pipe installed on the opposite side of the machine, it bolts right on. Note the outlet of the pipe is near verticle (wrong!)











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Baby Man cutting a 30 degree angle about 4 inches in from the outlet of the pipe. Rotating the cut piece 180 degrees allows for the proper transition to the silencer. This also enables the volume of the expansion chamber to remain constant. The angle was cut so that the pipe hugged the frame member and therefore would minimize impact to the stock fenders.










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Approximately 4" of similar diameter pipe was used to place the silencer in the desired position. The stock 300EX battery holder was moved to the other side. The solenoid was discarded. Note that one of the original battery mount captive bolts os used to mount the silencer.











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The semi finished product. Routing the pipe this way allows the stock plastic to stay on the machine. Note the stock breather cone comming out of the air box. It was cut just before the first rib to facilitate a flexible pipe connecting the KX carb to the 300EX air box. The air box cover was removed to allow for sufficiant air flow.









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(From left - The Panz, Mikey, Young Jeff and Baby Man)
The radiators from the KX were mounted on the front frame member - just behind the front bumper mounts/ The hoses were run along the horizontal fram member.












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Baby Man mounting the other rad and checking the fit of the stock rear plastic against the pipe. The front fender supports  were left in tact on the right side but needed to be modified on the pipe side.










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        The Panz securing the last of the rad hoses












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        The rad hoses are run in front of the shocks and along the frame.













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The stock KX kicker is too long. It was cut and aluminum welded and a larger contact plate attached to it.











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The front plastic fit well,













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    The finished product.












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