All 2006 parts on an 04-05 LSR frame

5991 Views 7 Replies 4 Participants Last post by George Porter, Sep 29, 2008

Trentk

Discussion Starter · Sep 22, 2008

I am still not 100% done but here is what I have so far.

I pretty much destroyed my 06 quad during my last race when the course turned into a mud bog ended up taking out the engine, tranny, rear bearing carrier, new crack in the frame, etc. I tore the quad down to the bare frame with plans of having it gussetted. Rather than gussett my frame I bought Jeremy's (4bidden) 04-05 geometry LSR race frame since it was a good deal and most people said it should work. All my parts showed up Friday and I only had this one weekend to get it together in time for the Silver State 300 on the 27th. The LSR frame looks the same basically but there are quite a few minor differences that make this swap a royal PITA. here is a list and some pics.

1. The engine mount tabs on the frame are closer together so all of the spacers and bolts from the 06 frame/engine need to be shortened. I think we took 5/8" off the front spacers, 1/2" off the bottom middle spacers and 1/4" off the top middle spacers. These measurements aren't exact, i am just going off memory.

2. The frame is narrower where the precision stabilizer mounts. I had to grind on the stabilizer brackets to get it to fit, also had to dimple the frame to get the bolts to fit.

3. Foot brake lever spring tab is in a different postion. Looks like the 06 spring will work but it looks kinda hokey.

4. Frame is narrower where the aftermarket oil cooler mounts. Had to modify the mounts a little bit.

5. Only one bolt hole on top of the front shock mount for the front fender brackets. used some self tappers to fix that.

6. No bolt holes on front crossbar for 06 headlight and electronics. Used self tappers here too.

7. With the tie rods threaded all the way in I still have way too much toe in. Will need to shorten the tie rods by xx amount or buy shorter tie rods.

Still haven't fully mounted the exhaust, gas tank and fenders so I am not sure what else I will run into.

starting point

Front end of the frame with 06 JD +2 LT a-arms

trying to get the engine in

working

oil cooler and front engine mount:

steering stabilizer, notice how close the bolts are to the frame. they wouldn't go through at all before the BFH was used.

close to running with all new rear end stuff

front headlight mount and fender mount screw location
http://godfatheracing.com/quad/PICS/septem.../quad%20025.jpg

rear brake lever spring
http://godfatheracing.com/quad/PICS/septem.../quad%20026.jpg

trying to set alignment
http://godfatheracing.com/quad/PICS/septem.../quad%20029.jpg

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4bidden

· #2 · Sep 22, 2008

I forgot about this until late yesterday and since I hadn't heard from you I figured it worked!

The headlight I knew there wasn't mounts for but didn't think about it. Was still picturing your aftermarket setup.

Glad you're almost done! Some (not so) minor pains now will be worth it now that you don't have to worry about the frame again!

Might want to ask Morgan about the Precision - I'm pretty sure he had one mounted on there before he sold it to me. Don't think he modified anything?

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Trentk

Discussion Starter · #3 · Sep 22, 2008

I forgot about this until late yesterday and since I hadn't heard from you I figured it worked!

The headlight I knew there wasn't mounts for but didn't think about it. Was still picturing your aftermarket setup.

Glad you're almost done! Some (not so) minor pains now will be worth it now that you don't have to worry about the frame again!

Might want to ask Morgan about the Precision - I'm pretty sure he had one mounted on there before he sold it to me. Don't think he modified anything?[/b]

if he had a precision for a honda he would have had to modified it because this one worked on my 05 and my 06 but wouldn't fit the LSR frame. It is about 3/8" narrower there.

now I gotta sell my nearly new IMS pro peg/nerfs/heelguards so make up some money!

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zackp00

· #4 · Sep 23, 2008

what do you want for your nerfs ???

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Trentk

Discussion Starter · #5 · Sep 23, 2008

Ran into a new problem. The airbox boot is about 1" from the carb due to the 06 subframe. Anybody got any ideas to fix that? I cant just add 1" of pipe that will throw the powerband all off since the intake is designed to be xx length.

The exhaust just barely fits and the top engine mount is no where close to fitting.

I will probably want $500ish for the nerfs not sure yet. They are over $800 new and they have 3 rides on them. I need to see what I paid for them before I put them for sale.

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4bidden

· #6 · Sep 23, 2008

I replied in your other thread -

Try a Noss on the intake? 04-05 guys have to use one with FCRs. Much easier than trying to put a 04-05 subframe on.

The upper engine mount is off?? Morgan said they bolted on in just fine using 06+ engine mounts.

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Trentk

Discussion Starter · #7 · Sep 29, 2008

I replied in your other thread -

Try a Noss on the intake? 04-05 guys have to use one with FCRs. Much easier than trying to put a 04-05 subframe on.

The upper engine mount is off?? Morgan said they bolted on in just fine using 06+ engine mounts.[/b]

I finally got the quad running late on Saturday. Here is more stuff that needs to be modified to work:

8. I am running +1" tie rods from JD Performance instead of the +2" that goes with these a-arms. The +2" were too long and I couldn't set the toe correctly.

9. The top engine mount has to be cut and modified quite a bit in order to line up with the head.

10. The plastic tray that sits on the frame above the engine has to be cut in various places in order to work.

11. You need to build some custom spacers for the bottom of the steering stem. My JD performance steering stem sticks out through the bottom of the frame by about 1/4". You need to take up this space with some fat washers othewise the stem will move up and down even after it is tightened.

12. With an 06 subframe the carb is about 1/2" from the air snorkel. I used some aluminum pipe and a silicone hose to take up this gap.

13. The exhaust doesn't slide together as fully as it used to due to the subframe being longer or the mounts being in a different location. It still functions without leaks.

I think that is it. I also discovered the Moose parking brake blockoff plate sucks. When you try to clamp down the rear brake piston to install new pads the moose plate prevents the piston from fullying opening.

Now I just need to come up with some type of heel guard solution.

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George Porter

· #8 · Sep 29, 2008

Now I just need to come up with some type of heel guard solution.[/b]

Real dezert racers dont need them!!! LOL J/K

Safty first!!! :thumbup:

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