Baja Warrior BEAST build

[RancidMDC]

Hey guys, I'm new to this website I actually just found out about it and I figured I would show you guys the build I just did on my Baja Warrior mini bike, I had a Baja Warrior when I was 15 years old and I loved it so much but was forced to sell it when I needed money 4 Bills when I turned 18, Now that I'm 29 years old I figured I would have a second childhood and get another Baja but this time I'm going to beef it up a little bit!!

 

[RancidMDC]

Well of course, the first thing I did was tear this sucker down to the bare frame!

 

[RancidMDC]

Now the goal here was to make this thing a BEAST so I'm going to need a bigger motor than the stock, so I went shopping around and came across the predator series motors at Harbor freight. They are in expensive yet decent enough motors. So I was checking out the 212cc, but than I look over and see the predator 16hp 420cc motor next to it on the shelf! And we'll, decisions were made and look what I bought! It has electric start and everything! Go big or go home right?

 

[Poboy kartman]

Welcome to the forum!!!!

 

[RancidMDC]

Got the motor home safely, stripped the exhaust off, the intake manifold and removed the stock gas tank to prep the motor for fitment on the bike and looks like I'm going to have to make some modifications to the frame to get it to fit. Took a bunch of measurements and it looks like I'm going to have to stretch the frame about 5 inches! So time to break out the sawzall!

 

[Poboy kartman]

You probably don't need to hear this , but some of our members have been buying the Powerland 420's for $170 shipped. I think the electric start one is $199.

 

[RancidMDC]

Got the frame cut in half and cleaned up nicely, went down to Alro Metals in Clearwater to pick up some round steel tubing for the bike, cut my 5 inch pieces that I needed for the bottom rails under the motor plate and for the top bar which connects under the seat, now time to break out the arch welder!

---------- Post added at 09:32 AM ---------- Previous post was at 09:27 AM ----------

---------- Post added at 09:33 AM ---------- Previous post was at 09:32 AM ----------

Poboy kartman, that actually sounds like a great deal but that concerns me on sale cheap it really is, the quality must be terrible

 

[RancidMDC]

Got everything welded together and I did a dry fit with the motor and everything fits good except this new motor is quite a bit wider than the stock motor so it looks like I'm going to have to widen the frame about an inch and also continue the motor plate in the new section I welded in and also resupport the frame

 

[RancidMDC]

Now it's time to clean up the worlds and paint the bike so nothing starts to rust. I also got my new headlights in the mail today so I will put on some brackets for those as well, and if anybody is curious I bought four 12 volt 35 watt LED light bars

 

[RancidMDC]

Now it's time to set the motor in place, line it up and bolt it down and see how she looks

 

[RancidMDC]

The motor fits great just need to hook up the throttle cable to it and bypass the governor, I'm not going to remove the gear from inside the engine, Now I need to make a header, I need to find a motorcycle gas tank that will fit on the top bar, I need to wait for my 40 series torque converter to come in the mail and put that on, and then I now need to find a battery that will be strong enough to start the motor, run the headlights and any other accessories I might decide to add later and build a bracket to hold the battery in place, I'm also thinking about turning the reflector on the back Fender into a working brake light

 

[bob58o]

Very cool Build.

What are you going to do for a clutch and gearing?
I think stock was like 10:1 or something with a jackshaft and those big 19" tires.

Nevermind, I see you are going 40 series. Cool

 

[Bbqjoe]

Looking good. A few of us here are into the warriors, I can't wait to see your continuing progress.
I saw a shock in a photo. Are you considering a rear shock mod?

---------- Post added at 07:10 AM ---------- Previous post was at 07:07 AM ----------

the motor fits great just need to hook up the throttle cable to it and bypass the governor, i'm not going to remove the gear from inside the engine.

ahhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Remove the funding gear!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

[RancidMDC]

Okay, so I found a Sportster peanut gas tank on Craigslist that matches up perfectly to the frame of this bike and it looks good!

 

[RancidMDC]

Yes, I'm going with the 40 series torque converter from gopowersports.com. Yes I know it's crazy expensive from that site. But they manufacture their own steel back plate to hold the driver pulley and the driven pulley

 

[RancidMDC]

Got the electric start key module and the battery mounted. Went with a 12v Duracell AGM 20ah batter from batteriesplus. Everything is mounted. I also decided to add a breather to the valve cover instead of running a rubber line into the intake manifold

 

[aham2003]

Joe has one for sale on here. Needs a driven but you should be able to save a few bucks that way.

 

[Poboy kartman]

What's crazy expensive is bypassing the govenor!!!!

 

[RancidMDC]

Ended up bending some 1 inch steel tubing to make a straight pipe header and Got the 40 series torque converter mounted, and I did not have to make any modifications to the engine at all to get this massive belt system to work, and I also made a guard to go around the pulley so it doesn't suck my leg into it on accident. Haha

 

[RancidMDC]

Here is how I bypassed the governor, it wasn't very difficult and I was able to use some parts off of the throttle plate that came with the engine