Best year LT 250 for hybrid?

• Best year LT 250 for hybrid?
  Posted by Rainman56 on 28 Nov, 2012 13:49
• Thinking of doing a 250/Zilla engine hybrid.Are any years between 87-92 a better choice than others?How much custom fabricating is involved?I,m assuming frame,engine mounts,pipe,shim axle sprocket out?Just trying to get an idea of what I,m in for ahead of time.Any input is appreciated:).
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• #1 Reply
  Posted by Heminutt on 28 Nov, 2012 13:57
• i am doing a hybird also. i was told a 87-90 are the easiest. i am doing a 89
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• #2 Reply
  Posted by Rainman56 on 28 Nov, 2012 17:02
• Quote from: Heminutt on 28 Nov, 2012 13:57

  i am doing a hybird also. i was told a 87-90 are the easiest. i am doing a 89
  

  
  Thanks for the info Heminutt.Maybe for airbox/filter due to different shock location?Like i said just hoping to get some info also so I know what I,m getting myself into:)
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• #3 Reply
  Posted by Roach on 28 Nov, 2012 17:55
• i dont think sprocket needs a shim?
  
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• #4 Reply
  Posted by Roach on 28 Nov, 2012 17:57
• dont forget the 500 petcock
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• #5 Reply
  Posted by Quadster on 28 Nov, 2012 19:11
• Quote from: Roach on 28 Nov, 2012 17:55

  i dont think sprocket needs a shim?
  
  

  I got three(whatever the thickness of sprockets are) welded together . Depends how bad the frame and swinger are tweaked!!
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• #6 Reply
  Posted by Rider414 on 29 Nov, 2012 06:29
• Can someone elaborate more on this? The output sprocket on the 500 motor does not line up with the drive sprocket on the axle?
  
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• #7 Reply
  Posted by Quadster on 29 Nov, 2012 13:32
• The 500 motor is a bit bigger/wider so the output shaft sticks out a little more than a 250. Normaly about a 1/4 +-inch spacer behind the rear sprocket . Motion Pro sells a chain alignment tool, but i just used a framing square and a straight edge.
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• #8 Reply
  Posted by Rainman56 on 30 Nov, 2012 12:25
• Whats involved in altering the frame?Cut and weld the tubes?Lengthening portions of the frame and fabricating the mounts?
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• #9 Reply
  Posted by Rider414 on 30 Nov, 2012 17:53
• There was a awesome thread on the old site that had all pictures where you had to fab/cut/weld. I have my eyes peeled for a LT250 roller!!
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• #10 Reply
  Posted by GrkGuy on 01 Dec, 2012 21:55
• ask lt500kid, we just told him how to fix his.
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• #11 Reply
  Posted by Rainman56 on 08 Dec, 2012 19:04
• Anymore input on this subject?Just curious what frame mods need to be made?
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• #12 Reply
  Posted by GrkGuy on 08 Dec, 2012 19:24
• right side bottom motor mount need to be cut out and rewelded back in in a higher location on the frame rail
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• #13 Reply
  Posted by Rainman56 on 08 Dec, 2012 19:30
• Quote from: GrkGuy on 08 Dec, 2012 19:24

  right side bottom motor mount need to be cut out and rewelded back in in a higher location on the frame rail
  

  
  Thanks,appreciate the info:)
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• #14 Reply
  Posted by Iceracer on 09 Dec, 2012 10:32
• Its actually a wider position not higher. I think John had a typo.
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• #15 Reply
  Posted by BadMoonRacing500 on 09 Dec, 2012 12:39
• Easiest way Ive seen is to put the zilla motor in with the swinger bolt, then you'll see where the frame rail needs to be notched for the lower mount. with that done it will drop in place, put the thru bolt in and then the SBLT front motor mounts. Then you'll see where the cut out for spark plug access and for the kicker to rotate need to be also the flat bracket w/2 holes on the front down tube needs to be notched for the pipe. I would also recommend some gussets.
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• #16 Reply
  Posted by Quadster on 09 Dec, 2012 13:23
• Heres a couple pics i found...
  
  
  
  
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• #17 Reply
  Posted by Heminutt on 09 Dec, 2012 13:49
• i just picked up a 88 roller. going to be starting my hybrd project soon.
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• #18 Reply
  Posted by Quadster on 09 Dec, 2012 14:04
• Also, make sure to notch enough to easily remove and install spark plug with bike together. I had to use a br8ecm (same as the other b8 or br8 plugs but shorter) and a plug wire off a lawnmower!
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• #19 Reply
  Posted by Rider414 on 09 Dec, 2012 18:11
• I'm still looking for a roller! Can't wait to do a hybrid.
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• #20 Reply
  Posted by WestTexasKing on 09 Dec, 2012 21:49
• 87-90 is easiest and requires the least amount of fab (it doesn't matter which year you get, they're all the same with the exception of 24 and 26 spline axles).
  85-86 is lightest and requires additional work to strengthen weak areas, some components do not interchange with later year models.
  91-92 is heaviest and takes the most work, but winds up being the strongest (provided you strengthen the same areas as all other frames)...you also get the no-link rear shock.
  
  As far as modifying the frame, you need a minimum of these modifications:
  Spark plug cutout
  RH lowest rear engine attach point needs to be 1" farther out
  Wishbone needs to be modified or new downtubes need to be made for the front engine mount
  RH frame usually needs some clearance for the kickstarter, my hybrid doesn't but it's also the exception rather than the rule.
  
  That's the absolute minimum, but most people gusset the tubing clusters and use additional tubing to strengthen other areas that need attention.
  You'll be putting more stress on the frame because...
  Engine is heavier
  Engine torques the mild steel frame more
  You'll likely be going faster which puts more stress on the frame too
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• #21 Reply
  Posted by GrkGuy on 18 Dec, 2012 07:32
• just make sure you do the frame rail on the clutch side, if not you will have to pull motor to take off clutch cover
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• #22 Reply
  Posted by ATVMXR on 19 Dec, 2012 12:00
• Quote from: Rider414 on 29 Nov, 2012 06:29

  Can someone elaborate more on this? The output sprocket on the 500 motor does not line up with the drive sprocket on the axle?
  
  

  
  
  i believe using a 85-86 sprocket hub fixes this....
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• #23 Reply
  Posted by Rainman56 on 19 Dec, 2012 17:32
• Do the hybrid frames hold up using them for MX???Not alot of metal in there on the tube mods,especially the upper tube for spark plug clearance.
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• #24 Reply
  Posted by Iceracer on 20 Dec, 2012 06:05
• Using the 85 hub and running the sprocket outboard works to fix chain alignment, as does useing a the center from a an old sprocket between the hub and sprocket. I use the inside race from a bearing between the bearing and hub on mine many differnt ways to do it.
  
  As far as holding up in mx, better bring a welder with you. The newest of these frames are 20 years old now, as a 250 there not terrible, but expect to chase cracks. The best thing you can do to alleviate this BEFORE YOU mess with an engine swap, is invest in QUALITY shocks and suspension components OEM doesnt cut it. You will be faster with good suspension than you can ever be with a Crap suspension and a big fast engine.
  
  Anyone I have ever talked to has said the same thing about Hybrids and MX, fun in practice but too much to hold onto to race, unless you run big wide open gp style stuff.
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