Baja MB200 chop with GX420 clone and Tav swap. The Baja Monster 420 project......

SnakePliscan

SnakePliscan

New Member
#1
#1
So to start, 5 pictures One of the bike the day i bought it. The bike is a 2005 Baja mini, originally sold by Canadian Tire Canada. The original owner i bought it from hardly rode it (the governor screw hadn't even been backed out for a few more revs) so bike was near new.
The Motor going in is a Power ease 420cc 15hp bought from midland tool.
Mods so far are chop, bend and weld the frame, cut the front rake in half move the seat back 4 inches and take most of the pull back out of the handle bars, weld in engine mounts. I'm thinking of chopping the fenders and mounting a headlight.

Also working out throttle linkage and mounting the gas tank.
Ive sorted out the TAV, as you can see in the pic, it wont fit without clearancing between the bearing housing and the rear oil filler.

Haven't decided on a color yet, feel free to make any suggestions.
 

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SnakePliscan

SnakePliscan

New Member
#2
#2
OOP's my bad, suggestions and comments not on the thread just PM me.

I will add that my plan in the long term after all the fabrication and testing is done is, while the bike is striped for paint or powder coat i will Hot-Rod the Motor. I have a flow bench so i will flow the head and see what i can do with it, ive been flowing and porting for 20 years so it's kind of a habit of mine. These clone motors are new to me so it's interesting and challenging.
Additionaly i'll do a cam swap with a hi-pro GX390 piece, if a 390 piece wont fit i'll regrind the one that's in it, along with high ratio rocker install.

Ive already got another mini project lined up after this one, a Broncco tx predator 212 build to sell.
 
SnakePliscan

SnakePliscan

New Member
#5
#5
Baja 420 Tank mounting

So i mounted a gas tank from a 212 Rato on here. the stock 420 tank is twice the size and a no go. I just used 1/8 flat bar and drilled in the appropriate places. the fronts are about 5'' and rear bracket is 6'' bent with pliers and in my vice.
 

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SnakePliscan

SnakePliscan

New Member
#6
#6
Baja 420 carb linkage mods to work with modded gov. lever

Heres the carb linkage, You can see it takes some doing, the 390/420 carb linkage is backwards compared to a gx200, i used welding rod to build a triangle peice off the throttle shaft i trimmed cut and welded the Gov lever and support. the picture shows the throttle is in the wide open position. Return Spring nicely opposes the pull cable. i will let the picture speak for itself. additionally the throttle works real well. Second feul shut off v/v is for doing carb swaps in the future. RPM Stop screw is in place for if a novice is riding.
 

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SnakePliscan

SnakePliscan

New Member
#7
#7
420 carb opinion

I dont plan on keeping the 390/420 carb (i put on a ebay carb with ajustable idle screw by the way, with no air filter and a muffler change it wouldnt run on the non adjustable stock carb) as it's design is to basic.

The 420 carb have one thing going for it, it's big.

It's modular dezign is it's down fall, the idle circuit is integrated into the main jet feul circuit and this makes the carb a challenge to jet right.
I don't like a motor that dosnt snap to the throttle and the this carb dosnt want to do that.
 
SnakePliscan

SnakePliscan

New Member
#9
#9
Baja 420 chop and bend

This is the frame being bent and the rake being reduced, i used ratceting tie downs to pull the tubes. pretty much just eye balled it all.
The frame is pretty coc-eyed to start with so i think it's better aligned now!
 

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SnakePliscan

SnakePliscan

New Member
#10
#10
Baja 420 seat frame and neck mods

Heres the mods cut the old support off, kept the flat part to weld those tubes to, moved the forward mount back about 4''

Made the big old seat smaller got do the uplstrey but put the old cover on for now.

Frount neck support just some old 1'' hydorlic tube i scrounged

Got a really sharp knife to carve down the foam seat
 

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SnakePliscan

SnakePliscan

New Member
#11
#11
Baja 420 frame veiw tube drop bend modds

Frame chopped and bent ready for motor, i flattened out the handle bars and it was to much i should put a little pull back, back in. My Lincoln HD 140 with 030 wire is kick ass. i was runnin 023 wire before and it wasnt as nice, the 023 is just for sheet. I run a 220 power cable from the house and have a 110 box (lower right corner of picture) with a 220 plug on it and i run each 110 leg to a spearate plug in the box..no voltage drop to my mig, welds balls on.
 

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SnakePliscan

SnakePliscan

New Member
#12
#12
420 390 TAV fitment

TAV to block clearance, If i tryed to mount the tav in the center mounting holes (more strait up) the rear bearing would be sitting right on top of the oil filler, and thats with the cap removed.
Infact the filler would need to be cut off and welded up. On gx390's or other clones this may not be the case but with my BE Power-ease 420 it is.
Im happy with the mounting as is, grinding for clearance with dye grinder whent pretty fast.
You can see the black felt pen mark i made on the filler, the filler casting is pretty thick. i wacked i little off the crorner of the motor mount too.
Cant see it in the pic but i ground some material off the top of the bearing housing too.
 

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SnakePliscan

SnakePliscan

New Member
#13
#13
Whats Next?

It mite be a while before i get to fenders and paint, fenders sooner, paint later cause im gona need to strip sand and bondo, time. im liking flat baby blue, VHT has that in a header paint.
Ive got a Motovox MBX11 that needs a hot rod clone too, stay tuned!
 

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deejaaa

deejaaa

New Member
#14
#14
that is jam up and jelly tight. you were right to name it the monster. i've hit 50 with my set up. it's fun but not a lot of places to run wide open.
 
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