XJ550 Yamaha Blaster ATV

I started this project a month or two ago. I bought an 81 XJ550 parts bike without a title. The bike itself was pretty rusty, smelled of mice and i'm pretty sure there were plants going on top of the motor. I was unable to save the carbs since it looked like someone tried to hammer the slides into them. After buying some carbs and intake boots off ebay I got the motor to run well enough to start working on the ATV frame. So far I have cut out the bottom of the blaster frame and welded in 1"x1" .120 square tube. This allowed me to sink the oil pan into the frame like on the bike. It also allowed me to install/remove the motor from the ATV just like on the bike. I should be able to adjust the valves in-frame. Below is a picture of a test fit. Let me know if anyone wants to see more pictures.

 

Sure !! More pics !!
Don't be afraid of jetting it a bit rich, as the engine won't get it's normal amount of cooling air, and you might be running Pods and modified exhaust. A pair of tiny electric fans might help too.

Welcome to the site !!

 

by tiny, he means tiny, an oil cooler will help as well, because you will be running higher rpms at lower speeds, but it should excel in the dunes. maybe, put a wind deflector liek you see on dirtbike on it to funnel in more air.

but yes, more pics would be lovely

 

I like the wind deflector idea. I'm trying to make the ATV look as normal as I can. I have seen a few other motor swaps where its more of a motorcycle turned into an ATV.. I really want this to look like a normal ATV but with a big motor. So far the hardest part for me is the motor mounts. It has to be setup in a way where I can still remove the motor from the frame, but they also have to give me enough room to fine tune the sprockets. I must have picked that motor up 15 times... My arms feel like they are about to fall off.

 

I was able to get the rear motor mounts tacked in tonight. It was more work than I thought it would be. This allowed me to bolt the motor in and start to plan out the front motor mounts. I will need to make the front mounts unbolt from the frame so the motor can be installed and removed without cutting. Also, the oil filter clears the frame nicely. I'll also be able to replace the clutch in-frame.

 

Lookin' good.

 

Haven't updated this in a bit. Here is the current status:

All motor mounts are in. I took the ATV for a test drive last weekend. It will need to broken down again to finish up any welding and add gussets.

Running video:
YouTube Video: XJ550 Blaster Running

Pics:

 

Awsome, how did the test ride go? Real fast I asume. I have been looking for a Warrior frame to do a similar build with a 1100 engine.

 

It was very fast but also very useable. It can do a good wheelie but only when commanded to do so. That being said, its still not something an amature atv rider would want to ride. It takes self control. Yes you can't use gears 3-6 on the trails but the power is there if you feel like doing a powerslide all the way down the driveway. I have not done the math yet, but the gearing seems to be right on.

 

Oh and I also wanted to remind everyone that no road safe XJ550s were hurt making this ATV. The bike i got this motor from was so rusty that I had to cut the chain off to remove it.

 

We need a video of some wheelies and power slides.

 

+1

 

http://www.youtube.com/watch?v=SWa6KonbqAM

 

Nice ............ Where did you run the exhaust? I cant think of a way to get it aroung the motor with out getting in the way of your legs.

Ready to sell it yet?

 

Still running stright headers. Very easy to burn your foot when shifting.

Build Photos:
http://www.youtube.com/watch?v=owfLojrypSA

 

so how much?

 

Does it look good enough to sell?

 

im jealous as hell.

 

i think im going to be doing the same with a banshee frame and a kz550 motor

 

Got the pipes on.

 

Video:

http://www.youtube.com/watch?v=FaI_AgvEnX8

 

It's done..

Tank cam video:
http://www.youtube.com/watch?v=42SqmJ0rN08



Rideby video:
http://www.youtube.com/watch?v=Dr6L1AYvAwQ

 

looks like a blast. It doesn't look like fast until you see the tank video.

 

nice man, must be fun

 

Its really not that bad. The transmission gearing is all wrong for an ATV though.. gear ratios are too far apart. I was never able to get higher than mid-5th in this field. I need a much larger sprocket in the rear.

 

Here is a two year update. Please forgive all the pictures.. A lot has changed.

I have used this ATV almost every Sunday for the last two years without any major problems.



The front sprocket was switched from 16t to a 15t
Rear sprocket was switched from 40t to a 50t

View of my snowblower tank and the new sprocket:




Here is a pic that showes the change in sprocket size:




What the new rear sprocket did to my chrome:





Made a brand new custom wiring harness. Only the cables from the motor were kept. Everything uses metric double crimp OEM style plugs. I Used a fuse box out of a newer bike with micro fuses.













Also switched to Dynatek coils:



Sticker adds another 5HP:



Installed a full skidplate:




Made a set of quiet pipes. I have the option to run the pipes in the picture or the D&D drag pipes.




Got some bigger rear tires for throwing some mud:







Installed a Dyna DRL-400 launch controller.




You hold the clutch and pin the throttle. It will hold the revs down until you pop the clutch. Video below shows it in action.

http://www.youtube.com/watch?v=GzhCSKhOvdU

 

excellent, now thats what im talking about! great idea and execution. definately looks good enough to buy. thanx for sharing.

 

Holy crap, thats insainly awesome.

 

f***yeah. Although really, is it that much more engine than you get from a big quad?

Any temptation to put slicks on it and hit the highway?

 

Thanks for all the comments.

Yes, modern quads can be pushing 60HP when tuned up well. Some of the BRPs are pushing 100hp. But they don't sound like a F1 car in the woods, no monster tach, and you don't have random people walk up to you and ask "what do you have in that thing?" I have a buddy with a CBR600 swap into another quad. We just rev the motors if I need to locate eachother.

Here is a vid that has some driving sounds.

http://www.youtube.com/watch?v=zX4wF_AHUjw


Forgot if I had a pic of the tach posted.

 

Some more mods. XJ650 Turbo oil cooler and lines. I'm not 100% sure about that fan, but we will soon find out.