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Donkey Puncher
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 Post subject: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Tue May 13, 2014 4:14 pm 
I've got a boatload of pics on this thing so I'll try to share the ones that may help future swappers.
This is not meant as a step by step walk through, more of an overview of some of the issues that cropped up for me.
Please mod at your own risk. I assume no responsibility for any one else's stupidity.



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Bought a complete but damaged Majesty 2006 (forks bent and some plastic rash)

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I'll try to give an overview of what you can expect and what may come up as a surprise.

The first thing you need to do is drain all the fluids (especially the transmission!) from which ever bike you want to de-engine first.
I pulled the Majesty motor before the Morphous:


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Washed up a very dirty engine:
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Here are the pages from the Majesty manual regarding motor removal:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 8:10 am 
All of the wiring is plug and play, you really can't screw it up.

The only wiring issue I had was that two of the connectors are the same. The leads from the fuel injector and the crank position sensor are identical and can be connected to the wrong part of the harness, so you may want to mark these when disassembling them.


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The Battery cables attach under the throttle body and are almost impossible to get to with the engine mount in the way.
Leave these as the last wires to disconnect after the motor is loose, and the first to reattach, before the mount is all the way in place:


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The fuel line needs to be disconnected from the injector, but the injector stays with the motor:


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Don't pull the injector out like this! :

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The ECU's need to be swapped. Both are a pain in the ass to get to, so I decided to remove the plastics on both bikes.
The Majesty's is located to the right of the instrument cluster, if you remove enough of the dash:


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The Morphous's is to the left of the battery box, beneath the instrument cluster:

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Also do yourself a favor and remove the complete rear tail section of the Morphous.
Its only 2 bolt on each side and the whole thing comes off:


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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 8:15 am 
The coolant lines are self explanatory, and the throttle cables need to be disconnected:

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In case you don't know what the main hanger / bolt / bracket set up looks like....
Here it is partially removed:


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Unlike this picture, you should probably remove the wheel/ tire and swingarm before the motor comes out:

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more to come....

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Junior Mint
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 12:08 pm 
:popcorn:

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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 1:43 pm 
:popcorn: :highfive: thanx for writing this up for us man!

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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 2:18 pm 
Thanks. Subscribed

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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 4:01 pm 
:popcorn:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 8:17 pm 
Once you start installing the 400cc Majesty motor into the Morphous, there are a few decisions to be made.

Which air box/ filter/ cleaner are you going to run?
The consensus seems to be, run the Majesty setup.
The Majesty uses a filter on both sides, where that Morph only has a central filter.

Stock Morphous set up:



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Previous dirty shot:

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The Majesty has a dual filter setup:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 8:36 pm 
Using the Majesty airbox simplifies the emissions Air Induction Valve difference between the two bikes.

The valve attaches to the muffler on the Morphous


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And the motor on the Majesty

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The only issue with the Majesty AIR valve is that it is too close to the Morphous frame so a small relocation bracket must be fabricated.
Its hard to see in pictures, but its too tight here:



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Rough bracket, but it works:

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Top down shot of bracket with slight bend:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 8:50 pm 
Another decision is the muffler.

The head pipe (and exhaust port opening on the head) is a larger diameter on the 400:

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Here you can see the crush gasket on both pipes side x side:
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Most people have gone with an after market muffler and adapted as needed.

I went a different route. Since I am using the Morphous swing arm, (where the muffler mounts) I decided to reuse the Morphous (250) muffler.
So far It hasn't caused any performance issues, that I can tell...

This meant mounting the smaller head pipe to the larger exhaust opening.
Since I have access to a lathe, I turned a "gasket" that mated the two different openings and filled the gap between the two:


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Rusty Trombonner
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 9:28 pm 
:popcorn:

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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sat May 17, 2014 10:33 pm 
I was all excited to see a Morphous swapped into a ruck

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sun May 18, 2014 5:45 am 
Another difference between the two motors is the oil fill tube.

The Morphous has this extension that angles it up to the front :


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While the Majesty does not. Actually the side case of the motor is a bit different,
as there is no way to bolt up the extension tube like I first thought.


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When installed with the Morphous muffler, the AIR pipe is right up against the fill port:

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The majesty gets its exhaust gas from a port on the head (see above pic of headpipe)
Since this part is no longer needed, off it comes:


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I cut it off and welded up a cap on the end of the stub, sprayed a dab of BBQ paint and its good to go.
If I would ever need to, I can weld it back together


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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sun May 18, 2014 6:01 am 
Don't forget to switch the coil/ plug wire that bolts to the side of the frame, Its more difficult to access in the Majesty.

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And another hint, Don't squeeze the rear brake handle while the caliper is not mounted.
It causes the piston to slide out far enough that you will have to manually push it into its bore.

This way does not work


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Follow these direction, but basically you are screwing the cylinder back in
making sure to stop when the pins on the pad will align the slots on the cylinder, while opening the bleed screw.


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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sun May 18, 2014 6:44 am 
The last big obstacle is to change the axle that the wheel mounts on.

The majesty has a wider wheel and swing arm so that it is:


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The Morphous is a much narrower set up:

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Here they are both removed already:

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To get this shaft out isn't to difficult...

First you need to access the CVT system like your were doing a belt change.
The only issue I had here were very stubborn screws that held the plastic cover over the aluminum cover...


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Even with the proper JIS screwdrivers, I ended up having to use a hand impact to break them loose, but still had to drill off two of the heads... Add these to the new parts list:

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Once the plastic cover is off, then you remove the aluminum cover held on by 8mm bolts all around the perimeter and one 12mm bolt in the center.
You may need to pry around the edges with a flat blade screwdriver while tapping the cover with a plastic mallet to pop it loose:


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Open it up and you get to the good stuff:

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