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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sun May 18, 2014 7:01 am 
$5 for a screw, ordered a few extra cause you have to do this twice...

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Anyway, I used an air impact on these nuts, don't have a holding tool and never used one.

24mm on the variator side:


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19 mm on the clutch side:

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It all slides right off:

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And this is what you need to remove to change the drive axle:

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Do yourself a favor and make sure to drain the trans or you'll have 8oz of 30w on the floor in seconds.

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These two washers need to slide off to let the big gear slide off:

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Then the big gear slides off and the axle can be pulled out:

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Clean up any old gasket and use a new one... you will need a new gasket!

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Make sure you get these two guide or locating dowels back into the correct holes:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 400 swap
PostPosted: Sun May 18, 2014 8:50 am 
Tbone Pez wrote:
I was all excited to see a Morphous swapped into a ruck


Sorry to disappoint...
:lol:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun May 18, 2014 9:21 am 
Here is a shot of both swing arms, the Morphous is on top

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Of course you'd have to have that on to install the exhaust and wheel.

Then its on to the airbox:

Since I used the majesty air filter setup, some of its mounting points don't line up with the Morphous swingarm.
But the front and rear mounts do and they seem to hold it steady enough:


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You can see where the bracket that holds the brake cooling duct? is right in the way of the outer half of the air box:


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I think that plastic tube is a joke, so its all gone:

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The left side mounts to the CVT case, so no issues there:

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For reference you can see the how the Morph setup is stock.
The long plastic tube is gone and I also didn't reuse the fender. It mounts to the air box. Since the Majesty doesn't use that type of fender, it wont bolt in.
I could always fab up a mount for it if problems arise:


BEFORE
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AFTER
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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun May 18, 2014 9:42 am 
On to a few things that you don't need to do for the swap, but that I wanted to change, mainly the look of the scoot.

I decided to just experiment with this plastidip stuff.
I can always peel it back off when it starts to get nasty and want to go with something more permanent.

Wheels first in black:


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Its always a good idea to make sure the brake rotors go back on the same orientation as before.

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Since the body had its fair share of scrapes, I figured I might as well do the whole thing since it was apart.

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Bought a gallon of anthracite and sprayed it with a HVLP gun I already had. Sprayed fairly easily,
but you want it on the heavy side so that it will peel off in one sheet when you want to get rid of it.:


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And now its done!

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Rusty Trombonner
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun May 18, 2014 10:26 am 
I love it :banger: :highfive:

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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun May 18, 2014 10:34 am 
I dont think I would ever tackle a swap like this but I do appreciate the effort you have put into this thread, thanks for sharing..

The color looks great! :highfive:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Wed May 21, 2014 10:08 pm 
Awesomeness!!!!'m

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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sat Jul 26, 2014 12:41 am 
So what kinda rpm's r u hitting at highway speeds now? :popcorn:

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viewtopic.php?f=93&t=88015
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viewtopic.php?f=93&t=88013


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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sat Jul 26, 2014 9:52 am 
I'll have to double check (these stock bar graph gauges suck) but I think I was about 5500 to 6000 at 65 mph +or-

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Chucks Big Ruckus

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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun Jul 27, 2014 12:44 am 
Nice! I remember the problems u were having trouble using the Morph swing arm and axle.....I'm sorry if my Alzheimer's is kicking in, but did u use the Morph tranny or the Majesty one?

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'05 Zuma Athena 70cc:
viewtopic.php?f=93&t=88015
'08 Morphous:
viewtopic.php?f=93&t=88013


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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun Jul 27, 2014 5:17 pm 
All the drive train components are from the Majesty except the last final drive gear that the wheel slides over.
The bolt on swing arm piece is from the Morphous.

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Rusty Trombonner
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Thu Aug 20, 2015 4:10 am 
So you have a 400 that looks just like 250? That's a serious sleeper.

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Shot Caller
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Thu Aug 20, 2015 10:50 am 
:banger:

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Thu Aug 20, 2015 1:46 pm 
Yea, it's been a fun ride.
The Majesty is no TMax, but it scoots along very well. Good distance cruiser.

It may be time for some cosmetic updates over the winter..
The plasti-dip is really only good for a season or two

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Donkey Puncher
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 Post subject: Re: Chuck's Morhpous 250cc to 400cc swap
PostPosted: Sun Nov 29, 2015 7:21 am 
chucktuna wrote:
Yea, it's been a fun ride.
The Majesty is no TMax, but it scoots along very well. Good distance cruiser.

It may be time for some cosmetic updates over the winter..
The plasti-dip is really only good for a season or two


Pearly white re-body starts soon:

Image

Image


Image

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