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    Yamabuggy 400 swap to 900
    #1
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    Hi,

    For people who miss my presentation, you can see it here : Swap project from France

    This buggy is road registred, 25hp with original motor. When i bought it, motor didn't start. So it's time to swap it with a powerful engine .
    Swapping is illegal in France, so i need something discreet. As you can imagine, i can't use something like 600 CBR or R1, as they sound like race superbike, policeman expects to hear something like 700 raptor

    In my dream, i would like an Aprilia V60 (RSV 1000), but my chassis is tight, so i buy a crashed Yamaha 900 TDM for his compact engine.

    I never do mecanic work before, no brakepad removing, nothing. I will assemble physical parts only, wiring loom and electronics will be make by a profesionnal.


    The day I got it :




    Let's go for the disassembly. Buggy in one side, motorbike in other one. I add numbers on each wiring loom connectors. :

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    Re: Yamabuggy 400 swap to 900
    #2
    Duck in a Tux jimmyg's Avatar
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    Sep 2016
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    Wow! Parts everywhere. No fear!
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #3
    Senior Member
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    May 2019
    Location
    California
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    Quote Originally Posted by Julien51 View Post
    Swapping is illegal in France, so i need something discreet.
    Wow that's rough. That would be sweet to have a street legal ride. Good luck with the swap.

    Sent from my SM-G930U using Tapatalk
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    Re: Yamabuggy 400 swap to 900
    #4
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    Quote Originally Posted by jimmyg View Post
    Wow! Parts everywhere. No fear!
    Now it's worse !


    Quote Originally Posted by XJZ33 View Post
    Wow that's rough. That would be sweet to have a street legal ride. Good luck with the swap.
    The dream of each french petrolhead.


    After few hours of work, motorbike is completely disassembled.




    I bought a reverse box that take place on gearbox output. Sadly, rod is to long to fit with my muff, need to cut it.

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    Re: Yamabuggy 400 swap to 900
    #5
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    I thought i can raise the motor with a friend, but it's to heavy to do it many time. In the meantime to buy a workshop crane, i did a pattern to see where I will be blocked with the chassis.




    On the main bar behind the seats, they are original engine support that touch my cardboard, so i will cut them.
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    Re: Yamabuggy 400 swap to 900
    #6
    Duck in a Tux jimmyg's Avatar
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    Sep 2016
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    Good progress.

    Ps Is your new motor a boxer engine.
    All dressed up and waiting for the beer to arrive.
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    Re: Yamabuggy 400 swap to 900
    #7
    Millenium Member darwinpayne2000's Avatar
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    Jan 2010
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    American Fork, UT 90 minutes from the sand
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    Ps Is your new motor a boxer engine.
    Yeah, I like that!!

    But no, Jimmy, it's simply CAD (cardboard aided design).
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    Re: Yamabuggy 400 swap to 900
    #8
    Senior Member
    Join Date
    May 2015
    Location
    Northern California
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    188
    Default
    That’s awesome they have street legal buggies there. Do you guys have a trail system or open land to explore out there?
    Dune 500
    YXZ1000R
    Desert kart "Panther" build
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    Re: Yamabuggy 400 swap to 900
    #9
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    Quote Originally Posted by jimmyg View Post
    Good progress.

    Ps Is your new motor a boxer engine.



    Quote Originally Posted by darwinpayne2000 View Post
    Yeah, I like that!!

    But no, Jimmy, it's simply CAD (cardboard aided design).
    Now you are sure i'm 100% newbie


    Quote Originally Posted by Calibuggy View Post
    That’s awesome they have street legal buggies there. Do you guys have a trail system or open land to explore out there?
    Yes, I live in the middle of Champagne vineyard, lot of off road way between plots, forest and fields
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    Re: Yamabuggy 400 swap to 900
    #10
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    It's time to buy tools : welding machine, grinder, protections, portable workbench... and a workshop crane




    Step 1, 2, 3... now ready to go




    I replace cardboard motors with seriousness thing. First observation, it goes into with the shoehorn




    We aim to the left, the reverse gear box is also passed, but it was close.




    A look to the right, good

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