swapping a 250 4trax rear diff into a 300 4trax - Honda ATV Forum
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post #1 of 42 (permalink) Old 12-09-2010, 01:42 PM Thread Starter
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swapping a 250 4trax rear diff into a 300 4trax

I posted a bearing source ? thread a while back, but in the meantime have found/purchased a 250 4trax w/ intentions of swapping the whole rear axle into my 300 fourtrax.
I found this picture online from someone else who has done it. It looks like they just welded a plate to the axle tube to mount the swingarm.

Click the image to open in full size.

I paid $300 for the 250. It's beat-up, leaky tank, poor tires, but runs very well.
If I cannibalize it for the rear end, will any other of the parts work on my 92 300 4WD Fourtrax.

I'm leaning towards just replacing the bearings in the 300, but really like the [design] enclosed axle tubes on the 250.

What would you do? just fix the 300 [gears look fine, bad pinion needle bearing], or swap the 250 unit in it, and go!

thx,
John
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post #2 of 42 (permalink) Old 12-09-2010, 01:53 PM
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I like the design of the enclosed axle tube, too. I've owned a lot of Fourtrax 300s and I always had to replace the axle bearings often. The bearings in the enclosed axle tube design don't go bad near as often.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #3 of 42 (permalink) Old 12-09-2010, 08:50 PM
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I WANT ONE OF THOSE REAR ENDS!!!!



and yes you just weld the mounting plate onto the correct place and bolt it up. pretty simple swap.

88' 300 fourtrax 2wd
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post #4 of 42 (permalink) Old 12-10-2010, 02:29 PM
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whats better about a 250 rear end over a 300?
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post #5 of 42 (permalink) Old 12-10-2010, 03:01 PM
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Quote:
Originally Posted by durakid View Post
whats better about a 250 rear end over a 300?
Full length axle tubes of the 250 make the bearings last longer.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #6 of 42 (permalink) Old 12-10-2010, 07:48 PM
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ahh, i see. so i just need that 300 motor!!
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post #7 of 42 (permalink) Old 12-14-2010, 10:14 PM
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i also like how the break is more out of the way. not out in the middle going to get hung on some thing.

88' 300 fourtrax 2wd
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post #8 of 42 (permalink) Old 01-18-2011, 08:45 PM Thread Starter
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Well, after much procrastination, I finally decided which direction to go.
I decided to mount the solid axle tube type rear unit from the 250 into my 300 Fourtrax.
I was going to just make a flat steel plate to weld to the axle tube, like the one pictured in the 1st post. But decided to use part of the axle tube from the 300.

I cut the section of the 300 axle tube off that originally bolted to the swingarm, then sliced it in half.
Since it was a larger diameter than the 250 axle housing, I cut a wider section off of the same tube to act as a shim/spacer. I then removed about 1/2", before i sliced it into 2 halves, so i could put the pieces in the vice and make smaller diameter halves to fit.

Click the image to open in full size.
Click the image to open in full size.

Then I bolted the differential to the swingarm, and set the lower pieces in place. I just needed enough of a lip to weld the brackets to the sleeve/spacers, and the sleeve/spacers to the axle tube.

Click the image to open in full size.

Same w/ the top halves. It has no choice but to line up!

Click the image to open in full size.

It's been "dry-fitted" now, so clean up the area to be welded, re-fit, and bolt into place.

Click the image to open in full size.
Click the image to open in full size.

I then just tacked everything in place, removed the unit, welded, painted, and reinstalled.

The finished project, a 250 Fourtrax rear differential w/ solid axle tubes mounted on a 300 4WD Fourtrax

Click the image to open in full size.
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post #9 of 42 (permalink) Old 01-18-2011, 09:59 PM
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Looks like you did an excellent job.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #10 of 42 (permalink) Old 01-18-2011, 11:15 PM
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Nice work!!!!!

88' 300 fourtrax 2wd
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