90cc Mini ATV to 200cc Engine Swap With TAV2 (4K)
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- Опубликовано: 8 июл 2019
- Replacing the engine in a Baja 90cc Kids ATV with a 6.5HP GX200 clone engine with a comet Tav2 30 Torque converter.
This quad has been just basically sitting around collecting dust for the last couple years and I also had a 6.5hp clone engine, from an old pressure washer, that I haven't touched in about 10 years. I had some free time so decided to see if I could pump some new life into this old 4 wheeler.
The stock engine on these is an 86cc 6.3HP engine with a centrifugal clutch, and it's pretty gutless since it is made for kids. It is also only electric start which is annoying when you want to use it and the battery is dead from sitting too long.
The new engine I put in is a 196cc 6.5HP engine (that is at 3600rpm though, once you bypass or remove the governor they probably run around 4500-5000rpm and probably put out around 7.5HP). On top of that I put on a torque converter clutch which gives way better performance then just a regular centrifugal clutch. Also no electronics so never have to worry about a dead battery again!
Overall the engine swap works well with way more performance then the stock ATV.
Part 1 of my Baja 90cc ATV to 200cc conversion video series.
Part 2: • Driving and Top Speed ...
Part 3: • Stage 1 Upgrade and To...
Part 4: • Going For A Rip In The...
Music (from youtube audio library):
Frame of Mine - Freedom Trail Studio
Floor Plan - Silent Partner
Shot on Sony A6500 w/Sony Zeiss 16-70mm F4 Lens 
Авто/Мото
Nice build
Thanks!
Thank you
If exhaust systems had an asshole...this one would fall out of it!
I was kinda hoping you were gonna put a 200cc 5 speed in it. But that works too nice job. I’m gonna do a build like this but with a smaller atv and a 200cc 5 speed manual
I didn't have one of those engines lying around lol. That would be pretty awesome.
Same
I'm gonna do a 5 speed 200cc
You're my hero
Thanks! lol
I’m doing this same setup I’m just wondering what gear ratio u have on urs?
There's not really a set gear ratio because the torque converter gives a continuously changing ratio. Other then that it's just the stock 10 tooth sprocket on the torque converter and the stock sprocket on the atv, I can't remember how many teeth it has. I never made any gear ratio changes.
my friend, where the VIN is located in this ATV? i jus bought one but it jus has a small plate and it say BAJA 90 2005 Guangzhou panyu huanan motors.
The Chinese bikes need a swap the 90cc atv with minarelli just big bore jet and exhaust prolly faster still
Do you think a brute force 750 engine will fit in a (alterra 450 2021)
I know nothing about either of those, but with enough redneck engineering, fabrication and welding, any engine can be made to fit on anything haha. 😛
Can u do a tutorial how to take the battery out I need to charge my Baja
I cannot, sorry. I have removed and thrown out the entire electrical system, including the battery, because it wasn't needed with the new engine. :P All you have to do is take the seat off though if I remember correctly, which is super simple.
Up next: Swapping a 450cc engine into a 125cc dirt bike
If only i had a 450cc engine lying around haha.
i want to replace a 50cc for something with more powa! i got it really cheap but engine is no good any idea what is the strongest i could replace it for?
I'm not sure how much space there is to work with in the 50cc atv. I have swapped a 50cc dirt bike engine with this same engine so you might be able to do the same with the atv. So somewhere around a 5hp to 6.5hp might be a good place to start. It's not an easy swap though. It requires lots of welding and fabrication.
@@MarcelsWorkshop responding 3 years after the video. Much respect.
@@WiltedRaven2 lol thanks!
I have 200 cc bashan can i change engine with suzuki 400 ltz , if yes i need to change sonething else or it is fine just the engine ,
Any engine can be swapped with enough welding and fabrication. I don't know anything about those 2 engines so can't tell you how much work it would be.
Can a 200cc Honda motor from a lawnmower work ?
Probably not. A lawnmower would be a vertical shaft, so you would have to rig up some crazy system to get that to turn the tires. You cant just turn those engines on their side to be horizontal shafts.
I was thinking about doing similar on my baja 90 atv
Do it if you have the time and gear. Huge improvement!
Yobi got a question I just bought a baja90cc four wheeler and it's runs but it won't move can't someone tell me what brand new part did I need to get it to move again
Marcel's workshop help me bro
@@damientaylor1334 probably a bad carb or not enough fuel getting into the engine, elevate the quad and try to move it, if it does then you're not getting enough fuel into the carb or engine.
Can I do this with a 125cc atv
Don't see why not. Depends how good you are at fabricating. Although depending on the engine specs of the 125, that may be a downgrade. The Baja dirt runner 125cc is around 9hp where as this 200cc is only around 8hp, because it runs at a much lower rpm. You would probably want to swap with a GX270 or bigger.
I have the same bike i believe. I want to swap the engine which is a good one to go with? T.I.A.
Any 6.5hp will do. I'd just go with the cheapest one I could find, but the Predator 212cc is probably the most popular. You may be a able to squeeze in a bigger 8hp or 9hp engine but no guarantees.
what about with a baja 150
Swapping a baja 150 engine with a 6.5hp gx200 style engine would be a downgrade since the baja 150 is already putting out 8.8hp. :P You would probably need to go with at least a gx340 size to get a significant performance improvement.
@@MarcelsWorkshop it's just a bad engine, plus I don't want to deal with the electric start, I'd rather put a pull start engine, what are some good engines I should put
@@sploofy4878 Well if you are happy with the current power but want to switch with something more reliable and keep the costs as low as possible, you could swap with a gx270 or any of the clone versions of that engine. Stock HP for that is around the same HP as the baja engine, but you could get a bit more out of it with some mods. That one also works with the TAV2 30 torque converter I used on this build, or any of the clones of it, just need to get the 1" shaft version of the torque converter. The max recommended hp of that torque converter is 8hp though, so it does max it out. I have used it before with a lightly modded gx270 clone though and it worked fine.
My only concern is I don't know what size chain the baja 150 uses. The tav2 30 only comes in 40/41/420 as far as I know, so if the chain is bigger then that, then you would need to either find a new sprocket for the atv or get a heavier duty more expensive torque converter, which also usually comes as 2 separate pieces instead of the whole thing on 1 simple mounting plate, so would need to find a way to rig that up.
@@MarcelsWorkshop the chain length can vary in distance/link from the jack shaft to the motor and and driveline
Way to destroy A quad lol the 90cc engine is better then a 200cc lawnmower engine
Nah the 90cc in this was garbage and the starter was failing. It has way more power and speed now and never have to worry about the starter not working or keeping the battery charged, since it doesn't have either.