1996 TRX400fw top end swap

[sasksodbuster]

well i have no luck in trying to find a cylinder (Jug) for an old 1996 foreman trx400fw (Part number 12100-hm7-000)
.. All i get is this product is discontinued!!! I here rumours that one might be able to do a top end swap off a 450 cylinder (Jug) from 1998 trx (there is much better supply of these).... has anyone done this?? if so what does one have to look out for??

 

[HondA11y]

I don't have direct experience in this but I think you can use a 450 cylinder but it's not a direct bolt-on.
The 450 has a larger bore, so you need the 450 cylinder, piston, rings, and a new top end gasket kit.
You also have to look out for the fitment of the cylinder base to your crankcase opening.
It might require a little bit of grinding on the crankcase for it to sit flush.
Hopefully someone here with experience would give you feedback!

 

[stephmeister]

For a '96 TRX400FW, it's true the original cylinder is long discontinued, and some people do swap in a '98 TRX450 top end since those are easier to find. If you go that route, you need to check bore size , head compatibility and make sure the piston, rings and cooling passages line up correctly, otherwise you could run into sealing or clearance issues. Have you looked into whether the 450's intake and exhaust ports match up with your 400's head?