TecateDan and Fabio's joint 500 effort

[fabiodriven]

Affectionately known as "The Green Monsta" (After the elevated highway that no longer exists in Boston, not the wall at Fenway Park) this bike will be based on a first-gen Tecate. We've got a 1986 KX 500 power plant we're using.

Making the square tubing bender-

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130105_131231_zps59b4dd9e.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130105_131902_zps45b6073c.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130105_132508_zps94eb8331.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_7920_zpsfb7e2ad4.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_2317_zpsfa7141a4.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130105_131943_zps76873b95.jpg

It's not much yet, but it's a start. I'll have Dan post some better pics of the jigs.

[El Camexican]

Are you replacing the stock down tubes with the squares? Same engine you were needing a left case for? In-frame pipe? MUST HAVE INFO!!!:Bounce

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/Tecate%20500/IMG_0921_zps99908f62.jpg

http://i1207.photobucket.com/albums/bb468/danielvpope/Tecate%20500/IMG_0926_zps7f343d56.jpg

http://i1207.photobucket.com/albums/bb468/danielvpope/Tecate%20500/IMG_0933_zps7342fb79.jpg

http://i1207.photobucket.com/albums/bb468/danielvpope/Tecate%20500/IMG_0934_zps13775de7.jpg

http://i1207.photobucket.com/albums/bb468/danielvpope/Tecate%20500/IMG_0935_zps55dad308.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_0936_zps295ace9d.jpg

I tried to make one that would make a 180 with a 3.875" radius. The small jig but when I tried to bend with it it just ruined the pipe. May have been the Jigs fault may have been the structural limit of the tube?? not sure. When Fab got here we built the larger bender with a 7" radius and made some 65 degree bends to match the old down tube angle

[thestud25]

Looking good men, can't wait to shred on it at Trikefest!

[fabiodriven]

Are you replacing the stock down tubes with the squares? Same engine you were needing a left case for? In-frame pipe? MUST HAVE INFO!!!:Bounce

Yes, yes, and yes. :D

[TecateDan]

This way I can just out run you casue last time I tried fighting you it took my rib 4 weeks to heal


Looking good men, can't wait to shred on it at Trikefest!

[El Camexican]

I tried to make one that would make a 180 with a 3.875" radius. The small jig but when I tried to bend with it it just ruined the pipe. May have been the Jigs fault may have been the structural limit of the tube?? not sure. When Fab got here we built the larger bender with a 7" radius and made some 65 degree bends to match the old down tube angle

Stuffing the tube with sand and capping the ends might help a little, but no matter how good a setup you have squares always deform on the inner radius. The thinner the wall the worse it is.

[fabiodriven]

Just a couple of pics of what Dan did this weekend.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_4897_zpsefbedc3c.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1206_zps272ecb70.jpg

[ezmoney1979]

Very ambitious build guys! I can't wait to see more progress. Does the kicker clear the frame like an 86-7?? You guys gonna cut up a KX500 pipe or hand built? I could ask a hundred questions but I like the element of surprise lol. Hey, that compression release looks familiar! You were right, it does work good! :beer

[Kintore]

AWESOME! cant wait to see it done! very cool guys

[fabiodriven]

The kicker should be fine EZ. I've got a modded Tecate kick start lever that goes onto the lower part of the KX kicker. It'll be the length of of the regular Tecate kicker. The compression release is key to starting it with the shorter lever. Without the compression release, the Tecate lever would never be enough to start this engine.

We're not sure what we're doing with the pipe yet, but we want something nice. That much we know.

[Dirtcrasher]

If you or Johnny need some diamond plate I have some plain steel, plain aluminum and chromed aluminum. .125 thick

Speedy Metals always treats me well with drill rod, plain steel DOM tubing, etc etc etc.

[JasonB]

Updates!? I like where this is headed

[fabiodriven]

Dan and I are going to convene tomorrow in the a.m. to throw some wrenches around. Thanks for asking. :)

[atc300r]

Cant wait to see what you guys come up with.Love 500 builds ,a friend of mine had a kx 500 that thing was an animal .Good luck with the build.

[El Camexican]

When I look at the Trikesylvania thread titles this one just appears as "TecateDan and Flabios joint" The "500 effort" part does not appear. I keep expecting some sort of Cheech and Chong themed post when I open it.;)

Anyway, it would be so cool to see you guys cut a KX 500 pile into a zillion little rings (make sure you number them!) and TIG weld them back together into the shape you need for an in-frame pipe and then chrome it. Don't forget to purge the inside of the pipe with Argon if you do end up doing something like that.

[TecateDan]

OH yea... Wait for the pics. Lunch break now but major progress

[CRAZY70MAN]

Beer break???? lol........give us some pics!!! Love that homemade jig..........

[fabiodriven]

I'll have the pics up tonight ladies.

[TecateDan]

I was too busy working to take pics but here is how she sits lAST PIC . John's got some great pics of some trick stuff and more to come!!!!!

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1078_zps4f283ed5.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1079_zpse51ce6c0.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1081_zps921bc8c2.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1087_zpsc68ebe5d.jpg

http://i1207.photobucket.com/albums/bb468/danielvpope/91B88D43-99EF-4D5D-AD71-3604AE13C71A-5637-0000076266F761BE_zps5ff830bb.jpg

[JasonB]

Heavens no, hell yes! I approve of this trike porn

[fabiodriven]

I'm going to start bringing my camera instead of using my phone for these pics.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_114111_zps1b5dd921.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_111913_zps4559ca61.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_122855_zps5ab3be9c.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_123754_zps2de4249d.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_123802_zpsb80782f3.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142220_zps01189572.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142238_zps626c9304.jpg

If you look close enough, you can see a couple of welds that I finished up that Kawi had missed. There will be some extra gusseting on this frame, but it doesn't appear to need a whole lot. There were a couple of hidden seams as well that Kawi deemed unnecessary to weld. You can't see them all in the pics.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_113703_zps004ff7fc.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_113721_zpsdd95c65f.jpg

The welds on these bungs could have been cleaner, but I forgot to clean that paint off right there. I blame Dan for not checking my work. :shiftyeyes:

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142313_zps028efa82.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_143019_zpsa3935f1c.jpg

If you've got a keen eye, you will see why I had to jump on Ebay and order another right side engine case while we were working. Oh the wonders of technology...

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_143028_zpsfa148ae8.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_143043_zps11de3ff8.jpg

This is the pipe that came with my 86 Tecate 500. It's a cut and cobbled KX 500 pipe that actually almost kind of fits this bike already. I think we're going to chop it up and make it work for the time being. It's already pretty close.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_143103_zps3bc60f55.jpg

Next time I go back over there, the first thing I'd like to pick back up on is finishing the frame by the bottom of the headset where the new metal meets the existing frame. Next time I'll be getting there earlier in the morning.

[90guy]

Man oh man loving the progress!

[Eric250R]

very nice guys, nothing like a bigbore 2 stroke.

[TecateDan]

:rolleyes::rolleyes::rolleyes::rolleyes::rolleyes: :rolleyes::rolleyes::rolleyes:I specifically told you to grind that paint off but you were all like once I get a bead going the paint will burn right off... HACK :rolleyes::rolleyes::rolleyes::rolleyes:


I'm going to start bringing my camera instead of using my phone for these pics.


The welds on these bungs could have been cleaner, but I forgot to clean that paint off right there. I blame Dan for not checking my work. :shiftyeyes:

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142313_zps028efa82.jpg


Next time I go back over there, the first thing I'd like to pick back up on is finishing the frame by the bottom of the headset where the new metal meets the existing frame. Next time I'll be getting there earlier in the morning.

[dcreel]

Looks great guys.. I wanted to mention about the footpeg mounts. On my '84 frame where the footpeg mounts came to a point at the top "of the pyramid" so to speak had just been spot welded at the tip. On a long run of whoops the spot weld broke and I ended up with a footpeg pointing at the ground. I think the area on the '85 frames are fully welded at the seam.

Just a thought.. If it would have let go off a jump it could have been a bad deal..

[hondawasaki]

Looking really good! Are you guys running the stock shock linkage? The airfilter area is tight back there. I know when my buddy had his '84 500, the airfilter was always the hurdle. Looking forward to some progress!

[fabiodriven]

Looks great guys.. I wanted to mention about the footpeg mounts. On my '84 frame where the footpeg mounts came to a point at the top "of the pyramid" so to speak had just been spot welded at the tip. On a long run of whoops the spot weld broke and I ended up with a footpeg pointing at the ground. I think the area on the '85 frames are fully welded at the seam.

Just a thought.. If it would have let go off a jump it could have been a bad deal..

Thanks for that info Doug! We will absolutely look into that!


Looking really good! Are you guys running the stock shock linkage? The airfilter area is tight back there. I know when my buddy had his '84 500, the airfilter was always the hurdle. Looking forward to some progress!

Thanks for the heads up! We haven't gotten that far yet, so we will cross that bridge when we get to it!

[Swinger]

Looks great guys. I will be watching and taking notes. I will be doing one of these as my next build as I already have the modified frame and a few other parts. Keep up the good work

[TecateDan]

Do you have a pic of the Mofified frame ? did you build from scratch or weld in the 86-87 carriage

[TecateDan]

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_143103_zps3bc60f55.jpg

THE PROB WITH THIS PIPE IS THE BELLY IS ON TOP and it hits the front wheel or IT EXITS THE WRONG SIDE. WELL NOT ANY MORE

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1140_zpsa5c7b960.jpg

qUICK SHOT OF THE FINISHED UPPER MOTOR MOUNTS. lOOK LIKE STOCK eHHH

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_0825_zps6961ea3d.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1148_zps64d7f8be.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1147_zpsb6142df1.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_0850_zpsb0c5fc89.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_0854_zps945bccd9.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1151_zps80dcd9d5.jpg

jUST NEED TO MAKE ON LAST CONE SECTION TO TRANSISTION INTO THE STINGER AND MOUNT THE MUFFLER! jUST MIGHT BE READY FOR TRIKE FEST AFTER ALL!!!! Oh and I am going to grind the snot out of the welds to make them dissapear.

IN TOTAL i ADDED ABOUT 2" TO THE BELLY OF THE PIPE? ANYONE HAVE ANY IDEA WHAT THAT WILL DO TO THE POWER CURVE ??

[fabiodriven]

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1148_zps64d7f8be.jpg


As you guys can tell from this pic, I was a lot smaller and more attractive today.

[TecateDan]

Due to bad weather John was not able ot make it. My wife is now claiming she want's it ot be pink since she's spent another day in teh shop with me.
Finishes up the fron motor mounts
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1169_zps02817d76.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1172_zps4ed70875.jpg

Time to Gusset the top and reinforce the down tubes

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1173_zpsfe3c9bdd.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1174_zps0a38e734.jpg


Right side done wiht the exception of some more grinding that needs to be done for some smoothing:

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1175_zps9f72b301.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1176_zps1a90131d.jpg

[Dirtcrasher]

Someone has the mig wire speed a bit high. A bit ugly but hopefully strong!

Nice work guys!!

[TecateDan]

My wife welded it and despite the look there was plenty of penetration. It's also 1" pipe welded then 1-1/4 welded over it to act as gusseting and to strengthen where the holes were drilled for the front motor mounts

[El Camexican]

Be a nice guy and get your wife a pair of safety glasses.

[TecateDan]

she has them but was not wearing them. After her first trip to the hospital to have metal dug out of your eyeball and she'll learn

[El Camexican]

Man up, tell her she has pretty eyes and that chicks don't look good in eye patches.

PS. It's cool that she is into the metal working thing.:beer

[TecateDan]

As long as her welds don't come undone when that 500 is pulling a wheelie across the finish line at the drags I agree....


Man up, tell her she has pretty eyes and that chicks don't look good in eye patches.

PS. It's cool that she is into the metal working thing.:beer

[El Camexican]

Just don't let her work on the steering-head when she's upset with you.

[TecateDan]

I just wish I could get her to Jockey the 500. 100lb driver and a 12" swinger would be sweet espically when you hit the

http://www.ebay.com/itm/Yamaha-50-70-90-100-110-125-cc-ATC-ATV-NOS-Nitrous-Nitro-Gas-Boost-Bottle-Kit-/330866482234?pt=Motorcycles_Parts_Accessories&hash=item4d092ddc3a&vxp=mtr

Sorry watched fast and furious last night

[Jeepermc]

Cool build.....but you could at least show it a little respect by not building it on the PooH crate.... =)

[fabiodriven]

Just so everyone knows, we have gotten more than one person questioning this frame. I think what most people fail to realize is that the left and right lower frame tubes are each one piece and I welded them to the existing frame myself. These tubes alone may have held up just fine. The cradle is plenty stout and I know how to weld. I don't have any tig or aluminum experience, but I have many, many hours behind the arc welder and especially the mig welding steel.

This is the frame prior to gusseting-

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142238_zps626c9304.jpg

This is the picture that I think is confusing people-

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1173_zps9ae6fbc7.jpg

Yes, there are ugly welds up top. Dan is not piecing together a bend or anything like that though. The picture is an odd angle and Dan didn't explain it well. The metal you see him working on is merely a gusset going over the existing one piece frame rail. Yes, the ugly welds are going to have to be ground and smoothed. If I had been able to make it to Dan's house this weekend (we had a snow storm and my 2wd truck couldn't move) the welds would have been pretty and they wouldn't have to be ground. I wasn't there, so we grind them. The strength is not compromised, just the look different. Let's not forget, this is a first-gen Tecate and they look like farm implements anyways. If any of you have ever looked at the factory frame welds on a Tecate, it only makes sense to assume the welders at Kawasaki more than likely got paid per-frame.

That being said, the progress we all see here is as new to me as it is to you all. After really looking at the pictures, the place that worries me is at the bottom of the gusset. I probably would have gusseted the top where the new metal meets the existing frame and that's it. I wouldn't have gusseted down the rails at all. I don't like how the gusset ends at the bend like that.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1174_zps8faf8590.jpg

[roostin atc]

Just meeting you guys recently I have no doubts on this build. I'm no welder but it looks good to me. Keep up the good work.

[TecateDan]

Here are some pics with the welds cleaned up a bit. Still need some real fine tuning but like john said there is already a full one piece cradle built and welded in this is all EXTRA gusseting and stengthening. The first frame was 1" square tube .086 wall I think and the second is 1.25" square tubing over that for gusseting . Also take it easy those are my wife's welds not mine!!!! There was plenty of penetration and I like the ground smooth look.

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1185_zps56f0b238.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1184_zpse272f7cf.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1183_zps66543f61.jpg

[El Camexican]

You guys have nothing to explain to anyone, it will look great when it done. Welding an old frame is a bi*ch. The factory welds are craap, there is paint and oil trapped under all the formed connections and the original welds are usually full of porosity. European makes are the only frames I’ve ever seen great welds on consistently, Jap rhymes with...

Keep in mind that when you are welding up all the unfinished factory welds that some of them are left that way for water drainage. If you chose to weld them solid make sure there aren’t any “feeds” that will fill a tube or joint with water that can’t escape.

One other thing, it’s a lot easier to work on a frame if its sandblasted first, but if you work on it like you guys are I’ve found that washing out the factory joints with a little thinner and then after they are wiped dry, I heat them a little with a torch to get the oil and paint all burnt off makes it easier to weld. It also reduces the chance of oil seeping out when you paint or powder coat it later.

Keep the photos coming!

[TecateDan]

Once it's done we'll have to weld one of these in reverse to showe off johns welds!!!


http://i371.photobucket.com/albums/oo153/hondawasaki/P1030541.jpg

[aldochina]

have you been living in the garage Dan!! Looks like the pipe you modded, but i cant believe you got all this done in a few days!! Looks killer either way! Let me know whats up with the sx tires!! i spotted them in the back!! whos got the connection!!

[TecateDan]

THAT IS NOT OUR 500!!!!!! just busting Johns chops that he should weld one of these up since he loves the looks of welds and I like to grind my welds


have you been living in the garage Dan!! Looks like the pipe you modded, but i cant believe you got all this done in a few days!! Looks killer either way! Let me know whats up with the sx tires!! i spotted them in the back!! whos got the connection!!

[roostin atc]

Looking good John, you and your helper make it look like a breeze. LOL

[TecateDan]

Looking good
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1278_zpsdc791154.jpg
Looking good
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1277_zps792cac26.jpg
Looks like drinking and grinding is not a good idea. NDB Just gotta weld some stuff back on and grind it again. REmember this is gusseting and for visaul purposes since there is already a one piece frame underneath

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1276_zpsc2c27410.jpg

[El Camexican]

Looks like drinking and grinding is not a good idea.

Maybe so, but drink a little more and you'll find it in your heart not to care:lol:


PS. I hate to be the one to break it to you, but your partner has left you for a Yamaha.

[TecateDan]

He's been the finance department lately.. He"s been sourcing parts and drop shipping them to me for later in the build. Besides if you've ever seen Trish in person ud love yamahas too

[fabiodriven]

If you said you wore the welding mask while grinding, I could accept this result. Other than that, you must be drinking a lot of beer guy.

[TecateDan]

I may be as drunk as Gary but the build continues. When u coming buy to hang out for a day. I could use a hand on the pipe and skid plate of u got time.

[fabiodriven]

I can do Saturday or Sunday!

[TecateDan]

The wife gets back from Canada tonight so let me check with her if we have any plans either day and we can go from there. I'll text you tonight

[JasonB]

coming along nice! more trike porn! NOW!

[TecateDan]

Love the pipe in you signature. Where did you get that done


coming along nice! more trike porn! NOW!

[TecateDan]

Any one know who's pipe this is or better yet have the dimensions for the build

Once it's done we'll have to weld one of these in reverse to showe off johns welds!!!


http://i371.photobucket.com/albums/oo153/hondawasaki/P1030541.jpg

[hondawasaki]

Any one know who's pipe this is or better yet have the dimensions for the build

Ummm I do, that's my pipe.

[nstyle73]

Did you ever get that one going, the pipe looked awesome, just wondered how it worked out.

[hondawasaki]

Did you ever get that one going, the pipe looked awesome, just wondered how it worked out.

Yes I did, runs very well. Thanks.

[El Camexican]

Ummm I do, that's my pipe.

That thing should be hanging next to the Mona Lisa. Did you fab it?

[TecateDan]

I asked the same question! He had it built by a shop in utah. I want the dimensions so I can build one!!!
That thing should be hanging next to the Mona Lisa. Did you fab it?

[El Camexican]

Maybe you can send the photo to someone who has one of those copy machines Flabio posted about the other day? (I want to put a :lol: here, but it might just work!)

[tecat-z]

Hondawasaki, your machine looks amazing. Fabio, you guys have a great start on that project.

[Dirtcrasher]

Those welds on the pipe look fantastic - TIG.

I don't mean this in a bad way, but prep and the right settings for a MIG on a frame should look nice and clean.

If your welds need grinding, there is an issue. You guys are smart, adjust that mig or tig and they will put factory welds to shame.

That pipe is a work of art!!

[fabiodriven]

When I weld there is no need for grinding.

[TecateDan]

where are all the pic's you took yesterday fabio?I only have ones of the completed project
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1286_zpsc25439d3.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1287_zpsefbabf6f.jpg

[fabiodriven]

I'll have them up later.

[TecateDan]

Where the hell are those Pics..

I'll have them up later.

[tri-Z ripper]

Just so everyone knows, we have gotten more than one person questioning this frame. I think what most people fail to realize is that the left and right lower frame tubes are each one piece and I welded them to the existing frame myself. These tubes alone may have held up just fine. The cradle is plenty stout and I know how to weld. I don't have any tig or aluminum experience, but I have many, many hours behind the arc welder and especially the mig welding steel.

This is the frame prior to gusseting-

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130203_142238_zps626c9304.jpg

This is the picture that I think is confusing people-

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1173_zps9ae6fbc7.jpg

Yes, there are ugly welds up top. Dan is not piecing together a bend or anything like that though. The picture is an odd angle and Dan didn't explain it well. The metal you see him working on is merely a gusset going over the existing one piece frame rail. Yes, the ugly welds are going to have to be ground and smoothed. If I had been able to make it to Dan's house this weekend (we had a snow storm and my 2wd truck couldn't move) the welds would have been pretty and they wouldn't have to be ground. I wasn't there, so we grind them. The strength is not compromised, just the look different. Let's not forget, this is a first-gen Tecate and they look like farm implements anyways. If any of you have ever looked at the factory frame welds on a Tecate, it only makes sense to assume the welders at Kawasaki more than likely got paid per-frame.

That being said, the progress we all see here is as new to me as it is to you all. After really looking at the pictures, the place that worries me is at the bottom of the gusset. I probably would have gusseted the top where the new metal meets the existing frame and that's it. I wouldn't have gusseted down the rails at all. I don't like how the gusset ends at the bend like that.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1174_zps8faf8590.jpg

My only 2c was going to be the top of the new down tube meets the frame a tube up the neck would have been a nice little extra support. Please take it as constructive criticism This is an awesome build i would not be able to accomplish myself. Excellent Job guys!

[fabiodriven]

Well Mexicanuckidian, I have not left Dan high and dry. I can do two projects at one time. :D

I spent the day at Dan's Saturday while he crapped his pants all day pretending to work. We made more good progress, mostly on the pipe. The pipe was the one thing about this project that had me concerned. It is a big obstacle. It is coming along now, but it ain't pretty. The metal is too thin to weld all pretty like. You just have to do what you can with it, and then send it off to Dan's Weld Grinding Co. Inc. (Blackstone, MA) to smooth the eye sores out. After everything was said and done, the exhaust hits our air box. I had a feeling we should have had the air box in while making the pipe, but I didn't put it in. Rookie mistake, but alas, just another obstacle to overcome.

Here are our hand made motor mounts.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_111437_zps1baf51fa.jpg

Here is where you have to notch the frame for spark plug clearance. I handled this part.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_111417_zpsd06d2a52.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_115708_zpsfc6b10e6.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_115715_zpsed768216.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_120434_zps61588334.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_120448_zps25fe612d.jpg

Here is where we started cobbling the exhaust together. At some point, we will be having a proper pipe made for this rig. This one just has to work for the time being. We cut the top of the frog's belly off and added a different one from and old stock Tecate pipe (Which is baffled on the inside, who knew? Not the silencer, the pipe!) to get us in the neighborhood of where we needed to be.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_144743_zps00789417.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_144749_zps323e41eb.jpg

Then I cut and notched the pipe to get it where I needed it to go. After that, I welded the slices shut.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_162459_zps93c02160.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_162448_zps012ed060.jpg

You can also see my plug notch in this picture.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_162505_zps366717b5.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130309_162925_zps9d775579.jpg

I would like to add that I have been somewhat critical of Dan's work in my absence, but the bottom line is this project wouldn't be where it is today if he hadn't picked up the ball and ran with it. When I am there with the frame in person, there is no doubt in my mind that it will hold up just fine. I can see how the pictures make is seem otherwise though.

[fabiodriven]

Dan took some initiative last night and corrected our incorrect pipe routing. Yay for Dan! :w00t:

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_8658_zpsbdd16cd3.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_1016_zps288e8355.jpg

[fabiodriven]

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_0489_zpsb1e1faa5.jpg

[TecateDan]

Pipe is noe complete except for a little grinding and then testing to make sure there are no holes. Airbox is next... Not sure if stock can be modified or if it will be from scratch???

[TecateDan]

Does anyone know a paint code for a gold volor that is similar ot the stock 84 tecate color rims? I have a full HPLV setuo for automotive and think I'm gonna paint then with a dupont centari single stage enamel if I can get a paint color code

[El Camexican]

Does anyone know a paint code for a gold volor that is similar ot the stock 84 tecate color rims? I have a full HPLV setuo for automotive and think I'm gonna paint then with a dupont centari single stage enamel if I can get a paint color code

Take a piece in to Dupont, they will match it for you for free.

[TecateDan]

Good Idea but I don't have a gold rim for them to match ...lol


Take a piece in to Dupont, they will match it for you for free.

[fabiodriven]

Didn't Ben send us one?

[TecateDan]

he did but it's in rust and primer. Not that I'm complaining about what ben sent just saying it is not any good for color matching


Didn't Ben send us one?

[90nut]

I also would LOVE to get some factory gold mixed up. I recently used some antique gold from ace hardware on my swingarm, was reeeaaallly gold. mixed in some black and its good to go. Not perfect but will look good while it holds up.

[TecateDan]

I'll probably get Dupont centari single stage U wnat me to get you a pintot ship out if I find it?

I also would LOVE to get some factory gold mixed up. I recently used some antique gold from ace hardware on my swingarm, was reeeaaallly gold. mixed in some black and its good to go. Not perfect but will look good while it holds up.

[TecateDan]

After many trailprotrailprotrailprotrailprotrailprotrailprotr ailpro hours of brasing and a coat of paint. Here is the finished pipe
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1300_zpsdba5d3be.jpg
Now on to sand blasting hte case halfs and starting the motor build
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1301_zps22a6ee5c.jpg

[fabiodriven]

She's coming along pretty good now. The carb/airbox area is tight. Very tight. With the compression release and its extra little cable, things are going to be interesting. It all appears as though it will work though. The pipe is looking pretty snazzy as well, at least for a cob-job.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_134348_zps6fd49a55.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_134638_zps493b3e93.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_134807_zpsa63e4431.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_143928_zpsbf257b2d.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_150103_zps94ee3bbd.jpg

This hanger is somewhat compromised and a replacement is on the way. This was used just for mock up.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20130317_150112_zpse7aec676.jpg

[briano]

Lookin good boys, keep up the good work

[RubberSalt]

Post #31 - The pipe.

THATS JUST UNETHICAL!

[TecateDan]

What's unethical?? making my wife grind or totally dismantling the PSI pipe.


Post #31 - The pipe.

THATS JUST UNETHICAL!

[RubberSalt]

It's HUGE!!! :-D

Snakes around the frame then back to the other side lol
I love it!

[90guy]

Looking good guys! looking real nice! :twisted:

[Bryan Raffa]

You need a 3rd person involved .. the rider!..... otherwise you two are gonna be fighting over who ride's it LOL!

[yaegerb]

[QUOTE=RubberSalt;1209135]It's HUGE!!! :-D

Snakes around the frame then back to the other side lol
I love it![/QUOTE

That's what she said...hehe

[roostin atc]

You need a 3rd person involved .. the rider!..... otherwise you two are gonna be fighting over who ride's it LOL!
Wouldn't mind a rip.

[torker]

Not only is this a great build. You guys are hilarious...

TORKER.

[fabiodriven]

Wouldn't mind a rip.

You'll get your chance Craigorino! We just need to find a place that doesn't have any trees for a couple of miles in each direction! :lol:

[JasonB]

coming along real nice guys! I want to see what the pipe looks like mounted

[ama009]

I am really enjoying this build! keep it up guys! Will this be one for the top tier showcase.......?

[thestud25]

Looking good men! Dan, you and I will scrap to see who rides it!

[RDH/86200X]

If you want a place with no trees for miles come to north dakota. Most of the state is that way.

[fabiodriven]

We'll be back on her soon. Dan's in Mexico and I've got far too much on my plate at the moment. I'll have much more time for this build once the dust settles.

[just ben]

grudge match at TF? this bike vs . the bike the engine came out of? I like the build so far,definetly out of the box

[Bryan Raffa]

$50 on the bike it came out of......:lock:

[JasonB]

Bout time someone bumped this! Money is on this bike streched vs stock machine it came out of ;)

[just ben]

Bout time someone bumped this! Money is on this bike streched vs stock machine it came out of ;)I was refering to fabio's 86 tecate that the engine was in last.Word is the guy who bought that bike bought another 500 to stick in it.

[fabiodriven]

$50 on the bike it came out of......:lock:

God knows they'll both walk by that 490.

[MIK6]

Hmmmmm.. I wonder who picked up that T3?? Ill have yo stop by and ask fabio about it.. i have a feeling I might have to help in getting it to its new owner.. lol
I hope a few of the new parts dont fall out of my truck on my way home.. lol

MIK6/ Mike

[JasonB]

I was refering to fabio's 86 tecate that the engine was in last.Word is the guy who bought that bike bought another 500 to stick in it.


oooooohhhhhhhhh ok. I thought the bet was for a kx500 not a kxt500 bike race. my bad

[TecateDan]

Bead blasting the case halfs today!!!! Sucky slow Job but I want them Pristine before I start reassembley. With the time restraint left before TF this is going to be a "rat Rod" build. No PC and shiny parts but all the mechanicals will be solid!!!!! It will be a goer not a shower. My Tecate may lend a lot of parts to this build temporarily to get it ready for TF. After TF and some solid shake down runs it will be dissassembled, stripped, and powder coated after TF.

[TecateDan]

Took all day but the cases are clean, glassbeaded and cleared. Ready for the internals this week. Stay tuned Fabio!!!

http://i1207.photobucket.com/albums/bb468/danielvpope/D382157D-D4EC-4DE6-89AF-DD90710F0536-5157-000005C4D986C1FD_zps51430d70.jpg (http://s1207.photobucket.com/user/danielvpope/media/D382157D-D4EC-4DE6-89AF-DD90710F0536-5157-000005C4D986C1FD_zps51430d70.jpg.html)
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1378_zpsf2a79d26.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1378_zpsf2a79d26.jpg.html)
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1380_zps0773d4ab.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1380_zps0773d4ab.jpg.html)
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1379_zpsbf4527c8.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1379_zpsbf4527c8.jpg.html)

[TecateDan]

I've heard wispers that it's not a 500 in that frame Fabio sold ?? Are we talking 500 vs 500 or someting else.


grudge match at TF? this bike vs . the bike the engine came out of? I like the build so far,definetly out of the box

[90guy]

Man that case looks clean! I think I need to start blasting stuff. I am impressed! Looks good guys!

[JasonB]

Them be some clean cases!

[just ben]

I've heard wispers that it's not a 500 in that frame Fabio sold ?? Are we talking 500 vs 500 or someting else.well I heard there is nothing in that frame at the moment but it will be recieveing another 500 and if all goes well it will also be a rat rod at TF. The motor your thinking of is in a 1st gen. frame,or atleast parts of one. Did you clear coat those cases? Just a warning from experience if you did, they will take on a different color as time passes they will start to look yellowish green. Pretty much like if they were not coated. If I wanna keep cast aluminum parts looking new I use a paint called alumiblast. It works great and keeps the parts looking freshly blasted.

[TecateDan]

I did clear them. I'm not going to reblastthem at this point but might paint over it with alumablast?? Ultimately WHen I have the money prob just send to GK for polishing

[88 Turbo Coupe]

Nice to see some modern day craftsmans at work!! All the best to ya!

[Bryan Raffa]

God knows they'll both walk by that 490.

yep god only knows.. because it has never been proven! gonna be ready by TF?:twisted: or we just sniffin weld smoke?:naughty:

and ya how about $100 at TF?.... see you there...?

[Dirtcrasher]

I saw RAFFA blow up his 490. Sad to see but it will be interesting to watch him go up against TEAM 500CC FAB-DAN-ELIMINATOR 500CC run. :naughty:

[TecateDan]

Is wet nitrous allowed???

[JasonB]

Wet nitrous = manlymen.

[Bryan Raffa]

Is wet nitrous allowed???

Cool .. you will blow it up before you even get there ..LMAO! dont worry about nos,, just get it together LOL

[fabiodriven]

Cool .. you will blow it up before you even get there ..LMAO!

No Raffa, we're blazing our own path here, not following in your footsteps. We'll gladly accept your $100 if you feel the need to help our cause.

[TecateDan]

Step one dissasemble the ransmission

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1384_zps4a4a403d.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1384_zps4a4a403d.jpg.html)
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1387_zpsde7d6cd0.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1387_zpsde7d6cd0.jpg.html)

Step two: Remove small amount of dirt in clutch

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1390_zpsd714ff9e.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1390_zpsd714ff9e.jpg.html)

Step 3 clean parts and lubricate with wd40
http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1389_zps8b7cc393.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1389_zps8b7cc393.jpg.html)

Step 4: change water 5 times to get rid of crap

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1392_zpsbb40baf3.jpg (http://s1207.photobucket.com/user/danielvpope/media/IMG_1392_zpsbb40baf3.jpg.html)

All of the bearings and parts for the motor are clean. Hate the way the clear looks so I'm gonnas blast the clear off and use the paint ben mentioned on the cases!!! Fabio if you want to be here when I build the motor I would say this weekend or next depending on when paint and final parts get here but the lower end is almost ready for assembly!!!!

[TecateDan]

Will be at my door Friday or saturday!

http://www.eddie-sanders-racing.com/product_p/esr%20keihin%2040%20as.htm

[redsox]

holy smokes. things are coming together nicely. carb is really nice. that thing will probably keep up with the m

[TecateDan]

It's all John. I just sit back and watch him work!

[El Camexican]

Will be at my door Friday or saturday!

http://www.eddie-sanders-racing.com/product_p/esr%20keihin%2040%20as.htm

Sweet carb!

[Bryan Raffa]

No Raffa, we're blazing our own path here, not following in your footsteps. We'll gladly accept your $100 if you feel the need to help our cause.

I can clearly see your not following my footsteps.... your working on a Kawasaki!!!!!!!!:lol::lol::lol::lol::lol::lol::lol ::lol::lol::lol:

nice carb! why didnt you go with a 41.5 if you were going that big?

[ktmcrasher]

Is there going to be a drag race at the end of all this? Is there drag racing at trikefest cos I've never seen results or videos?

[El Camexican]

Is there going to be a drag race at the end of all this? Is there drag racing at trikefest cos I've never seen results or videos?

Search trikefest on youtube, there are lots of great videos.

[fabiodriven]

Is there going to be a drag race at the end of all this? Is there drag racing at trikefest cos I've never seen results or videos?

No. The final piece to this build will be a a little basket with plastic daisies on it. Once that is installed, we all gather at the ice cream stand for root beer floats.

[ktmcrasher]

No. The final piece to this build will be a a little basket with plastic daisies on it. Once that is installed, we all gather at the ice cream stand for root beer floats.

I mean between yours & Raffas after the trash talk? Great build by the way, love the custom stuff, something that I will never have the skills to do

[El Camexican]

nice carb! why didnt you go with a 41.5 if you were going that big?

Here's a "Real Man's Carb" if either of you guys really want to get serious.

http://www.lectronfuelsystems.com/carburetor/lectron_48mm_power_jet_carburetor.html

[TecateDan]

I can clearly see your not following my footsteps.... your working on a Kawasaki!!!!!!!!:lol::lol::lol::lol::lol::lol::lol ::lol::lol::lol:

nice carb! why didnt you go with a 41.5 if you were going that big?

THe purpose of the build is an all around maching not a full on drag bike! to that end the pwk quad vent has much better low end and we do a lot of trail riding when were not at TF. To that end I didn't want to go PWK since they say the low end is not there. ESR assured me this will not be the limiting factor on my bike and has seen it improve low end over the 38AS as well as make the 500 an animal up top.... Perhaps in the future John and I will look into a ported cylinder and drag pipe but at this point 90% of the time this thing will live on the trails or Ice and an Air box was a must also so the Lectron wouldn't fit either. When you see how close the carb is to the frame you'll be amazed it fit together. If I/we build a full out drag bike I'g just use a hyabusa motor with a turbo and nos ....lol this is going to me a mx/drag/trail bike with dependibility being key!!!

[TecateDan]

This is the best part of the group build I can keep busy working while fabio slams anyone on the site that says anything!!!!!!


No. The final piece to this build will be a a little basket with plastic daisies on it. Once that is installed, we all gather at the ice cream stand for root beer floats.

[Dave8338]

No. The final piece to this build will be a a little basket with plastic daisies on it. Once that is installed, we all gather at the ice cream stand for root beer floats.

I thought you guys were wrenching on a Kwacker, not a Hurdley Ableson. :twisted:

[TecateDan]

SO I listened to Justben and bought some of that paint. Re-blasted the cases (2 of them so far) and I love the way the look vs the clear!!!! Bottom is the clear coat and top is the paint

http://i1207.photobucket.com/albums/bb468/danielvpope/4FDA6F15-787D-4E6D-9D9B-374FE3873F9F-9297-000008DB7B06896F_zps6a5ba2fd.jpg (http://s1207.photobucket.com/user/danielvpope/media/4FDA6F15-787D-4E6D-9D9B-374FE3873F9F-9297-000008DB7B06896F_zps6a5ba2fd.jpg.html)

[Bryan Raffa]

I mean between yours & Raffas after the trash talk? Great build by the way, love the custom stuff, something that I will never have the skills to do

No Trash Talk Just a little pre TF banter! LIKE THE OLD DAYS OF THIS SITE!



This is the best part of the group build I can keep busy working while fabio slams anyone on the site that says anything!!!!!!

I didnt think anyone said anything .. pertaining to your bike? so dont be so defensive! learn to take the ball busting! Something this site LOST long before both you showed up in 08 & 10... my build thred had page's! of people bustin my balls.. postin pictures up a long horn cattle and sayin my pipe looked like that...LOL everyone on this site needs to lighten up... wonder why 0ver 50% of the real collectors and and people like the ones who started this site DONT POST anymore... food for thought...

keep up with the build .. and I will continue to post less..:lol: < thats sarcastic!

[Bryan Raffa]

oh ya :postwhore... forgot.... 48mm ..... bahahahahahhahaha!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:p ostwhore

:acr

[fabiodriven]

oh ya :postwhore... forgot.... 48mm ..... bahahahahahhahaha!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:p ostwhore

:acr

That would explain the bogging and smoke screen.

[Bryan Raffa]

buy this one i bet its within 2 turns of the needle for that motor,, it has a alky needle in it..WOOF WOOF GIT OFF THE PORCH,,,,:lol::lol: YAMAHONDAMAN

lots of smoke!

[Dave Little]

Lookin' real good guys, keep up the good work.

[Bryan Raffa]

you guys get that left side case fixed????????????????????????

:shiftyeyes:

[Dave8338]

That would explain the bogging and smoke screen.

Now, that right THERE...is funny!

Good looking carb. Bet it inhales better than Big Bill Clinton, ever did. :naughty:

[just ben]

That paint is good stuff for being in a rattle can. I'm surprised you were able to find it easily,It's only sold in a few stores around here. Don't cheat on the center cases and paint over the clear,you won't have the same results as on the bare metal. Been there and I ended up blasting off paint and starting all over.

[TecateDan]

LIKE THE OLD DAYS OF THIS SITE! I didnt think anyone said anything .. pertaining to your bike? so dont be so defensive!

I could give a trailprotrailprotrailprotrailpro less what people say. It's just funny because normally you spend a ton of time bantering with people on the site which is great but it cuts into build time... Make fun of me or the build all you want I think it's a riot :-) I just like that John keeps the thread funny while I keep the build going

[TecateDan]

Amazon.com. $20 for a can but here in 2 days. Don't worry I blasted the cases AGAIN to get rid of the clear that hung on there like a trailprotrailprotrailprotrailprotrailpro then painted them. LOVE LOVE LOVE the way the paint looks. Hope it's durable ??? we shall see. Thanks for the tip Man

That paint is good stuff for being in a rattle can. I'm surprised you were able to find it easily,It's only sold in a few stores around here. Don't cheat on the center cases and paint over the clear,you won't have the same results as on the bare metal. Been there and I ended up blasting off paint and starting all over.

[TecateDan]

Yup bought a new case half!!! Needs a little JB weld near the sprocket but it's a real solid case!!!! I plan on blasting that case and JB welding it all up today and hopefully get it painted as well. John is coming over sunday to put the lower end together!!!! that and hopefully build the skid plate on the frame and mount the CDI box. At that point the carb will be here so we'll just need to figure out plumbing for the radiator and rebuild the powervales/top end -re-ring ? and it will be almost time for a put :-)


you guys get that left side case fixed????????????????????????

:shiftyeyes:

http://i1207.photobucket.com/albums/bb468/danielvpope/4FDA6F15-787D-4E6D-9D9B-374FE3873F9F-9297-000008DB7B06896F_zps6a5ba2fd.jpg (http://s1207.photobucket.com/user/danielvpope/media/4FDA6F15-787D-4E6D-9D9B-374FE3873F9F-9297-000008DB7B06896F_zps6a5ba2fd.jpg.html)

[TecateDan]

Some JB weld. Guys on KX riders say these spots can leak so time to seal them up.
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps7c1998e0.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zps7c1998e0.jpg.html)

Little bit of chain raish beinf adressed before paint
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps81630ce6.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zps81630ce6.jpg.html)

This is what John's been doing lately

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsb27a7086.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zpsb27a7086.jpg.html)

[El Camexican]

This is what John's been doing lately

There ain't nothing wrong with "doing" a little of that. Screwing the pooch, now that's weird.

[fabiodriven]

I've got a lot on my plate, what can I say?

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps623bc313.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps09706002.jpg
Cases looking almost like new and that carb made my tecate power wheelie in 4th gear
Now just need to stuff all this
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsaa1c5dc8.jpg
Into These and were good to go
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps3172b196.jpg

[tapage]

whats with the pink gas line?

[Dirtcrasher]

Case looks great!

John called me about the bore gauges. I found my set of 1-6" micrometers and I think I have the inside telescopic gauges but I have a friend that can probably help.

What do you guys need, 4" - 5" gauge??

[Bryan Raffa]

whats with the pink gas line?

it's code for tandem... should have went with the 41.5 for the extra $10 they cut that whole bridgeshit out!

[TecateDan]

86mm or about 3.5"


Case looks great!

John called me about the bore gauges. I found my set of 1-6" micrometers and I think I have the inside telescopic gauges but I have a friend that can probably help.

What do you guys need, 4" - 5" gauge??

[TecateDan]

I would have but it will not clear the frame and it's a PWK not an AS. This is mostly a woods trike so low end very important. Except at TF then it's all about top end and bath salt u maniac :-)


it's code for tandem... should have went with the 41.5 for the extra $10 they cut that whole bridgeshit out!

[TecateDan]

That's how they come stock. Have yet to chage it out to a new color!
whats with the pink gas line?

[fabiodriven]

For those of you who don't know how to retain information, we're using the carb we are because we ride in rough, tight trails. It's been said 10 times already. We're not building this to clean up at the drags at Trikefest, although our trail based bike is going to mop the floor with more than one of you. Let me say it now- when we're building a drag bike you all will know. Trust me.

[Bryan Raffa]

a pwk dont mind if you mind if you ride rough!! THATS WHY THERE THE BEST! 1.5 mm is NOT gonna make a diffrence!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!! on how it fits!!!!! its the same god dam carb... a 39mm!!! but bored bigger!!!!!!!!!!!!!!!!!!!!!!!!! :lol: lol ITS not ANY bigger outside!!!!!!!!!!!!!! RETAIN THAT INFO!:lol :lol::lol: TRUST ME!:p

now mop that up....mymint87

[fabiodriven]

Once your big bike makes it up the strip without falling on it's face, then you can give carb advice. We're not really looking for your guidance or suggestions here Raffa.

[Bryan Raffa]

wasnt giving you guidance..BUT I DID,,,,, but before you spew that the carb is BIGGER you should GIT the facts first ! be ready to re jet in Indiana! cant wait for the next thred on how to jet it!:postwhore

[TecateDan]

You are correct raffa the 39 and 38 share the same external dimensions. I meant the lectron elvamexican posted would not fit. As fabio said. THIS IS MOSTLY A WOODS RIDDEN TRIKE and Again the reason we decided to get that carb is we really didn't want to sacrifice low end. I ran it on my tecate yesterday and may just have to keep it on there so if it holds back the 500 ill think about the 41.5. We're going with a stock / slightly modified 500 psi in frame pipe too so I'm thinking that will be plenty of carb. In the future if we really want to build a drag machine it will probably be a fresh build. This is an all around machine!!!! As to jetting I've spent a year trying to get my tecate perfect with mik's and old kiehin's but with that new carb and 10 minutes in my drive way it's the best I've ever had it. I've read enough theoruy to have a phd in carb tunning. NOw that we got a nice barb I'm hoping ot translate some of hte theory into practice and from my experiment yesterday it seems to be working. A couple of plug chops and it will be perfect. Have no idea why I cheaped out on the carb before but never again. Laurel is 725ft above sea level so maybe one size smaller on the main than out here but overall not much difference. I think some of hte mountains we ride in hh are probalby close to that elevtion so go bother someone else Raffa!!! OR start a fight club thread :naughty::naughty::naughty::naughty::naughty::naug hty::naughty:

wasnt giving you guidance..BUT I DID,,,,, but before you spew that the carb is BIGGER you should GIT the facts first ! be ready to re jet in Indiana! cant wait for the next thred on how to jet it!:postwhore

[TecateDan]

Okay here is the days work. Also we have two left power vales? But that's for another's days work

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsa236a3b9.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpscb1392b8.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps728a4f44.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsf986da03.jpg

[Bryan Raffa]

You are correct raffa the 39 and 38 share the same external dimensions. I meant the lectron elvamexican posted would not fit. As fabio said. THIS IS MOSTLY A WOODS RIDDEN TRIKE and Again the reason we decided to get that carb is we really didn't want to sacrifice low end. I ran it on my tecate yesterday and may just have to keep it on there so if it holds back the 500 ill think about the 41.5. We're going with a stock / slightly modified 500 psi in frame pipe too so I'm thinking that will be plenty of carb. In the future if we really want to build a drag machine it will probably be a fresh build. This is an all around machine!!!! As to jetting I've spent a year trying to get my tecate perfect with mik's and old kiehin's but with that new carb and 10 minutes in my drive way it's the best I've ever had it. I've read enough theoruy to have a phd in carb tunning. NOw that we got a nice barb I'm hoping ot translate some of hte theory into practice and from my experiment yesterday it seems to be working. A couple of plug chops and it will be perfect. Have no idea why I cheaped out on the carb before but never again. Laurel is 725ft above sea level so maybe one size smaller on the main than out here but overall not much difference. I think some of hte mountains we ride in hh are probalby close to that elevtion so go bother someone else Raffa!!! OR start a fight club thread :naughty::naughty::naughty::naughty::naughty::naug hty::naughty:

NICELY RE EDITED!!! I'm coming for you PUNK .. witch one of you loud mouth punks is gonna have the balls to race it?....:lol: be on your A game ... I got a big &%$# 490 sandwich for ya! fight ....hahah waste my time bickering with douche bags ...:lol: I got racing to do and bikes to build.. your INTERNET games and romantic novels dont apply here ... keep up the good work!! everyone is watching!;)

[bkm]

That bike needs a +2 Westcoast swinger and I just happen to have one for sale.:naughty:

[fabiodriven]

NICELY RE EDITED!!! I'm coming for you PUNK .. witch one of you loud mouth punks is gonna have the balls to race it?....:lol: be on your A game ... I got a big &%$# 490 sandwich for ya! fight ....hahah waste my time bickering with douche bags ...:lol: I got racing to do and bikes to build.. your INTERNET games and romantic novels dont apply here ... keep up the good work!! everyone is watching!;)

Nobody's fighting here but you buddy. You posted a while back about nobody taking offense but you're the only one who has so far. I'm not internet BS-ing here. I have made myself clear that I will personally smoke you with our 500. I can't speak for Dan, but you can probably guess whose corner I'll be in on that one. I'm not blowing smoke or really talking smack, just defending my position. I've seen your 490 run multiple times in the last two years and I've never said anything bad about that bike. I genuinely like it a lot. I will tell you I am going to go faster than it, that's all. I didn't pull that out of the clear blue sky and say that, just defending my own build. It's really easy for you to tell us how to do it from there. You don't even understand what we're building it for, you've never ridden up here.


Okay here is the days work. Also we have two left power vales? But that's for another's days work

The manual we are using had a mistake in it. It said the two power valves are different on the 86 motor but they are not. Kawi shows them as identical.

Dan and I got a lot done today and also ordered a lot of parts. She'll be coming together very soon and she's gonna run like a raped ape. Cylinder mic-ed out within spec. Not perfect, but well within spec. The wrist pin didn't measure up though as well as the piston ring. I ordered a new ring, pin, and bearing just now along with some other stuff we'll be needing. There's a fresh hone in the jug (Thanks to Johnny Swinehart! Thank you!) and she should run great.

[MRSOUND]

I don't know whether to make my popcorn now or save for TF? lol Now I see why the views keep shotting up at leaps and bounds. Kidding aside looking good so far Dan & John, look forward to seeing it in Laural.

[Bryan Raffa]

I will personally put this build over 10,000! post!:lol: love ya john... :lol: nice job on the bottom end! so what are you going with for a swing arm for your All around rider?

[El Camexican]

Not that this fire needs any fuel, but I can't help but think all the Yamaha fans on here should pony up and get Raffa a t-shirt with this photo on it and a caption that says: "Kawasaki, it's what's for lunch"

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsa236a3b9.jpg

[hondawasaki]

stock vs stock comparo

http://forums.everything2stroke.com/threads/45096-Yz490-KX-500-Dirt-Rider-write-up

[Bryan Raffa]

stock vs stock comparo

http://forums.everything2stroke.com/threads/45096-Yz490-KX-500-Dirt-Rider-write-up

reading that artical..Proves that it will come down to the RIDER!:naughty: better do some port work guys!!!:Bounce

[fabiodriven]

We don't need your advise. Although appreciated, we've been building things for a long time. Thank you anyways Raffa. I tend to think the number of views of our thread has a lot less to do with you than you might think, but tell yourself whatever you have to.

I'd also like to thank Dirtcrasher for the use of his micrometers and snap gauges yesterday. That was really key for us.

[TecateDan]

It was believed to be said by Enzo Ferrari, maybe Carroll Shelby, maybe both, that "Horsepower sells cars, torque wins races", well, I happen to buy into that for the most part..

Look at the torque curve and remember that these are in trikes so that torque will not JUST cause wheel spin

[ktmcrasher]

You guys should go on Pinks

[TecateDan]

I new it was only a matter of time till this came up. Here's what I think of Pinks all out racing!!
http://www.youtube.com/watch?v=aDREuPvyu10
And this is what Raffa's new exhaust will probably look like
http://www.youtube.com/watch?v=Gmol26qMTxY

You guys should go on Pinks

[El Camexican]

It was believed to be said by Enzo Ferrari, maybe Carroll Shelby, maybe both, that "Horsepower sells cars, torque wins races", well, I happen to buy into that for the most part..

Look at the torque curve and remember that these are in trikes so that torque will not JUST cause wheel spin

I think the more appropriate quote for this situation is: “When the green flag drops the bull sh*t stops” Not sure who get credit for coming up with that one, but it sure has proved itself to be true over the years.

[Dirtcrasher]

I'd also like to thank Dirtcrasher for the use of his micrometers and snap gauges yesterday. That was really key for us.

You and Dan are very welcome. Use them as long as you need.

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/455crankho_zps248d44ac.jpg (http://s1207.photobucket.com/user/danielvpope/media/455crankho_zps248d44ac.jpg.html)

455HP at the Crank...

[El Camexican]

http://i1207.photobucket.com/albums/bb468/danielvpope/455crankho_zps248d44ac.jpg (http://s1207.photobucket.com/user/danielvpope/media/455crankho_zps248d44ac.jpg.html)

455HP at the Crank...

What kind of exotic hardware is missing from that photo that would allow that thing to make 113HP per cylinder?:wondering

[RIDE-RED 250r]

What kind of exotic hardware is missing from that photo that would allow that thing to make 113HP per cylinder?:wondering

Sneaky Pete's! ;) :D

[Red Rider]

What kind of exotic hardware is missing from that photo that would allow that thing to make 113HP per cylinder?:wonderingThe reed spacers aren't installed yet.

[barnett468]

Does anyone know a paint code for a gold volor that is similar ot the stock 84 tecate color rims? I have a full HPLV setuo for automotive and think I'm gonna paint then with a dupont centari single stage enamel if I can get a paint color code


Hello Tecate Dan AND Fabiodriven


I’m pretty it's this lovely color, double paint chip to be sure. It's probably not a color as one thinks it was. It reminds me of reminiscing about some of my old girlfriends, I'm sure some didn't look quite the same as I "remembered" them to be either. None the less I felt lucky to have them just the same, besides, they probably remember me to be better looking than I was too, lol. I also posted the original frame color along with some tasteful options a week ago or so, just enter colorrite.com in the search window to find it.


84-86 Tecate and klt gold rim color "Senna Gold"

http://colorrite.com/product/kawasaki-senna-gold-1515.cfm


lighter than senna, too light

https://colorrite.com/product/kawasaki-metallic-champagne-gold-1586.cfm


Hope this info helps.

[barnett468]

"double check paint chip"

sorry no edit button

[barnett468]

Hello Tecate Dan and Fabiodriven


Todays offerings bring us a mint garaged 100% all original 1985 tecate with the most xlnt photos of the gold wheels I have ever seen. 1 photo of the wheels shows them to be lite gold which they are not. It might have been taken with a flash. The other good right side views are the best representation of the color. If you look at the color chip on the paint link I sent you the darker looking color in the photos looks virtually identical to it.

I was able to enlarge the photos by pasting the link into internet explorer browser then using the enlarge feature in the lower right corner of the screen.


http://cgi.ebay.com/ebaymotors/1984-Kawasaki-Tecate-ATC-250-3-wheeler-Museum-quality-100-unused-condition-/251249274077?pt=ATVs&hash=item3a7f9facdd


Hope this info helps









http://cgi.ebay.com/ebaymotors/1984-Kawasaki-Tecate-ATC-250-3-wheeler-Museum-quality-100-unused-condition-/251249274077?pt=ATVs&hash=item3a7f9facdd

[TecateDan]

thank you! but 5 grand I mean yowza
Hello Tecate Dan and Fabiodriven


Todays offerings bring us a mint garaged 100% all original 1985 tecate with the most xlnt photos of the gold wheels I have ever seen. 1 photo of the wheels shows them to be lite gold which they are not. It might have been taken with a flash. The other good right side views are the best representation of the color. If you look at the color chip on the paint link I sent you the darker looking color in the photos looks virtually identical to it.

I was able to enlarge the photos by pasting the link into internet explorer browser then using the enlarge feature in the lower right corner of the screen.


http://cgi.ebay.com/ebaymotors/1984-Kawasaki-Tecate-ATC-250-3-wheeler-Museum-quality-100-unused-condition-/251249274077?pt=ATVs&hash=item3a7f9facdd


Hope this info helps









http://cgi.ebay.com/ebaymotors/1984-Kawasaki-Tecate-ATC-250-3-wheeler-Museum-quality-100-unused-condition-/251249274077?pt=ATVs&hash=item3a7f9facdd

[TecateDan]

Made this as a baseline last night to map the ports

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsaf95d306.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zpsaf95d306.jpg.html)

[barnett468]

thank you! but 5 grand I mean yowza


Hello Tecate Dan


I wasn't suggesting you BUY it for the gold wheels I was just showing the original gold color of the wheels you asked about so you can compare it to the OEM paint chip I posted for you, lol.

As far as t3's go though it is the nicest orig I have seen recently and considering they got 10k for the "mint" 250R on Ebay recently $5k for a near 0 mile, nice 84 doesn't seem horrible. If it was an 86-87 I'd buy it!


Regards

[El Camexican]

Made this as a baseline last night to map the ports

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsaf95d306.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zpsaf95d306.jpg.html)

Does that represent the flat layout of the cylinder, or are those the measurements you get straight across the holes? I'm wondering if a guy could wipe carbon paper all over the cylinder wall and then transfer the shapes onto a sheet of white paper. I've never played with port timing beyond the exhaust, pretty cool to see it layed out like that.

[TecateDan]

Negative. You can NOT MEASURE FLAT.

Here is a good link

http://www.macdizzy.com/cylinder_map2.htm

[250rRoostmaster]

Obviously you guys know your S*&t!! I love it when people can do just about anything to there bikes including porting!! Good stuff Fabio and Dan

[TecateDan]

WE ride in the Granite state a lot. That's really what they Call New Hampshire!! Armor is necessary since 86 cases are hard to come by. Plus once I finish welding it all together that will really stiffen things up a lot....

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsb01fc24a.jpg

Had to cut the coil mount off spin it around and move it an inch forward to fit the CDI under the tank. It's all tuck up and hidden now which will look sweet and clean when it's done..

http://i1207.photobucket.com/albums/bb468/danielvpope/IMG_1286_zpsc25439d3.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsa584fc00.jpg

Just got the tube to extend the swing arm.. Lot left to do but well just keep on trucking. Need to add like 10" to both sides. I'm just glad my welder started working again.

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsbdea4032.jpg

[El Camexican]

Holy skid plate Batman! How thick is that thing?

I hope your oil drain is on the side of the engine.

[TecateDan]

3/16" plate and I'm gonna drill a hole for the drain plug. U should see the under carriage of my tecate. Looks like it's benn sledge hammered

[El Camexican]

3/16" plate and I'm gonna drill a hole for the drain plug. U should see the under carriage of my tecate. Looks like it's benn sledge hammered

I can imagine. I ride in rocks too (see my last bike plate below) This one lasted 3 years and during that time I lost two rear disc guards to rocks. I hope yours doesn't need to be changed anytime soon, especialy if you're thinking to weld it solid. At least all that weight at the bottom should help the handling and drag launches.

168566

[3 Wheel Drive]

There's an 86 Tecate listed on Craigslist with a 500 in it, you just need to pull off one wheel!

http://seattle.craigslist.org/est/mcy/3777168060.html

[TecateDan]

I think those paddles tires are like 200 a piece and the motor is like a grand. The rest is scrap metal to me

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps036760f8.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps7e0aa3c1.jpg
Plumbing is all set and so is the wiring and decompression button that works off a hot start lever on the clutch perch. Just new ring and wrist pin to finish putting the motor together. Also need to find a place for the coolant overflow tank but getting very close to wrapping up with 50 I'd days left to tf...

[Dirtcrasher]

Looking good guys!!

[rg97]

Are you guys planning on cleaning up that pipe any more? The cutting and welding still looks kinda rough IMO. maybe its just the way im looking at it.

[TecateDan]

I'm not sure what I'm going to do with that pipe. It's a cob Job for sure. I think I want to see how it runs before I spend a lot of time grinding and smoothing that pipe. If it runs good I'll probably clean it up and make it look nice. If not now that the bike if built I may just drop it off somewhere and have a custom pipe made for it. We shall see. As I said a long time ago this will be a rat rod for TF then get the finishing touches afterwards :-)

[jeffatc250r]

That heap gonna be ready for nxt weekend?? 2 500's barkin through the woods will certainly wake up the wildlife.

[Dirtcrasher]

Does that represent the flat layout of the cylinder, or are those the measurements you get straight across the holes? I'm wondering if a guy could wipe carbon paper all over the cylinder wall and then transfer the shapes onto a sheet of white paper. I've never played with port timing beyond the exhaust, pretty cool to see it layed out like that.

I thought that was an excellent question. Took me 20 seconds to understand it but when I envisioned measuring across or the whole area, I understood what you were saying.

[El Camexican]

I thought that was an excellent question. Took me 20 seconds to understand it but when I envisioned measuring across or the whole area, I understood what you were saying.

Now that I have the answer to that I'm wondering how he took those measurements. Tube mics? Nuts turned out on bolts? String? Fess up T.Dan, what did you use to get in there and take those measurements? I guess you could use a square and pencil to make it and them measure the width at the top of the cylinder.

[TecateDan]

You use the piston to keep the form of the cylinder then measure

http://i1207.photobucket.com/albums/bb468/danielvpope/cut_zps7a69954e.gif (http://s1207.photobucket.com/user/danielvpope/media/cut_zps7a69954e.gif.html)

[Dirtcrasher]

Now that I have the answer to that I'm wondering how he took those measurements. Tube mics? Nuts turned out on bolts? String? Fess up T.Dan, what did you use to get in there and take those measurements? I guess you could use a square and pencil to make it and them measure the width at the top of the cylinder.

He's got my set of micrometers and telescopic gauges. It's a pretty good and accurate set, not Starett but not ENCO crap either.....

[Darius1502]

That will be such monster!! Amazing! You are going to be in for the ride of you life!

[TecateDan]

That will be such monster!! Amazing! You are going to be in for the ride of you life!

JeffATC250R has a CR500 motor in one of his machine and I love it. Only road / raced it with my tecate on the ice but Had to have one. John had the motor and I got the time. The 250's are sweet but lack some of the low end torque that the 350X has for the woods riding we do. Tecate had 37hp and the 500 had 46 but the torque is 27ft/lbs vs 41 I belive so this should actually be a great all arounf trike. Low gear is a tad taller than the tecate but that's perfect since the tecate is to tall anyways. Also the top end is 15% higher through the transmission so it's like having a better first and an overdrive. The only thing I'm concerned about is the vibration. Talk about arm pump.. May have to look into those isolated bars

http://www.gripnripracing.com/product_info.php?products_id=137

[fabiodriven]

Low gear is a tad taller than the tecate but that's perfect since the tecate is to tall anyways.

I think you mean first is too LOW in the Tecate, not tall.

[JasonB]

coming along nicely! those are an interesting set up for the vibrations. I am probably about 5 days from running my 500R for the first time but am prepared to pick up a set of Flexx bars for mine if the vibes are too rough. Jeff and a few others have already told me that people make too big a deal out of the vibes from the 500 motors. I have also seen where Billy posted up about his theory on piston weight and its affect on balance and vibrations after he turned a little of the material off the dome of a piston in his 500 a few years back to cut compression down for starting purposes. I have done some reading on it and it looks like if you keep the piston weight as close to the stock piston weight the less the bike will shake. Who knows though, Im just talking out my trailprotrailprotrailprotrailprotrailpro now :D
heres the bars im talking about
http://www.fasstco.com/shop/flexx-handlebars-atv

keep it going man! cant wait to see the finished product in person!

[bkm]

Those bars look really nice, spendy, but nice. You might want to get a measurement of the mounting area because the atc clamps are pretty far apart on the top triple.

[TecateDan]

I think you mean first is too LOW in the Tecate, not tall.

Why yes John you are correct. Thanks for those parts yesterday!

[TecateDan]

coming along nicely! those are an interesting set up for the vibrations. I am probably about 5 days from running my 500R for the first time but am prepared to pick up a set of Flexx bars for mine if the vibes are too rough. Jeff and a few others have already told me that people make too big a deal out of the vibes from the 500 motors. I have also seen where Billy posted up about his theory on piston weight and its affect on balance and vibrations after he turned a little of the material off the dome of a piston in his 500 a few years back to cut compression down for starting purposes. I have done some reading on it and it looks like if you keep the piston weight as close to the stock piston weight the less the bike will shake. Who knows though, Im just talking out my trailprotrailprotrailprotrailprotrailpro now :D
heres the bars im talking about
http://www.fasstco.com/shop/flexx-handlebars-atv

keep it going man! cant wait to see the finished product in person!

Jeff is a man from another planet.i don't think he complains about anything. He's a true mountain man so on this topic he's a little off. He runs chain saws all day so he's densenceitizd from the violence of the 500. It makes my tecate seems like its got a counterbalanced motor in it... I kinda like it though like that cause as soon as most people sit on it and feel the vibrations they don't wan to take it for a ride anymore...

I can't wait to see yours and them line them up on the drag strip !!!

[TecateDan]

Wanted to check my port specs and they are right where I want them. Just a heads up the clymer manual for stock port degrees is wrong!

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps16540091.jpg


http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsa6fde560.jpg

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps95084344.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsf6342bd9.jpg
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpsb3d57b36.jpg
Added a toolbox from an sx and a custom aluminum expansion tank for the radiator... Small amount of grinding and frame is done. Motor is done and assembled. Woot getting close

[redsox]

looking good man. cant wait to see that thing!!

[Dirtcrasher]

Looking great guys!!

[TecateDan]

looking good man. cant wait to see that thing!!

you better get a faster machine if you want to see it cause I'll be gone before you catch me on that SX... :lol::lol::lol::lol::lol::lol::lol::lol:

[RIDE-RED 250r]

Clymer is often wrong on a few things...

Looking real good fellas! :beer

I love how a sparkling clean mill looks sitting on a bench... I know, I'm weird... Just something about it!

[barnett468]

Hello Tecate Dan

If you decide you want to reduce the amount of vibration in the handle bars there are at least two additional ways to do this besides installing the kit you posted a link to. Those are a creative modern version [albeit a less effective one] of the original rubber mounted bar holders that ran through the triple tree like the old BSA’s and Triumphs etc and had a rubber vibration damper on both sides if you remember those.

Doing either one of the following has been proven and is guaranteed to noticeably reduce the overall feel of the vibration. I won’t bore anyone with physics behind it.

1. Buy a set of solid aluminum bars without a cross bar. They used to be quite common in prehistoric times but I don’t know if they are sold new anymore. Try Renthal and Ansa Racing. Flanders doesn’t have many bars anymore

2. Install a solid steel slug in each end of ANY tube type bar that is as large and long as you can fit in them.

PS – I see a Competition Cams degree wheel on it which makes me wonder, are you into muscle cars ie. Hemi Mopars, Boss 303’s, old Vettes etc?

[barnett468]

Hello Tecate Dan

Sorry I meant to post the following with my post above unfortunately I have no edit button.

I tested the 86 500’s when I worked at Kawi and they did in fact have a noticeable vibration. Obviously you have it in a 3 wheeler but due to many factors, doing this only magnifies the vibration in the chassis. I think only Jeff Ward, Brad Lackey and Goat Breker [simply because he could care less] could hold on to one of those bikes for a 40 minute minute moto back in the day, lol.

I did see in one of your photos that you’re arms are a bit bigger around than mine so it might not bother you as much as it did me, lol.

[TecateDan]

I'd love to know the physics if you feel like writting it up. Regadless thanks for the post. Need to get it running and see how it is then decide were to spend my money/time.



Hello Tecate Dan

If you decide you want to reduce the amount of vibration in the handle bars there are at least two additional ways to do this besides installing the kit you posted a link to. Those are a creative modern version [albeit a less effective one] of the original rubber mounted bar holders that ran through the triple tree like the old BSA’s and Triumphs etc and had a rubber vibration damper on both sides if you remember those.

Doing either one of the following has been proven and is guaranteed to noticeably reduce the overall feel of the vibration. I won’t bore anyone with physics behind it.

1. Buy a set of solid aluminum bars without a cross bar. They used to be quite common in prehistoric times but I don’t know if they are sold new anymore. Try Renthal and Ansa Racing. Flanders doesn’t have many bars anymore

2. Install a solid steel slug in each end of ANY tube type bar that is as large and long as you can fit in them.

PS – I see a Competition Cams degree wheel on it which makes me wonder, are you into muscle cars ie. Hemi Mopars, Boss 303’s, old Vettes etc?

[redsox]

you better get a faster machine if you want to see it cause I'll be gone before you catch me on that SX... :lol::lol::lol::lol::lol::lol::lol::lol:

i'm adding nitrous to the M. the weight of the front trail pro will help keep it down when i shift into fourth. :naughty:

[TecateDan]

Started Final assembly

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps6566daaf.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zps6566daaf.jpg.html)

[El Camexican]

Wow! She's starting to look store bought!:beer

[atc007]

Wow! She's starting to look store bought!:beer

I was thinking the same thing. Looking GREAT !!!!

[just ben]

How well does that decompression work?

[hondawasaki]

Looking good guys! can't wait for a ride report!

[Dirtcrasher]

Looks better every day, I promise not to lose it in the woods :D, but I have to take it for a rip!

[fabiodriven]

How well does that decompression work?

Very very good Ben. It kicks over like a 125 with that, no kidding.

[El Camexican]

Very very good Ben. It kicks over like a 125 with that, no kidding.

How do you open it? Also wondering how much air gets past it when its running.

[fabiodriven]

How do you open it? Also wondering how much air gets past it when its running.

It is a plunger type design that pushed inward when used. It is set up so combustion actually pushes out on the plunger effectively serving to seal the unit closed tighter rather than blowing it open. There is no leak at all through the valve itself, however where the cylinder was drilled through to mount it, there is a slight "opening" as the rings cannot seal the recess in the cylinder where the hole was drilled. I don't think it will have any adverse effects, but we shall see.

[fabiodriven]

Dan's doing final assembly as I write this and he may actually be riding the bike right now. If not yet, he'll be out there very shortly.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG9570991_zps37450887.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMG9570991_zps37450887.jpg.html)

[jb2wheels]

This is a great thread/project!

Hmmm - I do have an 85 roller with no engine. I should start the KX500 engine hunt. They're not cheap though.

[Red Rider]

There is no leak at all through the valve itself, however where the cylinder was drilled through to mount it, there is a slight "opening" as the rings cannot seal the recess in the cylinder where the hole was drilled. I don't think it will have any adverse effects, but we shall see.Aren't decompression valves usually installed in the cylinder head, rather than the side of the cylinder? Did you guys choose the location for ease of access and/or operation?

[El Camexican]

It is a plunger type design that pushed inward when used. It is set up so combustion actually pushes out on the plunger effectively serving to seal the unit closed tighter rather than blowing it open. There is no leak at all through the valve itself, however where the cylinder was drilled through to mount it, there is a slight "opening" as the rings cannot seal the recess in the cylinder where the hole was drilled. I don't think it will have any adverse effects, but we shall see.

Makes sense, the passing of air by that cut-out is a given, but supposedly by the time an engine is good and hot the piston is almost the same size as the cylinder bore, so not much should get past it when you are at operating temp. I was wondering if suction on the down stroke could suck it open, but I guess you still have lots of pressure from combustion on it until the piston has passed the exhaust port. That all said I hope it doesn’t get carboned up and have a piece come off and clip a ring at some point.

[El Camexican]

Dan's doing final assembly as I write this

It's about time he started contributing some labor to this project.

[JasonB]

oh hell yes! GET IT!

[TecateDan]

http://i1207.photobucket.com/albums/bb468/danielvpope/null_zpseb6d043c.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zpseb6d043c.jpg.html)
http://i1207.photobucket.com/albums/bb468/danielvpope/null_zps51c46d4c.jpg (http://s1207.photobucket.com/user/danielvpope/media/null_zps51c46d4c.jpg.html)

Click this one for a quick sound bite
http://i1207.photobucket.com/albums/bb468/danielvpope/th_FB553C03-39D0-4409-AC14-518866696C28-29150-00001D928FA43B2D_zpse524b481.jpg (http://i1207.photobucket.com/albums/bb468/danielvpope/FB553C03-39D0-4409-AC14-518866696C28-29150-00001D928FA43B2D_zpse524b481.mp4)

[TecateDan]

Ask Fabio it was like that when I got it


Aren't decompression valves usually installed in the cylinder head, rather than the side of the cylinder? Did you guys choose the location for ease of access and/or operation?

[TecateDan]

I just started it and with out the decomp you cant kick it with the short lever !!!!! with the decomp on it's as easy as pie. The only wierd thing is it makes a horroble snorting sound and a bit of smoke comes out of it when restarting it...lol It's nice to have it run off the hot start button on the clutch perck


Very very good Ben. It kicks over like a 125 with that, no kidding.

[fabiodriven]

Aren't decompression valves usually installed in the cylinder head, rather than the side of the cylinder? Did you guys choose the location for ease of access and/or operation?

I have seen them installed in the head before. To be honest, when I started messing around with this 500 engine about 5-6 years ago, I wasn't very familiar with the internet. There were limited places I could get any info on anything at that point. It was just word of mouth and asking other people what I should do. I don't remember who turned me on to the guy who ended up doing the work on the jug, but I talked with him on the phone for a long time before sending him my cylinder. He assured me that he had been doing these compression releases for a number of years and had very few complaints. Prior to talking to him, I really didn't have any knowledge at all of how to go about this. He was pretty much my only option at the time, so I went with him. So far it has caused us a slight amount of grief with carb fitment, but that's about it. The valve has worked exactly as it's supposed to up until now, but it has very little time on it at this point.

[El Camexican]

Something leaking in the first assembled photo?

[fabiodriven]

Something leaking in the first assembled photo?

Small head gasket issue. No worries, she'll be good to go.

[MojaveRider]

Looks great, can't wait for a ride report.

[RIDE-RED 250r]

Sounds like the same type of decompression valve found on my Husqvarna chainsaws...

[Red Rider]

when I started messing around with this 500 engine about 5-6 years ago,...I see. I didn't realize this all started so long ago. Nice work so far guys. Keep it up.

[hondawasaki]

Dan's doing final assembly as I write this and he may actually be riding the bike right now. If not yet, he'll be out there very shortly.

http://i146.photobucket.com/albums/r275/fabiodriven/IMG9570991_zps37450887.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMG9570991_zps37450887.jpg.html)

I'm glad you guys went with an '85, the extra braking will be appreciated by all that dare to swing a leg over the beast. The '84 drum sucks!

[fabiodriven]

The 84 front end is still going on.

[Eric250R]

Aren't decompression valves usually installed in the cylinder head, rather than the side of the cylinder? Did you guys choose the location for ease of access and/or operation?

4 strokes have the decomp valve in the head, works by opening the valves and relieving pressure. Obviously no valves to open in a 2 stroke head.

And great job guys, thing looks freakin awesome !