One year upgrades! 1984 ATC500X

[plevib]

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After too much time jetting and then rebuilding cuz i didn't do the first part right.... I've decided my air cooled two smoke days are over. It was fun while it was running, but my 250r was just too fickle and blew up to easily. I will one day own a liquid R, but that's a ways away. And i want a machine i don't have to worry about when i go on longer rides. So here's my plan. I bought a xl500r motor, and i'm gonna make it fit..... hopefully.

From the before, you can see that it's a VERY clean trike. When i got it, it didn't need anything except "some carb work".... after a summer of jetting, seizing, cussing, lather rinse and repeating, i'm going this direction with it instead

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Sorry if this offends the purists. But i'm not just mindlessly cutting. i've measured and figured and i can make it all fit. it's actually pretty surprising how well it fits and how the sprocket lines up

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Here's a mock up of all the parts

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I've started some of the fab work, I'll get pictures up as later.

Major engineering hurdles,

1) Engine cradle (not too complicated, just needs to be bigger)
2) Intake manifold (it will need to drop down to avoid the frame)
3) Kick starter .... it goes backwards. probably will require shortening and fender trimming. Hopefully one day it will have a ft500 stater, but those are expensive (and my wife has an ft500 with all the parts i need sitting right there in my garage! :naughty:
4) Axle flip (this one's actually pretty simple, just have to move the front bracket for that bar)
5) exhaust (i have a trx450r muffler i'm going to try to use because of the angle at which it ducks back into the frame)
6) Foot pegs (using stock ltr450 pegs)

This is for your entertainment. I'll keep it updated, but this is going to be a long term project. hopefully it'll be done by summer. If you have useless criticism about the err of my ways or how you could tune a 250r carb in your sleep uphill both ways through a blinding snowstorm, save it :p If you have helpful comments or thoughts, i'd love to hear them!

four wheels<two wheels<three wheels, but i never was very good at math :lol:

[RapidRick]

I'll be watching. Interesting hybrid. Good luck and patience. :)

[atc300r]

This is a cool build. Cant wait to see it completed.

[ps2fixer]

I don't know a ton about this swap, but I do know there was an aftermarket frame made exactly for that engine, but the base was the 350x frame.

[Hurley250R]

If you have trouble jetting a carb correctly, seems to me cutting/welding/fabricating a frame to fit a giant heavy fourstroke engine is opening another much larger can of worms. Wish you luck and prove us wrong, but from what I see, you took a perfectly good aircooled R and ruined it.

[sledcrazyinCT]

Are you selling of parts from the 250r motor? Is DG pipe spoken for?

[sledcrazyinCT]

I don't know a ton about this swap, but I do know there was an aftermarket frame made exactly for that engine, but the base was the 350x frame.


My coworker has an 82 XR500 that will probably never get finished, and I have an extra 350X frame so if you can find a link to this conversion you speak of please share.

[ps2fixer]

It was a whole aftermarket frame from my understanding, I was helping make a wire harness for one of them since the CDI etc is completely different.

Here is a photo, I don't really have an overview shot, it was just photos to help figure out the harness layout.

https://gyazo.com/da794ebd81153a7b29f1a88e9d08cc9c

[plevib]

Thanks ATC King for the carb advice, I didn't know that. I'll try to keep the angles to a minimum. But i don't see a way around it so hopefully it works out.

Yes there will be room to get the inspection covers off and with a stubby screw driver i believe there will be enough room to adjust the valves.

I've started welding the cradle, and with the valve cover off the engine picks out nicely. not totally ideal, but it will work.

yup. i'll have to pull the engine to take the side covers off. not a big deal, i don't plan on opening this motor unless i have to.

I have the original rear fender too, so i'm going to trim that one for now. I will eventually find a ft500 engine and convert the 500x to electric start. Then i'll put the maier plastic back on. if the electric start fails, i can take the seat off to start it.

Thanks for the helpful input ATC King.

Hurley250r, i'm sure your one of those guys who can tune a carb with your eyes closed in a blinding snow storm uphill both ways....

The 500x motor only weighs 24 pounds more. I had already thought of that. That doesn't exactly make it giant and heavy.

I may have trouble tuning a two stroke carb (i'm not alone, search craigslist and see how many blown 2 strokes you find) but I've done my fair share of fabricating

1982 xt550 suspension upgrade using 03 yz450 parts http://advrider.com/index.php?threads/1982-xt-550-rebirth-carb-suspension-and-brake-upgrades.1088470/

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1976 f150 custom +6 suspension, 460 engine conversion, automatic conversion

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1998 Katana faring removal, custom gauge cluster, headlight, front fender

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so thanks for judging my abilities before you know anything about me. I do intend on proving you wrong. Hope this ruffles your purist feathers ;)

I'll do some more work and put pictures up later this weekend! It's cool to find people who like this sort of project :)

[Jmoozy27]

Are you selling of parts from the 250r motor? Is DG pipe spoken for?

X2 on the spare parts, let us know what you don't need.

Good luck on the build, I'll be watching.

[plevib]

The motor is for sale. Needs rebuilt

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Pipe is for sale too. Minor surface rust on expansion chamber, everything else is perfect, no dents. I'll post pictures tomorrow.

[Hurley250R]

Thanks ATC King for the carb advice, I didn't know that. I'll try to keep the angles to a minimum. But i don't see a way around it so hopefully it works out.

Yes there will be room to get the inspection covers off and with a stubby screw driver i believe there will be enough room to adjust the valves.

I've started welding the cradle, and with the valve cover off the engine picks out nicely. not totally ideal, but it will work.

yup. i'll have to pull the engine to take the side covers off. not a big deal, i don't plan on opening this motor unless i have to.

I have the original rear fender too, so i'm going to trim that one for now. I will eventually find a ft500 engine and convert the 500x to electric start. Then i'll put the maier plastic back on. if the electric start fails, i can take the seat off to start it.

Thanks for the helpful input ATC King.

Hurley250r, i'm sure your one of those guys who can tune a carb with your eyes closed in a blinding snow storm uphill both ways....

The 500x motor only weighs 24 pounds more. I had already thought of that. That doesn't exactly make it giant and heavy.

I may have trouble tuning a two stroke carb (i'm not alone, search craigslist and see how many blown 2 strokes you find) but I've done my fair share of fabricating

1982 xt550 suspension upgrade using 03 yz450 parts http://advrider.com/index.php?threads/1982-xt-550-rebirth-carb-suspension-and-brake-upgrades.1088470/

227335

1976 f150 custom +6 suspension, 460 engine conversion, automatic conversion

227336

1998 Katana faring removal, custom gauge cluster, headlight, front fender

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so thanks for judging my abilities before you know anything about me. I do intend on proving you wrong. Hope this ruffles your purist feathers ;)

I'll do some more work and put pictures up later this weekend! It's cool to find people who like this sort of project :)


I hope you do prove us wrong. I have no idea on your abilities as a fabricator, but from the little bit of reading I gathered you probably just bit off more than you can chew. However I retract my statement and assumptions now that you have shown us your previous work. Bolting a lift kit on a truck, fork swap on a dirt bike and taking the faring and front fender off a motorcycle clearly shows you are a custom fabricator! :lol: I will stay out of your build now and not be the negative guy. Show us a smooth running, well built machine by the end of the year that doesn't look like the monstrosities we see on craigslist and I'll be the first to say excellent job! If nothing else let this be motivation for you, good luck my friend and I like your ambition!

[plevib]

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Engine cradle bent, just need to weld

[plevib]

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Dg pipe for sale too pm me.

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Cradle is mostly finished. I'm going to gusset the front after a figure out all of the motor mounts

[NETRA3]

I like it! That trike is going to be a tractor!

[boy&hisdogs]

This is going to be so cool!

[plevib]

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Front and rear engine mounts are done. Foot pegs are off of a ltr450.

[plevib]

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Kick starter headache resolved! Kind of.... the only issue is that it only allows about 3/5 of the full kick. I shortened it by about an inch and a half. Now I have plenty of room

[ps2fixer]

500cc + shorter kick starter + shorter kick range should make for an interesting experence if you ever end up needing to kick start it. I think those machines had a compression release, so make sure that is adjusted correctly :). One of my 350x's needs the cable adjusted or replaced, it is a pain to start, big time when warm. Good thing it is the pretty machine and basically is never rode, I have an ugly one for that which has the cable working extremely well.

[plevib]

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Got some more engineering hurdles behind me. I had to flip the drag link thingy for the rear caliper and move the mount

[plevib]

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Rear brakes are done! Just need some paint. And I'll have to find a shorter brake line for it. I also gusseted the engine cradle. Lots of progress today!

[plevib]

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A little paint.

[plevib]

I haven't had time for a few weeks now. But this project will happen! I've been distracted by my 200x. I rebuilt the forks, all new bearings, twist throttle, new bulbs, new chain, and spacers (can't afford a wide axle right now) . But that one still has a way to go. Desperately needs a new seat and fenders, the controls slide on the handlebars, and the rear brakes are missing, could use some gaskets and seals. But with the 200x in much more rideable condition I'm ready to focus back on the 500x. Hoping to have some time this weekend to work on it. I'll be fabbing up the intake and exhaust. Wish me luck!

[plevib]

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Intake is half done, flange is next. Hopefully the engine doesn't run like crap. ..... this is definitely the most unsure part of the build. But I'm way too far now. I have a couple other ideas if this doesn't work. .....but hopefully it juse works haha

[plevib]

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People must be getting bored of this build haha. ... oh well. I'm trucking on with or without you guys! Hah! Anywho, intake is %100 done :D just have to make a gasket and find a chunk of hose to attach the carb

[ps2fixer]

Making your own intake and exhaust seems interesting. Correct me if I'm wrong, but isn't shorter intake generally better (head port to carb) for quicker throttle response? I seem to remember reading about a Toyota intake design where they use longer intake tubes to help give the engine better bottom end grunt, but that was on an EFI engine.

BTW I'm sure people are looking yet, just no comments :P.

[plevib]

Yep, you're correct on the long intake not being ideal. But due to the frame this is one of the best options. If it absolutely runs like crap I could shorten and raise the intake by notching out the gas tank. But that is an absolute last resort. As far as the power delivery, my understanding is that longer intake = more horsepower at higher rpms. But yes. Crappy throttle response. So we'll see how that works. ...

[ps2fixer]

Yea I'd be interested in the results. I have seen home built intakes on a track at the local airport before and the 4 cyl engines was 4 tubes into 1 larger tube, and at the end was a large single carb, or atleast It looked like a carb, maybe they were hiding some injectors on the bottom side. The little go cart things had pretty good track times and were built at a college.

[plevib]

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Intake and exhaust are done! I'm getting really excited! Now all I have to do is take everything apart, prep and paint it, seal the motor, build a wiring harness, jet the carb, build skid plates....

It'll be a few couple more months. ......... especially because a three wheeler racing group just got started in ND! So I'll hopefully be busy with that. But that's also motivating to finish this machine and try it out racing. Anywho, I'll keep plugging away at this project. It's really starting to look nice. I'm stoked

[Red Rider]

Looking good. Are you going to be able to get a throttle cable attached to the carburetor without it being kinked? From the pics, it looks tight.

[ps2fixer]

What is the exhaust sourced from? It sort of looks like a 450R but not sure.

I can see why the intake is how it is now, almost need an updraft old old carb like the old 50's tractors :).

[plevib]

Thanks red rider! Yup. It's tight. Like everything else on this build haha. But yes before and after I finished the intake I mounted and tested it. The throttle works without any issues. I'll post a picture of how I routed it. The angle isn't bad. And yes, the muffler is from a 450r. I picked it because of the angle where it ducks back into the frame. And it fit absolutely perfectly for this build! Yeah the intake is a gamble. It may be fine, it may run like crap, it may not run at all haha. But I'm hoping for the best

[Mr. Clean]

I am enjoying watching the progress. It will be a great build when you get it all sorted out.

I have a trike built back in the 80's before the 350x came out that is a chromoly frame with XL500 motor. The chassis was built by a legend Nick Nicholson and I am in process of restoring it now.

Search here for Nicholson and the internet lots of good information and maybe a few ideas you can use.

[350for350]

This is shaping up good! It's nice to see someone use a unique frame. I like it. I'm interested in these because some day I'd like to shoehorn my spare xr 500 engine into my 350x.

[plevib]

Thanks Mr clean, I'll keep that in mind. And yeah, this build was the child of necessity, but I do like that it is unique. I've seen quite a few 350x frames on here with 500 motors. It looks like a fairly simple conversion with cool results, but the 350x frame is prone to crackling so I'm told. The 250r frame presents numerous problems for this project, but is much beefier. When it all comes together I think it will be an awesome and bullet proof machine! Here's a picture of the exhaust painted

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(I stole the tires for my 200x. I'm going racing in 2 weeks! Never done it before and I'm stoked!)

Race info here
http://www.3wheelerworld.com/showthread.php/178933-Atv-Event-in-Valley-City-ND-April-2-2016

[plevib]

I stand corrected. longer intake=more torque.

[Jmoozy27]

Looking good... Glad your sticking with it. Looking to hear a ride report soon.

[averysdad]

I just picked up my first air cooled 250r last week. I have wanted one for a long time I may be in way over my head if it's easier to fab all that than it is to jet the carb on a 250r.

[DohcBikes]

That intake is not going to work.

[plevib]

I can't wait for a ride report too jmoozy27 haha... It's absolutely easier to jet the carb, but I just got sick of trying to learn and blowing 200 bucks every time I failed.... I also missed low end grunt. And dohcbikes, you might be right. I'll find out soon enough. But my only other option is to modify the gas tank, so that's an absolute last resort.

[plevib]

Going racing on Saturday! I'm very excited! I'll be on a 200x stop and say hey!

[ps2fixer]

Good luck, post some photos if you can, people here love photos, and if there are 3 wheelers in them, they love them even more =).

[plevib]

So.... The 200 blew a bearing somewhere in the transmission, I ended up racing a 185 of my buddy's. It was still a blast. Mr twisted wheeler has the video of the two stroke class on YouTube so you should check that out for sure. He also hooked me up with a bottom end for my 200x so I'll have that running again hopefully by next race. I'll be bumping up the compression, and using a xr carb and cam if I can afford it haha. ... I'll start a thread for that project and post the link here for you guys

So back to the 500x! I do believe I'm done with the fab work. I burned the midnight oil building the engine last night. I have the wiring rigged and have spark. I'm currently draining the two stroke gas out of the tank for a test fire (posting while I wait haha). Cross your fingers!

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[plevib]

https://youtu.be/ZJZoGN-W50s

IT'S ALIVE!!!!
started on the fourth kick! With the 250r carb without touching the jetting or anything! And it had very good throttle response for the minute I ran it! I'm so pumped! That much closer!

[onformula1]

Do you have a link to the race video?

[plevib]

https://youtu.be/TUfsy-q27_I

[plevib]

Here's the four stroke class. I'm goofy guy in green. They tried to line us up in rows of two but the other guys didn't catch on so we just formed a line haha

https://youtu.be/l57YZHYZgDs

[Jmoozy27]

Nice job!!! You got the holeshot!!!!

[plevib]

Thanks! That was the first and last time I was in the lead that race haha. ... hey does anyone know how to move this thread out of new member discussion?

Also here is a longer video after some carb tuning. After I took this video I got it to idle quite nicely. Good throttle response off the idle. Obviously I don't know how it runs under a load yet, but all of my fears (and people's doubt) about my home engineered intake are silenced! :D I'm very pleased it turned out so nicely!

https://youtu.be/k4q2QRmDrUw

Also on a side note, this thing is gonna be a definite sleeper. I'll look pretty stock to someone who doesn't know their trikes, and it's actually pretty quiet.

[ps2fixer]

What I personally do about threads is to update the first post with the link to the latest thread on the subject, but keep this one open for those stuck in this section yet. Basically the same thread in parallel. The other option is to hit up an Admin and request it.

I figured the intake would work, hopefully the longer intake tube gives the better bottom end grunt like other online forums suggest (for cars). It might make less HP overall with the longer intake, but the TQ will be higher in the lower RPM range, but this is purely what I have read. Should be a fun wheelie machine, or hard launcher.

[plevib]

Ok I'll try talking to someone. And I'm glad you had faith in my intake cuz I didn't haha. ... and yup, it'll be totally opposite to the 250r that it was before haha. ...... all low end power. I think it'll love hills! :D

I did a little fab work tonight. I modified the shifter. Now it's very comfortable. I also created a clutch cable bracket. On the xl the bracket is the frame so I had to make one for my application.

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All I'd have to do is put a chain on it and I could ride it! But alas, I will do the right thing and make skid plates and paint it first. :/ I would say I'll have skid plates made and hopefully it all painted this weekend. Then next weekend, reassembly, work out any kinks, and ride the crap out of it! That's my goal

[ps2fixer]

Well I knew it would atleast run, I have seen some toyota engines with intake tubes 9 inches + per cyl, then they hook into a main tube that spans about a foot or so long before the throttle plate. Fuel injection vs carb blah blah, not a massive crazy difference really, fuel still gets in the engine and fires to make it run. I do think the carb car engines are shorter intake tubes though, so should be interesting to hear the ride report, hopefuly peak TQ isn't at 1200 RPM lol.

[OZQUAD44]

You could throw one of those vortex things into the inlet if you do have fuel suspension issues, but I would just give it a go how it is, it may be fine.


Sent from my iPad using Tapatalk

[plevib]

Vortex things? Never heard of that. What does it do?

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One skid plate done. Hopefully I'll get the other finished tonight but probably not. As usual I didn't get as much done this weekend as I wanted to..... but my Saturday was spend driving to Mr twisted's store to trade the 250r motor and exhaust for a 200x bottom end, a rusty dg exhaust for a 200x, a 350x headlight shell (I'll show you guys what I have in mind with that later), and most of a 1980 xl185 (cuz he was gonna put it on the street for someone to take). I'm tickled pink with the trade! Plus I got to check out some of his collection. Holy cow! That man has some sick trikes! Anywho, back to work!

[thcowboy]

Are you going to leave the front fender sitting on the tire? Nice build!

[plevib]

Thanks! No, so there's that guide for the front brake line in the fender, and there's a screw in the fender holding that part on, the nut was just spinning in the hole. So I just left it there.

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Front skid plate done. Off to paint!

[plevib]

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Looking sweet

[OZQUAD44]

Vortex things? Never heard of that. What does ?

They're a very simple helix style gadget, branded as hyclone I think, that gets installed in the intake tract that puts the moving air flow into a spin. Similar in concept to some vacuum cleaners on the market, and air intake pre cleaners as fitted to some trucks.

The concept is the air is made to spiral along the air flow path either to throw particles away from the the final destination of the air flow (in the case of a vacuum cleaner or air intake pre cleaners) or to maintain air velocity though a restriction (in the case of a hyclone intake gadget)

I'm not vouching for the validity of gadgets of this nature, I'm just suggesting you could try something like this if fuel suspension becomes a problem as a result of the limitations of your intake.

But like I said, give your set up a go, it may work just fine as is.

[plevib]

Hmmm interesting. I'll keep it in mind if this doesn't work. But the way it sounds I'm thinking it will work well as is.

So as usual I didn't get as much done as I wanted to. I'm anxious to ride it! But I have the skid plates %100 done! I figured out chain slider mounts and finished up a few things that I just had tack welded and then I got some of it taken apart for paint. I pretty much just have to remove the triples and swing arm and then I can sand!

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[plevib]

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So excited! I'm putting it together tomorrow!

[rustyhondas]

Good for you !

Allot of challenges along the way , hell of a job making that crazy intake work

Not sure about those skid plates on a race bike , you can totally get away with not having them

[plevib]

Thanks! Yeah the skid plates ended up really heavy duty cuz that was the thinnest diamond plate the place had haha. ... I'm just getting into racing so I suspect this will mostly be a trail rig. But I didn't think about pulling them off for races, that's a good idea!

[plevib]

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Assembly! Finally!

[plevib]

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Getting there!

[plevib]

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Almost there

[plevib]

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Holy crap it's been a long road getting it here! But it's a monster! Crazy torque! It's really rich on the top end so I've got more carb work to do, but it pulls like crazy on the bottom end. I'm gonna drop the front sprocket to a 12t, cuz 14 is really tall. I'm gonna fab up led headlights for it with a 350x headlight shell. And I want to get a mikuni for it because the two stroke idle adjustment doesn't work well on this engine. I also want to bend the forks back, get new fork boots, it needs new handlebars, and I'll probably get new controls for it too. And a tether kill switch. But it drives!

[DohcBikes]

While jetting don't rule out the intake as a possible cause for issues.

It looks great, very well done.

I passed on purchasing a 225dx with an xt500 engine a few weeks ago. It was not built well like yours is.

[plevib]

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https://youtu.be/4-puKryWNyc

[Jmoozy27]

An keihin fcr carb off of any modern four stroke dirt bike should get you in the ballpark. Looks really nice and original. Good job.

[DohcBikes]

^ excellent suggestion.

They are a bit pricey but I know for a fact that a DRZ400 carb will run that engine very well.

[86125m]

I fi did not know any better I would say it looked factory. You have done a wonderful job does not look home made in any way.

[ps2fixer]

Are you using the OEM left side switches from the 250r? There are a few options out there for replacement switches. If you shot me some photos of the plugs and wire colors I could probably wire one up for you to be plug and play (colors might not match). Here is what the switch looks like. It has a "spare" starter button, but a horn or something witty could be wired up to it. Would be pretty simple to add in an option for the tether to be parallel with the kill switch too.

Thing to remember if you're looking to source a switch, most of the newer model quads (like 95+) have the reverse electronics for the kill switch. So if the 250r kill switch is correct for your engine, then a newer switch would work backwards (off for on, and on for off). The one photoed below is one of the few left in production with the old style of kill and would be correct for pretty much any Honda atc.

Photo is the 350x switch assembly I replaced =). New one works so much better than the old one.

[plevib]

Thanks for the advice and compliments! I'm glad you guys think I met my goal of a stock, honda looking build! I tuned it a little more last night. Before I got rained out I got it pretty much dialed in. It just needed leaned way out. I got a quick zip in before the rain got too bad and it revved all the way up without hesitation. But I definitely need a 12t front sprocket. .... I'll order one this week.

As far as the carb, there's no way that drz 400 carb will fit haha. Thanks for the suggestion, but I figured I'd just go with a mikuni vm36. Fairly cheap and compact. Then it'll actually idle haha.

And as far as the electrics go, the harness is built from scratch. And ps2fixer, sorry when I said controls I meant clutch and front brake.
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(I'm an electrician, so a clean harness with new wires and electronics made me happy) right now I've got the lights hardwired because I usually never turned them off anyways and I'll pull the headlight for races. And the only control is going to be a tether kill switch. I like simplicity.

[plevib]

https://www.youtube.com/watch?v=zFINukEcCRE

Here is a walk around video

[briano]

Very nice, good job on your build. I was almost one of the naysayers when you started this project, but I wasn't. Again, good job, that looks like it should have came that way. How hard would electric start be on that? I'm not real familiar with that engine.

[plevib]

Thanks! Well the only electric start version of that engine was the 82-83 ft500. They didn't sell well in America. That paired with the fact that everyone wants to convert their xl500 to electric start makes the electric start parts VERY expensive. Like at least 600 bucks.... (the really ironic part is my wife has a beautiful 82 ft500, but I'm not stealing parts off of that) but my machine actually starts loads easier than I was expecting! Even with the short kicker and 2/3 kick! I was very pleasantly surprised. So I've scrapped the electric start idea. (Unless I stick a trx400 or 450r motor in it one day when I'm rich haha)

[ps2fixer]

When you're rich, don't forget your best friends that helped you along the way =) lol.

The 350x version of the engine is really easy to start when the compression release is adjusted correctly. I can fire mine up in 1 kick most of the time, did that after it sat around 2 months.

[rustyhondas]

I'm proud of you man

Can do attitude ,blue collar build .

[Red Rider]

Yes, nice job on all of the fab work, and attention to detail. It came out very nice. Have some fun on it now!

[plevib]

I did very get to ride it after that last video! It's torquey! Even geared way high haha. .. and it pulls wheelies! But yeah, the 12t front will help a ton. But I got go pro footage, I'll edit it tonight and post it.

Here's my plan for the headlight

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[ironchop]

Great build and nice work.

You'll love those LEDs

Sent from my Z958 using Tapatalk

[plevib]

Thanks! Yup I figured "hey, I've already got WAY too much money in this thing, why not splurge for some led's!" Haha....
Actually it was 27 dollars for 4 of those lights on a screaming amazon deal! So I bought 12 of them haha.....
They'll go on my trucks too.

I pulled the spark arrestor core out and put just the screen back in tonight. It sounds much better now! (Basically that trx muffler is just a can with a screen at the end now haha) it was obvious that I'll have to jet again, but I think I'll get much better high end out of it. Plus it sounds so much better. It really barks, like an old thumper should! :D

[plevib]

https://www.youtube.com/watch?v=QGX18h_hSO4&feature=youtu.be
Ride video!

This is before i pulled the spark arrestor core, so you hear the old thumper top end more than the exhaust haha... towards the end the road was so bad it almost bucked me off haha.... but other than that it's a tame test ride

[AK47KID]

That's awesome. Wonder if I can put 500 in my 200x frame

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[plevib]

Thanks for the compliment,

Well first of all, the 200x frame is significantly more light weight than the 250r frame. It wouldn't hold up to the torque. Second, you can make that 200 motor pretty quick for not too much money. Third, you've got a really really nice 200x! I'm all about modifying stuff, but think hard before you cut it up.

Just my thoughts, do what you want with your trike!

[plevib]

https://youtu.be/IiePE8TXUYw

She barks good now! I think the carb is all dialed in. As soon as my 12t sprocket arrives I'll take it out again!

[AK47KID]

Thanks for the compliment,

Well first of all, the 200x frame is significantly more light weight than the 250r frame. It wouldn't hold up to the torque. Second, you can make that 200 motor pretty quick for not too much money. Third, you've got a really really nice 200x! I'm all about modifying stuff, but think hard before you cut it up.

Just my thoughts, do what you want with your trike!
I meant it more as a joke if anything. I finally took my 200x out for a spin even though it doesn't have brakes I can't really open it up.if I was going to do a foreign engine in my 200x I'd actually use my other 200x that has a " soon to blow " engine. ( i have 2 200x's ) the "black trailprotrailprotrailprotrailprotrailpro" as I call her has a P.O.S 185 engine in it. Runs like crap and the previous owner I traded for it had some kind of crappy weld job on the exhaust. There were leaks everywhere. I'd Rev it up and you could see smoke coming out every weld he did. Not to mention he cut the fender for the pipe which makes me mad. He should've got the right pipe for it. And for the black ***** I'm still thinking of what engine to put in it.

As for the 200x I recently got... I'm not sure. For one brakes are on top of the list. I'm going to get a different grab bar. As I figured out the six pack rack doesn't allow much room for wheelies... I can't decide if I want to take the air box out and put a direct fit K&N on the carb. I'm definitely going to polish the bike to look newer. New tires. Or at leased tube these ones. And some more things I can't think of...

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[AK47KID]

How bout a nice red rider bee bee gun with a compass on the stock and a thingy that tells time instead ? .......young man ......young man ?.......SHUT UP !
You first

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[ps2fixer]

That sister marry elephant reference (I think) ^^

Not sure if this is the correct video, no sound on this pc. https://www.youtube.com/watch?v=xWIxCbB9-JA

As for the 200x, why not another 185s/200s engine, or find a 200x engine and build it up? Could always try out a xr/xl 250r bike engine if you can find one, forgot which one has the 6 speed though.

[AK47KID]

That sister marry elephant reference (I think) ^^

Not sure if this is the correct video, no sound on this pc. https://www.youtube.com/watch?v=xWIxCbB9-JA

As for the 200x, why not another 185s/200s engine, or find a 200x engine and build it up? Could always try out a xr/xl 250r bike engine if you can find one, forgot which one has the 6 speed though.
Im trying to do one trike at a time. Im trying to steer away from pull start engines. I was actually thinking of buying a pirahna engine that fit in the 200x frame

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[86125m]

I think I would try and rebuild the 185s engine but thats just me.

[plevib]

Ok well back to the 500 haha....
12t sprocket made a massive difference! Launches hard and wheelies like a champ haha... my gopro was dead so o didn't get any footage but I'll probably get some footage at my parents farm this weekend. I'm stoked!

[350xtrike.rider]

This thing is stupid cool! Looks really good in the 2nd gen frame!

[AK47KID]

Ok well back to the 500 haha....
12t sprocket made a massive difference! Launches hard and wheelies like a champ haha... my gopro was dead so o didn't get any footage but I'll probably get some footage at my parents farm this weekend. I'm stoked!
Get footage!

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[plevib]

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Got the brackets done for the headlights! It looks sweet a s they're crazy bright! (They're crooked cuz they're not tightened down all the way) Testing them on the trail this weekend!

[AK47KID]

Thexy

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[AK47KID]

Hey!?! Wheres our promised footage???

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[bad to the bone]

Thats a cool build. Looks almost factory made.

[AK47KID]

Did plevib die on it or something? I mean seriously we haven't heard from him since may 5th.... just wondering

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[plevib]

Not dead. Just extremely busy..... didn't end up going out to the farm for footage, and now I'm chasing down a spark problem. Hopefully I get some time to dig into it more in a couple weeks. There's a race on June 11th I'd love to make it to, but I don't know if I'll have a machine together :(
Being an adult sucks! If any one needs me I'll be in my footie pajamas playing with Legos while watching GI joe....

[AK47KID]

Not dead. Just extremely busy..... didn't end up going out to the farm for footage, and now I'm chasing down a spark problem. Hopefully I get some time to dig into it more in a couple weeks. hopefully it's just somethin easy to fix. Hopefully you can get to the race and get footage that way...



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[plevib]

She lives! :w00t:
I have no idea what the actual problem was. I tore apart the whole wiring harness, replaced a couple connectors that were probably fine but I wasn't totally happy with, and put it back together and it came to life. So in conclusion, I don't know what I did but I'M GOING RACING! :beer:beer

[plevib]

So yup. Got to the races and lost spark again. Deepa But I finally found the problem! Fur reel this time! Haha

232943

I never touched the pickup coil when I built the motor, but I've learned my lesson. I will check every single bolt on an engine that Is unknown to me. .....
I'll finish putting it together tonight, hopefully ride it this weekend without any problems! .....hopefully. ...

This project has been fun, but has had way too many headaches. Hopefully I'm working the last of the kinks out!

Thanks guys for the encouragement and advice in this build!

[plevib]

233328

Yup...... that's the cam.... I did get about 3 fun hours of ride time on it before the cam sprocket bolts worked loose. Well I have a new cam and I'm tearing the engine back down to flush the little bits of metal and I'm going to loc tite EVERYTHING going back together. I had no idea this motor would rattle itself apart so bad! Anyway. As usual I'm tearing it all back apart 4 days before a race haha. .. hopefully I'll get to race.

Anywho, I just got new forks of the unbent variety and a mikuni vm34 to install when going back together. I'm fairly happy with how it's running but I think this carb will work better. Pics tonight or tomorrow!

[plevib]

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New carb. I like it much better than my pj knock off (it was free) I'm ticked off at the ebayer that I got the forks from. He shipped them with one upside down in the box. I know the box probably didn't stay right side up but one fork was fine and the other leaked all the oil out.... for this race I'll just put more oil in it but it's kinda irritating.

[AK47KID]

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New carb. I like it much better than my pj knock off (it was free) I'm ticked off at the ebayer that I got the forks from. He shipped them with one upside down in the box. I know the box probably didn't stay right side up but one fork was fine and the other leaked all the oil out.... for this race I'll just put more oil in it but it's kinda irritating.
Dat carb tho.... it's beautiful

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[plevib]

233387

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My trike was a little bow legged.... I guess maybe one shouldn't run down frozen and unknown creek beds. ...haha!

233389

Finally a good set of forks! She's pretty. I replaced the oil in them but I haven't taken them apart yet. Progressive springs, new seals, and new boots are on the way but I wanted these puppies on for the race on Saturday! :D

I also cleaned the engine, installed the new cam, and used loc tite on everything going back together. Tomorrow it'll go back in and I can try out my new carb!

[plevib]

Something I didn't realize, I got 83 r forks and they are about a half inch shorter than the 84 and the springs are way lighter than the springs in my 84 forks (idk if they are stock or not). So I'm assuming that I'm loosing a little travel with the 83 forks, but pairing them with the 84 springs stiffened the front up nicely ( kinda like a pvc spacer) . It'll be interesting to see how it handles jumps. Obviously nothing crazy. Maybe I'll send the progressive springs back if I like this setup

[plevib]

Something I didn't realize, I got 83 r forks and they are about a half inch shorter than the 84 and the springs are way lighter than the springs in my 84 forks (idk if they are stock or not). So I'm assuming that I'm loosing a little travel with the 83 forks, but pairing them with the 84 springs stiffened the front up nicely ( kinda like a pvc spacer) . It'll be interesting to see how it handles jumps. Obviously nothing crazy. Maybe I'll send the progressive springs back if I like this setup

[plevib]

https://youtu.be/ulBikrKXlQU

sorry for the wait guys, had to work more bugs out but i'm very very happy with the results!
it was a long road here but it was worth it!

[fabiodriven]

What a great friggin build man! Nice job!

[SteveCZ28]

thumbs up for a great build. at the beginning I was like others, doubting the build. but as I read throught the entire build, im pretty impressed. I love the led 350x headlight set up. with the black housings it kinda makes it look like a zombie 350x. which is a neat look. kudos to you for sticking with it, and proving the nay sayers wrong.

[plevib]

thumbs up for a great build. at the beginning I was like others, doubting the build. but as I read throught the entire build, im pretty impressed. I love the led 350x headlight set up. with the black housings it kinda makes it look like a zombie 350x. which is a neat look. kudos to you for sticking with it, and proving the nay sayers wrong.

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Here's a good shot of those zombie lights ;)

[plevib]

WARNING ZOMBIE THREAD! XD

So after a year with this fun toy I've got her torn all apart again :D

So first, while that crazy intake did work pretty well, it's poor design made the max carb size a 34mm. Which was fine for a stock motor, but with plans for some upgrades I decided to further the hacking and make room for a bigger carb :D
I also had some stress cracking issues with the original front frame piece. I replaced it with a thicker wall tube with curves instead of angles. I'm very happy with the results! https://uploads.tapatalk-cdn.com/20171025/8d050ddc5ad5431e58de564dcfdff0b1.jpghttps://uploads.tapatalk-cdn.com/20171025/95fddd36f8b0521985d5c5097d4ab1f2.jpghttps://uploads.tapatalk-cdn.com/20171025/3cb47196dc935e950697ed214ba380c9.jpg

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[plevib]

OK so first I noticed damage on the bottom case that started leaking a lot of oil. So I picked up another and swapped guts. And then the same old temptation kicked in "well while I've got this motor apart I might as well. ..."
So, I found I used 12:1 piston and jug, I removed the counterbalancer, installed a xl flywheel which is %30 lighter, upgraded to heavy clutch springs (the clutch plates are in great shape so I decided not to replace them), plumbed in for oil coolers and a filter to dump clean, cool oil on the head, and on a side note upgraded those stupid stripped out timing mark covers (I seriously recommend this upgrade! They are 30mm and 14mm listed for a 06 cr250 but they fit old Hondas perfectly)
I spent a pretty penny on a gorgeous header for a xr600. It will take a little work to make it fit but the stock tubes are 24mm and this header is 28mm.https://uploads.tapatalk-cdn.com/20171025/e8979010a006aa99f35632e59af3211e.jpghttps://uploads.tapatalk-cdn.com/20171025/0dd8477347cbe9b627b5ce6085392eab.jpghttps://uploads.tapatalk-cdn.com/20171025/3c3983e4fae9a587fed0d359fccaeef2.jpghttps://uploads.tapatalk-cdn.com/20171025/11c42106bd6a304f86662411a2aa9134.jpghttps://uploads.tapatalk-cdn.com/20171025/4cd072c555638b21dac9abcd0aeb982a.jpg

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[plevib]

OK so on to the most important part of any 4 stroke engine. The head!
So the head I had on the bike was totally clapped out. Every single bolt was stripped, helicoiled, and stripped out again. The valve guides were very worn too. So I decided to just put the head out of its misery and buy a different one. Well long story short, the eBay head I got had a marred cam journal because ebay sucks, so I ended up with a free head that I couldn't use my cam in... well some searching around at options and I decided that I'm gonna hit two birds with one stone

Megacycle cams sells a xl 500 needle bearing cam that doesn't ride on the aluminum and I can get it in whatever grind I want. It's pricey at almost 400 dollars bit since I got the head for free my budget might be able to handle that! So I'm going full poor boy wanna be race setup with this head. I ported the head to match the 42mm mikuni I picked up, as well as the exhaust side to match the 28mm head pipes. I was able to grind down the emission bumps and the transition to the valves.

So now to my conundrum. Info on hot rodding this engine is scarce, and this is the first time I've gone this far in a head. I've got a cam picked out that I think would compliment the rest of the engine, says good strong mid range and upper. It's .410 lift and says it needs shortened valve guides (stock lift is like .330) and obviously race springs and keepers. The valve guides that are in it are in great shape, so I'm hoping to shorten them with an end mill and home made guide. The issue is I don't have a good idea how far I'll have to go.... so I'm probably going to have to order the cam, and assemble the head on a bench and see how far down it pushes the valve and how much I'll have to shave off. I know someone is gonna say that I'm doing this all wrong haha... but as previously stated, I don't have a ton of money to give to a machine shop. I'm guessing it would be well over 1000 dollars to have this done at a shop https://uploads.tapatalk-cdn.com/20171025/23bacb61dfe61dc00cc8a703d35022f2.jpghttps://uploads.tapatalk-cdn.com/20171025/eb24453524ced4bfc237659d5948b2fb.jpghttps://uploads.tapatalk-cdn.com/20171025/e8000a3c218a8a89a8225f61013813c6.jpghttps://uploads.tapatalk-cdn.com/20171025/307256188fb20fad5d14d4ff858add3f.jpg

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[plevib]

Oh, and here is what it was looking like up til a couple weeks ago when I tore it apart againhttps://uploads.tapatalk-cdn.com/20171025/7757d5d7d7a5d821172c2a1a502223c7.jpghttps://uploads.tapatalk-cdn.com/20171025/d11f312d0f61abc8c35dffee615f2cd7.jpg

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[big specht]

The ascott head should have bigger valves and better ports as for the flywheel why use the xr one?

[plevib]

The ascott head should have bigger valves and better ports as for the flywheel why use the xr one?I actually had a ft head on it and the valves are identical to the xl/xr. It just has larger flanges for the exhaust and no decompression setup. As for the flywheel, the xr flywheel is %30 lighter than the xl. I should have taken a picture comparing the two, it is a significant difference. That paired with the removal of the counter balancer should make this a teeth rattling, shoulder popping rev machine ď

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[El Camexican]

Still got that head apart? Might want to consider putting epoxy on the intake floors to flatten them out a bit, it should make a diffence at higher rpm, but don't take my word for it, do a little reading if you're into spending a few more hours on your project.

[legacy51]

Any updates on this? This is such a cool build and it seemed to have ended prematurely.