TecateDan and Fabio's joint 480R effort

[fabiodriven]

I bought someone else's unfinished project from Ohio. It's an 84 ATC 250R with an 82 CR480 engine. This was the original build thread from who I can only assume was the person I bought the project from. http://www.3wheelerworld.com/showthread.php/162350-Official-Atc-480r-Build?highlight=480r

For those not familiar with the CR480 engine, it is a four speed in 81 and 82 trim, with the 83 engine being a five speed. They are all left side kick start with the counter shaft on the right side. The right side counter shaft makes the first and second gen 250R's a good choice as a home for this engine as they are right side drive as well. This engine is 55hp from the factory which is good, I can have fun with that, however it is not going to be enough. I bought this trike over the winter with the greatly appreciated help of Kiser, who was my boots on the ground. He drove quite a ways to go look at this bike for me and yay or neigh it. If it weren't for him this may not be happening right now. Also big thanks to Specht for storing it. My sister and her husband were able to pick it up from Kiser and Specht on their way up from Arkansas, so I just had to drive 45 minutes away to pick it up. The original plan was to have it ready for Trikefest. I was going to build it all myself. Then I got wrapped up in my Mustang which consumed gobs of my spare time until work picked up for the season and there was no hope for this bike this year. I jokingly asked Dan if he felt like building it and much to my surprise he said sure! I was only kidding when I asked! So I picked it up a few weeks ago and dropped it off to Dan. When we went through everything it was a bit disheartening at first. It literally needed everything aside from the engine. The engine appears to have been completely rebuilt and every gasket is brand new as well as the top end. It doesn't even look like it's been fired. The bike needed literally everything else. Very little progress had been made, next to nothing really, as far as engine fitment and mounting. The 480 pipe is useless, the ATC pipe is useless, and all braking and control systems need to be made pretty much beginning to end. Ironically enough the drag pipe from the Tecate 500 fits this 480R like a glove! I was tempted to use that pipe on this project, however having read up on the 480 I found that they do not respond well to pipe alterations and everything I read says nothing is better than the factory pipe on that engine. So we have a trick coming possibly. I don't want to say much yet because time is of the essence and sometimes things happen, sometimes they don't. If this happens 55hp will be a number we can all get out of our heads and then some.

The build is happening at Dan's house and once again he's taken the bull by the horns. He's able to go out there after work on weeknights on his own and has made a lot of progress on this by himself. I spent the day there today and we killed it. We got a lot done today. Up to this point it's been mostly motor mount work and building the main rear mount that both mounts the back of the engine and the top of the rear shock. It's the one the swing arm bolt goes through. Basically a lot of cutting, grinding, and welding thus far. The kick starter needs to be extended out in order to clear the frame. In order to accomplish this we will be welding two kicker bases together. I got the idea from some kid on Facebook.

[fabiodriven]

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[DohcBikes]

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[kiser]

Looking great Fabio! That bike deserved to be finished and I hope it makes TF this year! Good luck and keep us posted.

[AK47KID]

Subscribed.

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[Bren_downe]

I remember the kids build from foolers.com. That swinger sure is slick!

[ATC-Eric]

Sweet. You just dont see enough 480 conversions out there.

[userj8670]

Didn't someone do a 480 ice racer some time ago if I recall?

Seems like you guys are well in ypu way with this project! Gonna follow closely

[nicker71]

That swingarm is wild!! Looking forward to this build, very nice work!

[Billy Golightly]

Looking forward to seeing this one at TF. That swingarm is pretty rad looking!

[yaegerb]

Dans got some mad fab skills and the welds are looking good. Where in hades did you get that swingarm?

[fabiodriven]

There's a guy in NY with a 480R that he raced at Icefest when I was there in 2011. His name is eluding me right now, he used to post more back in the day.

The swing arm came with the bike and I have no idea who made it but yes, it does look great!

Dan does have some mad skills doesn't he? He also has a bit more time to use on this than I do. Dan does weld but I prefer to do as much of the welding as possible. All those beads yesterday are mine. [emoji3]


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[fabiodriven]

I have to rebuild a generator as well as getting a truck and massive trailer together which is far less glorious but every bit as important as this!


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[RIDE-RED 250r]

Cool to see you and Dan building again! Nice work thus far :beer

Back about 15 years ago, my little brother had an '83 CR480 and I had an '89 CR500. That 480 was nothing to scoff at, not by a damn sight. Only thing was I never got so I could kick it with my left foot, had to stand along the left side of the bike and kick with my right. LOL!

[rayatc84]

Great to see another 480R build.
I'm working on the same project, but unfortunately I haven't got enough time to work on mine: motor mounts and kick extension are built and if everything goes well, I hope to have the exhaust pipe done in a couple of months.

[riverrat]

Sweet build! Can't wait to see it done.

[Dirtcrasher]

That motor slips in there great; Very strategically placed motor mounts too :D

[yaegerb]

Great to see another 480R build.
I'm working on the same project, but unfortunately I haven't got enough time to work on mine: motor mounts and kick extension are built and if everything goes well, I hope to have the exhaust pipe done in a couple of months.

Holy crap man, where have you been?? Good to see you chime in!

[JacobMonster]

Subbed. This is an awesome build. I thought my 82 was gonna stay relatively stock, now you had to go and give me ideas ;_;
Can't wait to see it completed. Awesome work so far bud, keep it up!

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[cr480r]

Ironically enough the drag pipe from the Tecate 500 fits this 480R like a glove! I was tempted to use that pipe on this project, however having read up on the 480 I found that they do not respond well to pipe alterations and everything I read says nothing is better than the factory pipe on that engine .

I wouldn't be afraid to try the drag pipe if you run out of time. People use cr500 pipes on kx500 swaps all the time and claim they are within 1hp... The 480 pipe reviews you read were probably in regards to available 480 pipes used in motocross application. They were probably more concerned with rideability and power delivery than output. If you don't go the custom route I would get an aftermarket 480 pipe to chop up. The factory pipes with the pinched seams usually look aweful when modified. And once modified it won't be factory pipe anymore.. Lol

[fabiodriven]

She's going in for a custom pipe and match port job but thank you!


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[Scootertrash]

I think I remember seeing this project in an older thread?

Nice to see a project get moved back up to the front burner. I'm faaarrr too familiar with how projects get pushed back for other projects...

Can't wait to see it done!

[fabiodriven]

There's a thread I linked from the original owner in my first post, possibly what you were thinking of? I've not started any threads on this machine other than this one.


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[fabiodriven]

So for a brief update, I just got off the phone with our pipe builder/porting guy. Unfortunately he just doesn't have time to port our cylinder in time for this year's Trikefest. This most likely means we won't be hanging with the big boys like we had hoped, but we'll still have a very fun and nice machine.


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[cr480r]

Port it yourself :) these big bore jugs are alot easier to work on than 250's.. there's only so much you can do with a 480 jug anyways. The tiny reed box, straight walled transfers, steep angled exhaust port, and 4-stroke style crankwheels are somewhat limiting when compared to the 500's.. But even bone stock it will win races with a good rider. Ride it like a Tecate and you won't be impressed. When I got my '83 it was missing 3rd and 5th gear. A double short shift from 2nd to 4th would have the front wheel headed for the sky everytime.. With 2 gears missing it would still out accelerate and mph a 2004 CR250 my buddy had.

[fabiodriven]

That's fantastic man, thank you! Dan's going to call the port/pipe guy tomorrow and pick his brain. If need be Dan is going to port it.


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[86T3]

What's the matter Fahhhbio, don't like seeing the back of my 500?

[fabiodriven]

For the abridged version...

Trucks and trikes and trailers, oh my! It's been mechanical mayhem between everything that has to be ready for Trikefest. No spare time to post in detail or even take pictures really. At this juncture I have thousands of dollars and countless hours invested in this trip and this 480 is fully involved in its fair shake of that time and money. Dan and I spent hours yesterday, the whole day putting the bike together and it is close, it did run. I won't get into detail right now but there was a problem internally either due to the previous owner's assembly job or a sub-par part, of that we're unsure yet. There was obvious shoddy care taken to a poorly and improperly repaired clutch hub that was never mentioned or disclosed of. There are other things that were mentioned that were untrue as well, but I went in expecting that. I'm happy with this bike thus far and I think it will be a trip when it's done. It's lacking on the finishing touches, if it will make it to Indiana at all. Unpainted surface rusted swing arm, unpainted welds, cut and grind massaging here and there... It needs to be together right now and that's what matters. We have a slew of parts on order that all must arrive this week in order for this bike to make it and that's the short version. It must come together this coming weekend, but it ran and it ran well, albeit briefly.

[fabiodriven]

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[86T3]

Hahahaha, I was wondering what Ben was talking about on facebook last night. Stinger looks just right. I'm sorry about the engine problems man, that really sucks. I hope it's not too extensive or expensive.

[yaegerb]

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Holy expansion chamber. I see what you did there. Gonna line up on the inside lane and put the fear of god into the poor baystad sitting to the right of you. Sprinkle him in sweet two stroke oil....LOL

[350xtrike.rider]

Wow! Just make sure to wear an ear plug in your right ear! :lol:

[fabiodriven]

Everything is now hinging on a clutch hub that shipped late. It's the most important part we're waiting for and it's late. The bike was supposed to be assembled, running, and riding tomorrow but that's not going to happen now. We're going to do everything we can and then I'll take it home with me and install the hub one day after work next week. If everything falls into place this bike will be running. Everything has to fall into place very soon though.

[El Camexican]

Come on man!

232612

[fabiodriven]

As of now this bike has fallen together and it will be in Indiana this year. I'm astonished by what it has become, it brings a tear to my eye. It's very easy to work on and there isn't a whole lot to it. This build I had more "hands-on" personally than the Tecate 500, probably closer to 50/50 this time, or even 60/40 in my favor. We did build it at Dan's and he did do some after hours work, but not nearly like he did with the 500. He built probably 80% of that bike himself, maybe better. This bike was essentially built in three days really. Two really long days and one shorter day. Dan and I are able to "divide and conquer" as well as come together on the parts that require more than one brain or two hands. At some points we're passing the welder back and forth and waiting in line for tools. It really hadn't sunk in leaving Dan's house what we had just accomplished, but on the ride home with the 480R in the back of the truck I was starting to realize what we had just done. I got it home and my buddy who has been spending a lot of time at my house helping me with the truck and trailer came by to see the 480. He was just blown away and he started wiping it down and waxing it. I was working odds and ends and installing the "480R" decals and we were able to just stand back and take it in. It's so much more than I had expected, I'm truly happy with how this bike has come out. There hasn't been one drop of paint sprayed on it, it's all raw. Raw metal, raw welds, necessity, ingenuity, and lack of time have all culminated in the form of this old Honda. It's raw, it's right off the build table, but it will show and run.

At the beginning of the build we had purchased an entire used kicker internal assembly. Shaft, springs, ratchet mechanism, everything. I bought it because at that time we were under the impression we'd be lengthening the kicker shaft in order for it to clear the frame. We had a change of plans and ended up welding two kicker bases together instead, so the spare parts went on the shelf. Last weekend was the first time we fired this pig up and it ran really well, however the kick starter went haywire and started flailing about like an out of control fire hose. We concluded that the internal mechanism was either faulty or improperly installed. Upon disassembly and inspection we couldn't see what the issue was, but we did have an entire spare kicker assembly on the shelf. I put that in and continued re-assembly. Almost at the same time Dan and I noticed an incorrect "repair" someone had done to the inner clutch hub. That's the part that your clutch spring bolts actually thread into. Someone had broken one of those elongated bosses off that the clutch springs go into and instead of replacing the hub they tapped the back side of the boss and screwed it in from the back of the hub. I was glad we had figured that out but nervous about if we had time to locate another hub and replace it. I found one on Ebay right then and there and ordered it sent out ASAP. Well the "new kid" at that particular Ebay store messed up on shipping my part not once, but twice, and our entire build was relying on that part. We were hoping to do final assembly yesterday with the new hub in place. Well that didn't happen, but we did use the bad hub for the time being just for some tuning and testing. I've been running it to do jetting and the usual things you need to go through, but the new hub should be at my house tomorrow.

My first impression when I rode this bike was "holy frickin fack". It has a lot more power than I had expected. I haven't gotten to wring it out yet, just get on it here and there. From what I've heard about the Honda 480, it is an explosion of mid-range hit with a very early sign-off, hence the recommendation to short-shift. I'll have to say, with the middle hit it has I can definitely do some damage. I'm curious about this "early sign-off" and I have to shake it down and see what that's all about, but it has a lot of potential. During certain resonant frequencies while decelerating and quick throttle blips it hurt my balls. It was slapping my balls enough to make me flinch. It's a pretty violent vibration.

At this point I have a few small things I'm touching up on. Gotta make a chain guide for the top of the swinger, get a kill switch on it, shite like that. Both brakes work and it seems to run well. I took the 188 main jet out today and replaced it with a 205 to see what she liked. The 205 was way too much, so I brought it down to a 190 and I'll keep working with it from there.

There are so many people who have come together for this bike, for this trip in general. I have so many friends and they've been so helpful. Obviously Dan and his wife, but there are so many more. I'll be thanking everyone on Facebook at some point soon. I've been working my tits off these last couple months. This is our busy season at work and my Trikefest prep must begin as soon as the weather changes. I got a good jump this year and here we are right down to the wire again, but it's not been from lack of effort. Every day I get home from work and jump right on my Trikefest stuff, whether it be the truck, the trailer, the generator, whatever. It's all coming together though and I couldn't be more pleased. Thank you all for reading.

[fabiodriven]

It has different rear tires than what's pictured, I changed the 22's out for 20's today.

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[averysdad]

Please post some videos!!

That is the coolest bike / build I have seen on this site in a while.

[fabiodriven]

There really isn't much to record around here at the moment. I'll be frigging up my grass pretty good doing some 1-2 shifts in the yard for the sake of jetting and tuning over the next four or five days, but I'll be at Haspin for Trikefest by Sunday or so. I'm sure the cameras will be rolling.


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[Dirtcrasher]

FANTASTIC!!

Cannot wait to see it in person.

I foresee this machine as a top contender!

[El Camexican]

looks sweet! Does the light work?

[RIDE-RED 250r]

Love your "raw" builds you and Dan put together John! Looks great, and sounds flat mean!

I'm sure a bit of grinding on that cylinder can take care of that "early sign-off"..

[86T3]

We going to play a game of "Start my 480 you f'n p+$$y" this year?

[thestud25]

We going to play a game of "Start my 480 you f'n p+$$y" this year?

HAHAHAHAHAHAHAHA!!!!!!!!!!!!!!!!!!!! Greatest part of TF15! Joe, you let that little 120lb 14 kid start your 500 when your hulkulian ass couldn't!!!!!!!!!!!!!!!

[Dirtcrasher]

I like how clean and smooth it all flows.

Look at that tank!! Awesome shape!!

[fabiodriven]

looks sweet! Does the light work?

No but I have something for that.


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[fabiodriven]

We going to play a game of "Start my 480 you f'n p+$$y" this year?

Yes. And yes, I would like to see your tits.


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[fabiodriven]

Thank you all for the kind words. I can assure you all I'm almost as surprised and impressed as you. This thing came together fast and it's a real looker.

I've spent the last two evenings after work doing jetting and plug chops. She's close enough to dial in at Haspin now, so jetting is good. I'm sure my neighbors are relieved that jetting is completed. Over the last two days I've literally seen two separate neighbors wrangle their kids and dogs and herd them into the house before their ear drums shattered. This thing is really, really loud. Our long awaited clutch hub is slated to arrive today so I know what I'm doing after work today. Also, if anyone knows who sells Loctite by the gallon I'd appreciate that.


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[plevib]

Sweet build man! Wish I could be at trikefest to see it!

[atc007]

Gorgeous build,quite the smokestack ;) Enjoy it !

[TecateDan]

TF2017 500 vs 480.... since I'm gonna port both this year I have a favorite but we shall see.. fell bad for who evers on the start line that year

id also like to point out jon taught my daughter "bheg poo poo" during this build. Tonight I farted and said bheg poo poo and my daughter blerted out uncle john

[atc007]

So Great to see you guys in on another project together. Life is short ;)

[fabiodriven]

The girl was a farter long before she met me. She gets it from her mom.

[AK47KID]

Sweet build man! Wish I could be at trikefest to see it!
Me too but I live on the other side of the country

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[cr480r]

So how did it go?

[fabiodriven]

Hey! Thanks for asking!

At this time the bike is complete and it runs really well! It has exceded all of my expectations having been built in such a short time.

When I first started jetting, the round slide 40mm Keihin had a 188 main in it. After the rebuild and with the pipe we'd put on I figured it would want more fuel, not only that but you always start fat with jetting, so I bumped it to a 205 first. By the way, there's a generous amount of room to work on this bike. You can swap a jet most likely easier than a factory 250R.

So the 205 was way too fat. I worked my way down in .005 increments until I got it running good here in Massachusetts and I believe that was at 175. I wanted to step the pilot down but didn't have the correct jet available to do so. I got it good enough to load up and was going to continue jetting at Trikefest in Indiana.

I also had my 20" tires on the rear to be a bit more forgiving so I could ride and jet and get used to the bike without it shooting right out from under me. I worked my way down to 172 then 170 and with both of those jets it was burning the rear tires right through fourth gear and across the finish line on the strip. Also with those two jet sizes it sounded like it was running fine to me, however the peanut gallery was insisting it was still breaking up on top. As I swapped in the 165 (I skipped the 168) I also swapped on my drag wheels with the Four-Snows. At first I ran them in the less aggressive direction. I was amazed that it spun those tires right through fourth gear and across the finish line as well. I brought it back to the trailer to go down from a 13T to a 12T on the front sprocket, rear is 42 I think. This sprocket change was not going to help with traction, but I was aiming to be winding out 4th at the big end. I figured spinning the Four-Snows around to the aggressive side would handle the traction issue, I was betting on it. Also at this time I used a rachet strap to lower the rear and sucked the forks up in the triples to drop the front.

On race day they groomed and watered the track and traction was no longer an issue, but then came the wheelies! I'll take wheelies any day. In my first race it wheelied really big but pulled hard, and we barely lost to Cori Shively on her ATC500R. She's very seasoned as well so that was by no means a bad race. It was really close.

In my second race, I was lined up next to race and the two going before us were at the line waiting to go. They were having technical difficulties with the Christmas tree and attempting to fix it, all the while you have finicky open class bikes lined up, running, and getting hot and grumpy. Finally after what seemed like forever they launched the two in front of me. Myself and an XR600 conversion lined up and staged. This race should have been in the bag for me. Just then, a good willed and excited friend approached me from the rear yelling and screaming. I could feel his presence and after the problems they were just having with the tree I figured it was messed up again. I looked over my shoulder and as I did the lights went green. The race was lost right then. Upon my return to the launch pad I asked if I could run again, I wasn't really happy with how that had all transpired, but I was told no I couldn't. At that time I had been outside in the hot sun all day and watched every single race of every single competitor prior to mine. All I wanted to do was plop my arse in the river, so I left the track and that's what I did. I didn't find out until after that I still could have competed for third place. They are very clear on the rules and how the whole thing works ahead of time, but when I get in that situation on the bike I forget everything they just said. It's all clear as a bell ahead of time, but the excitement and the suspense get the better of me once we get going. I'd have loved to have run again but it just didn't happen.

Overall I'm in love with the bike. It runs absolutely fantastic and I'm able to start it quite well now. I'd never be able to start this engine in a bike frame, the trike is the only reason I can get this engine to kick over. It's worth having an in-frame pipe made for it so I can ride it like a regular bike and that's something I'd really like to do when I get the money. So all in all, it's a great bike!!

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Practice run-

https://www.youtube.com/watch?v=9L2qVFUcWJ0

Vs ATC500R-

https://www.youtube.com/watch?v=bQn2_E-HAag

Vs XR600-

https://www.youtube.com/watch?v=ILQb348C9Jk

Thanks for looking!



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[Scootertrash]

Awesome! I love it when a plan comes together! Nice work guys!

[cr480r]

Thanks for the update and videos. Very nice for those of us that coundnt be there. Very nice bike!!

[El Camexican]

Having heard that thing firsthand and up close I can tell you it sounds awesome! The events that led to the drag race loss were regrettable I wish they would've let them run again as the 480 was much faster and even came close to winning after starting the run two seconds after the other trike had a launched.

[RIDE-RED 250r]

Dammit man that thing honks!!

Hammer down! :beer

[86T3]

They said it was double elimination so I don't think you could have raced for 3rd.

[fabiodriven]

Oh no shite! I thought they said triple elimination. The river decision stands as correct!

[fabiodriven]

I'm sick of this beautiful bike sitting around looking good and doing nothing. I took it to Trikefest this year and it ran great, even on the year old gas from Trikefest 2016. It's a shame the bike doesn't get used more. The engine feels so strong and manageable, I'd really love to ride it in "regular" trim instead of drag trim. I just ordered a used CR480 factory head pipe, which will be my first step getting that to fit. I'll order a silencer once I see what I'm able to do with the pipe. I also would like to put a stock swing arm on it, although I don't have to, but I'd like to put the bike back to stock and see how it rides. If anyone happens to have an 84R swing arm for sale, please let me know.

[tripledog]

they said triple elimination.
Thanks for the heads-up.

[schlepp29]

Looks great fabio! I to would like to see this at trikefest next year

[fabiodriven]

The pipe arrived yesterday and today I got to cutting. At first it almost looked like it wasn't going to take much work to get the CR pipe in the ATC chassis.

https://uploads.tapatalk-cdn.com/20170929/f35a850946f237ee65eb105dfce39594.jpg

After I started working with it a little bit, it was clear this was going to take some work. I started by cutting the pipe for my first bend and left a hinge. After that it was clear that I was going to need to a lot more cutting, so cut I did.

https://uploads.tapatalk-cdn.com/20170929/da0fe59adba82b82c7feee9b7f1f161f.jpg

The CR480 cylinder head has very small fins on the left side for the pipe to clear on the dirt bike. Thankfully the ATC has the exhaust on the correct side to utilize the clearance provided by the factory on the CR head, however I had to take the small fins right off to get more room for the pipe.

https://uploads.tapatalk-cdn.com/20170929/04a03765be6bde112d288de02eb78f58.jpg

I was able to mock up the meat of the expansion chamber using a floor jack and some rags to hold it in place. The tolerances are going to be extremely tight, so at least two strong mounts are going to be an absolute necessity for the expansion chamber alone. However, the pipe does look like it belongs there at this point.

https://uploads.tapatalk-cdn.com/20170929/8c19f9d0033bf5a62f715294f19bf6b1.jpg

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https://uploads.tapatalk-cdn.com/20170929/fa6ccb0a71279d43cd5a803ff336517d.jpg

Thanks for looking.

[HondaRidr]

I ended up using the cr480 head pipe and joined it to a 250 pipe on my build. It works pretty well for what it ishttps://uploads.tapatalk-cdn.com/20170929/8c9a6623caa0bf821d1969c9368ff8fc.jpg

Sent from my SM-G930T using Tapatalk

[fabiodriven]

Dude I like that a lot. I wish I had another expansion chamber lying around. I just ordered an FMF turbine core (not turbine core II) muffler with a spark arrestor. I'd love to keep this thing as quiet as possible and have a spark arrestor as well as being forestry approved. Hopefully it's quiet. I'm going to wrap the head pipe as well.

I'm trying to think of a fairly cheap thin wall tubing I can procure to make up the rest of the exhaust to join the expansion chamber and the silencer. I was going to peruse the hardware store but I'm not faithful I'll find anything. Any suggestions are appreciated.

[sledcrazyinCT]

Maybe something on this site?

https://www.lowbrowcustoms.com/fab-parts/exhaust-fabrication-parts.html?dir=asc&order=price (https://www.lowbrowcustoms.com/fab-parts/exhaust-fabrication-parts.html?dir=asc&order=price)

http://www.coneeng.com/pdf/Header%20Kits,%20Tubing%20and%20Bends%20PDF.pdf


I have a 3 foot slip roll you are also welcome to use if you want to. I can't even tell you last time I used it so feel free to keep on loan until you get your exhaust built

[86T3]

That looks really good John, i wouldn't have thought someone could cut a pipe and make it come together so nicely. I think your best bet would be to ask around locally for crushed pipes that you can salvage stuff off of. Maybe you have some 2 stroke friends nearby that crash a lot?

[fabiodriven]

Thank you my friends and thanks for the laugh Joe, lol! I found a piece here I can mess with once the silencer arrives but I won't know until then if it will work. If it doesn't that site looks perfect, so thank you.

[barnett468]

.

You can also check the electrical conduit section at the hardware store and you can also use copper tubing from the plumbing department if you have the right rod and gas torches.


PREVIOUS KAWASAKI INTERNATIONAL R & D PROJECT ENGINEER AND ATV DEPARTMENT SUPERVISOR AND THE ONLY PERSON ON 3WW WITHOUT AN EDIT BUTTON OR A STAR :)

[El Camexican]

Yep, electrical conduit is great, but the best place for cheap thin walled tube is under bridges where homeless people abandon shopping carts.

[Dirtcrasher]

If you want a slick finish, use SpeedyMetals and get the exact size cold or hot rolled tubing. OD, ID, Gauge etc etc....

[barnett468]

I'm going to wrap the head pipe as well.


Just in case you didn't know, the two wraps below are by far the best and most durable but may be overkill for your app. They both have lava rock in them.

https://www.designengineering.com/category/catalog/dei-cycle/motorcycle-exhaust-pipe-wrap-kits/titanium-exhaust-wrap-lr-technology

http://www.thermotec.com/products/carbon-fiber-exhaust-insulating-wrap.html



PREVIOUS KAWASAKI INTERNATIONAL R & D PROJECT ENGINEER AND ATV DEPARTMENT SUPERVISOR AND THE ONLY PERSON ON 3WW WITHOUT AN EDIT BUTTON OR A STAR :Bounce

[fabiodriven]

I actually have an old roll of eBay's cheapest offering on the shelf already, but thanks. I'd certainly try the stuff you're suggesting if I had to buy some.

[fabiodriven]

I got the head pipe all welded up today. It's a really tight fit but it's in there. The exhaust wrap is actually going to have three purposes; It's going to contain heat, it's going deaden sound, and it's also absolutely essential for covering up the ungodly frankenpipe that lurks beneath it. This bike will have a pipe professionally made for it at some point along my travels, but this will do for now. I'm going to guess that the method used by HondaRidr in post #67 would be a far better way to go at this as opposed to the way I've done it. It makes a lot more sense in my mind to use both the ATC and the bike pipes and combine the two than it does to just try and cram the bike pipe in there as I'm doing. I haven't seen his in person so I don't know, but it looks pretty good in that one picture.

I'm waiting for the silencer to arrive and then I'll be able to continue on with this.

https://uploads.tapatalk-cdn.com/20171002/938287d17be4fec48ae002d995c5725f.jpg

https://uploads.tapatalk-cdn.com/20171002/0c8f1ea6e2954b5c24ef05ad5c984876.jpg

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[big specht]

You aren't going to know what to do when you can hear your self think while it running. You've never heard it that way.

[fabiodriven]

If redneck ingenuity is your thing, you've come to the right place. I spent some time trying to mount the silencer today, and I've been using stuff that I have lying around. It's made from 1/8th diamond plate, which is overkill obviously, but it's what I have. Aluminum would be a much better choice of material but I don't have a tig welding machine nor do I know how to use one. I'm not highlighting this mount because it's particularly exciting, but because it was fun spending time creating it and I like how it has come out. This bike is cut and weld, that's how it is, so throwing crudely fabricated stuff at it wouldn't be anything new.

I threw these two pieces together real quick.

https://uploads.tapatalk-cdn.com/20171006/3495a8499034ce92d2adf1e2691fa6cc.jpg

Made this little T and I had the rubber piece on the shelf.

https://uploads.tapatalk-cdn.com/20171006/897a8c381f29bb71486828835a26a23c.jpg

https://uploads.tapatalk-cdn.com/20171006/4b9f5b22f68b8f3991184e103f43e2f9.jpg

https://uploads.tapatalk-cdn.com/20171006/827cd73f9525aabcd4b267140d869f99.jpg

For spacers I used a wrist pin from an LT50 as well as another small spacer, both on the shelf.

https://uploads.tapatalk-cdn.com/20171006/4cf574fd237894c558ce804c705ffc01.jpg

The bracket will be able to spread the load of the weight of the silencer as well as keep it tucked up high. I will build another mount for the rear of the silencer likely tomorrow.

https://uploads.tapatalk-cdn.com/20171006/3ca7da79eda42b90b6572b1c5ff1af70.jpg

https://uploads.tapatalk-cdn.com/20171006/65b5648339487c6165c6a9178d9e8115.jpg

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[fabiodriven]

I have found an 83R swing arm for sale. I know there are differences between the 83-84 rear suspension. Does anyone know if the swing arms are interchangeable?

[atc007]

You would need most of the rest of the 83 Pro Link. The link mounts about an inch higher in the 84. You could "probably" whack the mounts off and move them up.

[fabiodriven]

Well the entire exhaust system is fairly complete at this point, save for some work involving mounts and fine tuning, but it is on the bike and I was able to run and ride it.

First of all, regardless of muffler wrap and an intentionally quiet muffler, this friggin thing is loud. There is no stopping that. The cylinder is massive and the sound just reverberates off the giant fins, it's not even exhaust noise. It's engine noise.

It is going to need jetting, as it is very rich right now. I'll likely have to upgrade the carburetor instead of messing with the old round slide PE. It works fine and the bike runs well, but obtaining the right jets for it might be tricky and I know I can get a jet kit no problem for a PWK.

It will gain a bit more sac once properly jetted, but just scooting around here it seems very tame and manageable. I was trying to picture in my head how much faster than a regular air hammer this would be and although it's gotta be faster, it didn't really feel that much faster. I'm curious to see. It wasn't until I got off of it that I remembered how much longer this swing arm is, and with the stock swing arm I would have known for certain the monster that lurked between my legs. Also the three wheeler has a lot of power.

I didn't want to post another picture until it was complete, but I'm going to post a couple anyways. Don't judge the welds that haven't been ground yet and whatever other incomplete parts you might happen to see. My welding machine was very "affordable" and it whales on the middle and heavy gauge stuff, however it lacks grace when trying to weld thinner stuff. I'll continue dicking around with this thing and honing it. I have to rebuild the forks and I'd really, really like to get a compression release on it. That might be kind of a priority.

https://uploads.tapatalk-cdn.com/20171006/0c0f97f9fcd74b20f555ddd297a62e92.jpg

https://uploads.tapatalk-cdn.com/20171006/fd0d23cc1b7313d95a9739a17f01817c.jpg

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[Shawn Powell]

Fabio , wrap the pipe all the way to the muffler. One it covers up the welds / protects them, two it will help flush the exhaust vapor out. Sounds small and insignificant but I did it on my custom SupertrApp on the 350x and it made a difference not only in sound but bottom end pop also. I originally did it to cover up my ugly custom made mid pipe. Just my .02 cents. Looks good. Love the bike.


Sent from my iPhone using Tapatalk

[fabiodriven]

Thanks for the advice and compliment!

I just priced jets, I didn't realize how cheap jets are. I'm going to try and jet the old PE before I run out and buy a PWK. I'm keeping things cheap for now.

[El Camexican]

That's not your machine that's you. Pretty ugly welds homie. You know I'm not gonna lie to ya about it so don't let it hurt too bad.

Not to derail this thread, but they sell different types of welding machines for a reason. Welding thin base material with a MIG unit meant to weld up to 1/2" thick plate is not easy at all. The amount of heat required to melt .045" or .060" wire will blow a hole through thin walled tube almost instantly. Even .035" wire is a lot for what I assume is no more than 16ga. tube. Would love to see some of your welds posted up Dude.

The trick I use to weld thin metal with an over powered machine is to spot weld the whole thing one zap at a time and to stop every 2 or three spots to let the material cool. If you do blow a hole in it you can take a piece of bare electrode or even a coat hander and zap it into the hole. The down side top this method is that it's almost impossible to do it without a few pin holes popping up due to the impure air that is expanding inside the tube as you weld and contaminating the back side of the weld. There is a procedure that eliminates this called purging that involves filling the tube with inert gas, but that's usually used for TIG welding.


Fabs. make sure that if you get that thing wet you don't park it with any moisture on that pipe. That wrap is notorious for promoting corrosion. Also, is that a 4 stroke silencer? I seem to recall reading something about restriction differences between 2 and 4 stroke silencers. Might want to check on that if you haven't.

[fabiodriven]

Nico thank you for saving me a lot of writing, lol!

It is the welding machine, not me, trust me. It's made in Italy and it's very cheap. I used a Miller 250SX for years when I worked in an exhaust shop spending my days WELDING EXHAUST. Not everything I welded was clean, new metal. I welded stainless to aluminized steel, old to new, old to old, and paper thin "metal" which had become more rust than anything else. If I can weld anything, I can weld exhaust. This machine stutters and stammers until you get the bead going as if it's not enough power on the lowest setting, but once it clears up it blows right through the work. There are only six heat settings, it is not infinitely adjustable. 1 is almost too cold (but then gets too hot) and 2 is way too hot. Also it has a slight issue going on with the gas delivery I'm trying to sort out.

It is a two stroke silencer Nico designed to fit a KX500 and it is US forestry approved. The exhaust itself isn't that loud, it's the engine that's loud.

Also, if the pipe rots to pieces it is what it is! Lol!

[fabiodriven]

Why ?.......I`d get the pwk 39mm .......whats the reed block ? stock ?.......boysean ? .......Moto Tassinari say ......you buy my sh!t ......it run better ashole ! (he make it ...a buck fiddy arsehole) .......it should make the hair on the back of your neck stand up and take notice .......can you ride it long distance or is it vibrato maximuss ? ......... if it`s just drag`s fogetaboutit !!!!! .........drill bits for jet kits .....for the right now .....ya know now !!!..... hi Shep !

The reeds were new when we built this Glamy but I don't know what kind they were. I don't know who Tassanari is, but I saw Jess Tassanari really drunk at a bar a couple of years ago with a hot lesbian friend in tow. They made a scene and were very openly affectionate with one another until the manager kicked them out. I suggested they ease off the drinking and calm down over a Fabio sandwich, but that didn't happen.

I don't have many long distances to ride here to find things out, but now that it's slightly quieter there are a ton of rattles you couldn't hear before. I'll be addressing all of those. It does vibrate obviously, but I don't have near enough time on it to know how much of an effect it will have on me. There's a crappy little place I can ride up the street and I'll be taking it up there to scare the kids soon.

[El Camexican]

Nico thank you for saving me a lot of writing, lol!

It is the welding machine, not me, trust me. It's made in Italy and it's very cheap. I used a Miller 250SX for years when I worked in an exhaust shop spending my days WELDING EXHAUST. Not everything I welded was clean, new metal. I welded stainless to aluminized steel, old to new, old to old, and paper thin "metal" which had become more rust than anything else. If I can weld anything, I can weld exhaust. This machine stutters and stammers until you get the bead going as if it's not enough power on the lowest setting, but once it clears up it blows right through the work. There are only six heat settings, it is not infinitely adjustable. 1 is almost too cold (but then gets too hot) and 2 is way too hot. Also it has a slight issue going on with the gas delivery I'm trying to sort out.

It is a two stroke silencer Nico designed to fit a KX500 and it is US forestry approved. The exhaust itself isn't that loud, it's the engine that's loud.

Also, if the pipe rots to pieces it is what it is! Lol!

I've been out of the game for a while, so I'm not sure what's out there now, but when we used to build hinges for bus doors, you know the ones that pull up on the side of a Greyhound bus? All that stuff was super light tubing, but we had to weld it to 1 inch thick forgings. The guys were having all kinds of hell switching back-and-forth between thick and thin without stopping to adjust the machine's every 30 seconds until our consumable supplier suggested we try a pulse welder. $3000 bucks for a tiny little welder, but holy crap I swear to God a monkey could weld Kleenex with that thing.

[fabiodriven]

I had some friends over yesterday and I ended up running the 480 a bit. One friend in particular was able to ride it and he was absolutely blown away, he loved the machine. Rave reviews from him.

After riding it for a second time, I really wanted to update this. In retrospect, my description of this bike being more tame than I expected was a relative description. I have to remember, I am somewhat used to this bike and I spend a ton of time on my Buell, so I'm used to having a lot of power. Even my Buell has seemed slow to me lately but I know it's not the bike, it's just me getting used to the power that bike makes.

So the 480 ran great yesterday and it almost seemed as if the jetting wasn't as far off as I had originally thought. It is absolutely much faster than a 250R, there is no question about that. My friend was obsessed with the bike and we spent a long time gathered around it shooting the shite last night. He's a life long Banshee guy and he has/had plenty of other bikes. He swore the 480 would walk all over a Banshee, there was no question in his mind. Obviously that would depend on how the Banshee was modded. He was curious how it would do against 450 quads, but I've walked right away from many 450's at the drag strip.

We realized yesterday that the way I routed the exhaust is absolutely perfect in regards to the kick starter's action. It looks like I did that intentionally. The truth is I didn't cycle the kicker once while I was fabricating the exhaust, I didn't even think about it. I'm very pleased my subconscious mind was looking out for me and routed the pipe perfectly.

I still have to remove the exhaust again for final fitment and sealing and to clean it up a bit. Other than that, there are some alarmingly loud rattles that must be addressed. Some of them are the front engine mounts, others might be exhaust, others are TBD. The vibration is strong and the rattles very prevalent, but the power is insane. All you have to do is look at the the throttle and the thing just stands up!

[Dirtcrasher]

Hey, sometimes in fabrication you just get lucky! :D


It's easy to overlook a couple of all the details making this stuff fit, but sometimes, time is of the essence...

[RubberSalt]

I just priced jets, I didn't realize how cheap jets are. I'm going to try and jet the old PE before I run out and buy a PWK. I'm keeping things cheap for now.




Be careful with some of those Chinese jets. Supposedly, they arnt always true to the size they say they are. I just picked up a Chinese 38mm PWK Air Stryker. Took some time jetting it. Both the pilot and the main were way out of whack. After getting it jetted, it runs better than my Keihin 38mm PJ I had. The Chinese carb does use OEM jets/parts, so that is nice.


As for the jets being the wrong size, the ones that came in the carb I got claimed to be a 170 main and a 50 pilot. Neither had markings and both were under sized compared to name brand jets. I got a bunch of Chinese Jets that are smaller. I've got larger ones showing up later this month. I'll be comparing their sizes to the real deal once they get in.

When it comes to Keihin main jets, their sizing is very easy to follow. The diameter of the hole is the size of the jet. If the jet is a 100, then the hole is 1 mm in size. A 150 is 1.5 mm. A 170 is 1.7 mm. Chinese are useful when drilling them out to get the size you need. I'd hate to ruin accurate jets for jetting purposes. <3 my jet kit.

[fabiodriven]

I wasn't planning on buying knock off jets, never would. I wonder if the jets I was looking at were knock off or not now that you mention it.

[HondaRidr]

It looks good Fabio! Just wanted to throw in that the 83 swingarm will fit right in but the upper shock mount/rear engine mount, both linkage pieces and the 83 shock are all different.

Sent from my SM-G930T using Tapatalk

[El Camexican]

I wasn't planning on buying knock off jets, never would. I wonder if the jets I was looking at were knock off or not now that you mention it.

Were you on the JetsRUs site? They sell both and the knockoff jets are about 30% cheaper. In theory it's just a holes in a piece of brass, but when drill bits get worn holes get bigger and rougher. I stick with original jets simply for the threads, some of the knockoffs seem to thread in a little harder and the last thing one needs is a broken pilot jet in a $250 carb. I'd feel feel pretty stupid having saved $2.50 on a jet if that happened.

Genuine Keihin jets have their logo on the mains and pilots, the knockoffs don't. All I can tell you about Mikuni jets is that the font they use looks top shelf and any knockoffs I've seen have much less refined. You can tell them apart pretty easily when you have both in hand.

Not sure if anyone else has noticed this, but the Mikuni jets seem to thread in a lot harder than the Keihin's the first time. I've had a few Mikuni pilots that had to be worked in very carefully the first time, almost never had that come up on the Keihin jets.

[fabiodriven]

I took the 480 out two days ago for its first real ride in the woods. There's a small place up the street from me I never bother going to but I'd been seeing a lot kids riding out there lately and I wanted to run the 480 to see what rattled off.

The bike ran great and jetting is actually pretty close. I do get a little pre-ignition on deceleration and some typical air cooled pinging, but I'd like to see if I can smooth that out with jetting. I'm not sure what it would require or how feasible it is but my 81 300R was the first air cooled bike I ever rode that didn't knock, ping, or ring-ding. I'd like to try and replicate that. I'm guessing more idle or pilot fuel? It idles great so I'd like to keep it that way.

The front engine mount had been vibrating violently and wore itself out a little bit, so I had to add a washer. When I put the bolt through, I filled all the spacers and frame with Motorcraft 7.3 oil pan sealant, which is an RTV with an abnormally high adhesive rate. It's strong stuff, and I think it will help dampen things.

https://uploads.tapatalk-cdn.com/20171015/edc993dbe36f383201e46b795cc0dcd0.jpg

I need to find a flywheel weight and I've come up with nothing yet from searches. If anyone can help me out in that regard I'd be grateful.

I need to make chain guards for the swing arm. Honestly I had no idea what this noise was while I was riding but as it turns out the chain was hitting both sides of the swing arm.

https://uploads.tapatalk-cdn.com/20171015/088446414065f2f2e379f6683d8fc11f.jpg

I found some whoops after riding for about 20 minutes and grabbed some throttle into third and fourth gears to really hammer on things and see what breaks. It is a home made swing arm after all. I was moving along at a rather good clip over the entire section, then I turned around and went right back. At the end of it the shock was no longer damping and I assumed I'd blown it.

As it turns out, the banjo bolt on the shock reservoir vibrated out and it puked oil everywhere. Honestly I've never had to have a shock rebuilt or anything, so I just don't know. Do I have to get this thing charged or filled now or something along those lines? Obviously it takes nitrogen, and obviously the seal has been broken so...

It's definitely going to need a head stay and I'm pretty good at starting it now, but I'm going to add a compression release.

Thanks for looking.

[El Camexican]

For info on the flywheel try contacting Steahly. If they can't help call Falicon Crankshaft in FL. It's possible they've done this for someone in the past or can tell you can who can do it.

I need to make a couple chain guides. There's two types of plastic that I know of to use, but can't remember the industrial names. Swinwhart would know. I think the one they use to make cutting boards is the strongest, but it's so hard that it's almost as loud as steel when the chain slaps it.

Are you sure what sounds like detonation on deceleration isn't that chain? If not the pilot jet and air screw are what I'd try adjusting to be richer. For whatever reason when things get to be larger than 250cc in a two-stroke jetting seems to become very difficult to tune regardless of the brand.

Can't help you on the shock. Knew a guy but...

[El Camexican]

Looking at your set up again, I wonder if you could put a slot through the tube and run a plastic wheel on a bolt through the center of the tube as a combination of chain guide and chain roller? The only downside I can think of other than slightly weakening the assembly is that you would have to make sure you had a drain hole at the lowest point of that tube because you'd get a lot of water in there.

Not sure if what I said makes sense so think plastic pizza cutter and you'll know what I mean.

You could also weld vertical flat bars on each side of the swingarm and mount standard chain rollers in between them, but you'd have to extend the flat bars High enough that the chain could never slip off the roller, or it would make a heck of a mess.

[Shep1970]

Just putting it out there, if u want to make some sort of clamp on or two piece bracket to hold a chain guard/wheel in place out of playdough or preferably "wood" to pour/ and make it out of aluminum it would be an option.
Nice bike by the way.

Shep

[Dirtcrasher]

Hi John, just wondering: Did you help with all the swingarm tubing? Was it Chr-Mo - or is it just a type of steel tubing or NPT pipe used that you could MIG or TIG?

Is that all TIG welded??

Just curious because the jig is still all set up and a few guys asked me if I could make them fit. This will make things even easier.......

[HondaRidr]

The bike ran great and jetting is actually pretty close. I do get a little pre-ignition on deceleration and some typical air cooled pinging, but I'd like to see if I can smooth that out with jetting. I'm not sure what it would require or how feasible it is but my 81 300R was the first air cooled bike I ever rode that didn't knock, ping, or ring-ding. I'd like to try and replicate that. I'm guessing more idle or pilot fuel? It idles great so I'd like to keep it that way.


What carb do you have on it? I read about a guy having an issue with his stock carb on his cr480. He put a tube over the pilot jet to extend its reach down into the fuel bowl so it wouldn't run dry after holding the throttle open and then cutting the throttle. Might be worth a try

Sent from my SM-G930T using Tapatalk

[fabiodriven]

At the moment I have the 650 in pieces, my neighbor's 87 SX apart, and the 480 apart as well. Also both of my pickups are down as well as the Zinger and Buell. We're in it knee deep ovah heyah.

I just got back from the post office where I sent the 480 cylinder head out to Adam Millar for the installation of a compression release. The 480R still needs the shock worked on, forks rebuilt, swing arm swapped out, and quite a few other things. One thing I'm debating on doing is making another head pipe using an 83-84 ATC250R pipe, so if anyone reading this has access to a pipe that they might let go for cheap, please let me know. My cobbled 480 pipe does work, but it is crammed in there tight. It was hitting the bottom of the gas tank, so I'm debating on denting the under side of the tank in. I might build a better pipe though, we'll see. I also have to build a head stay.

My concern right now is the 39mm Keihin PWK I bought. The price seemed very fair on Ebay, and I didn't realize until the other day why. The used carb I ordered is missing the choke assembly. I've had the carb here at the house for weeks and somehow overlooked this fact. I looked back at the listing because I was a bit bent out of shape about this when I first realized it, but in the listing the pictures show it with no choke and the description says "see pictures". The seller definitely did not advertise the fact that the choke was missing, and ultimately it was my fault for not seeing it. Kinda sucks but it is what it is.

Because of this, I now need to procure a choke for a 39mm PWK, and I have no idea how to do that. A quick search on Ebay netted no results. I'm not opposed to buying the parts new, but I don't know where I could buy just a choke for a PWK carb.

So if you have a choke that can help me out, or if you have a pipe you don't need for an 83-84 R, please let me know.

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[El Camexican]

JetsRus will have them

[ironchop]

Or call SUDCO in a pinch

Sent from my Z958 using Tapatalk

[fabiodriven]

Thanks for that guys. I was assuming Jets R Us might have something like that but I wasn't sure. I went ahead and ordered all my jets while I was on there. The PWK I bought came with a 52 pilot and 175 main. Based on some quick research, I ordered pilots 42, 45, 48, and 50, as well as mains from 162 to 182, all original Keihin jets.

[HondaRidr]

How much is that compression release running ya? Been thinking about that alot lately. I also found out that the crf450/04-06 trx450r kicker shares the same splines. The trx kicker would fit real good if it was spaced out from the bike a bit. I borrowed one from a friend to check it out. In the pictures it was sitting on the very end of the kicker shaft.https://uploads.tapatalk-cdn.com/20180411/e6d227fbef6f95b99351edc1d927cb74.jpg

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[ironchop]

I must say that when this thread mentioned "joint effort" I pictured something completely different [emoji41]



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[fabiodriven]

How much is that compression release running ya? Been thinking about that alot lately. I also found out that the crf450/04-06 trx450r kicker shares the same splines. The trx kicker would fit real good if it was spaced out from the bike a bit. I borrowed one from a friend to check it out. In the pictures it was sitting on the very end of the kicker shaft.https://uploads.tapatalk-cdn.com/20180411/e6d227fbef6f95b99351edc1d927cb74.jpg

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https://uploads.tapatalk-cdn.com/20180411/843b2d0421f7e80b1dccfaf00a5f0637.jpg

I don't know how much the compression release is going to cost. I spent $30 on the valve itself and sent it along with the head but I'm thinking Millar usually supplies his own valves. I bought mine ahead of time because I didn't know Millar was going to be doing the work initially. Initially I was just going to drill a hole through the head and send the valve through, done. Once I saw what MRE does, I decided to send my head to him. I'll post pictures. He's in Canada so it already cost me almost $50 in shipping alone, and he'll have it next week. I really like the idea of the small hole in the combustion chamber itself as opposed to the huge disruption the valve itself could potentially be if I had just fired it through the way I was planning. I do not want to give this engine any more reasons to pre-ignite.

I also ordered a used second gen R pipe last night because I really liked the idea of using that rather than the franken-pipe I've created. I think you're on to something there HondaRidr.

As far as the kick starter goes, I welded two bases together to get the proper clearance for the kicker to swing past the frame. You could do the same with that one I would imagine.

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[fabiodriven]

https://uploads.tapatalk-cdn.com/20180411/11b635f51e3e941f8ad359cd06081ad6.jpg

[HondaRidr]

And your kicker clears the frame like that? I did the same on the stock cr480 kicker but added a spacer in between the two knuckles so it sits out from the bike more than yours. Even with that it is very close to the bike. I can take a few pictures of my pipe for you tomorrow if you would like to see how we did it

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[fabiodriven]

And your kicker clears the frame like that? I did the same on the stock cr480 kicker but added a spacer in between the two knuckles so it sits out from the bike more than yours. Even with that it is very close to the bike. I can take a few pictures of my pipe for you tomorrow if you would like to see how we did it

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Yup, no issues with clearance on my kicker.

Yeah if you want to share some pictures of your pipe go for it dude!

[HondaRidr]

We had to cut the section of the 480 headpipe and turn it a little as you can see in the second picture. If you look at the mount we moved the whole pipe out from the frame so it would clear the bigger head. Also where we joined the two pipes you can see the 480 pipe was actually a little larger diameter so we had to cut slits in it and bend it in so that they would be closer to the same size. I know it's not perfect but it works good. https://uploads.tapatalk-cdn.com/20180413/ab5bd2811d638b0ef7826195b3e4622b.jpghttps://uploads.tapatalk-cdn.com/20180413/bcbe3b8e67e054140a26c4abe39fcfb9.jpghttps://uploads.tapatalk-cdn.com/20180413/679085e703381e71143eff037b615177.jpghttps://uploads.tapatalk-cdn.com/20180413/e850b8c7d854e6da999b05a9f68aafbf.jpg

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[fabiodriven]

That's a lot better than what I have currently I'd say. I think you did a really good job with that. My 480 head pipe is already cut and twisted so that's half the battle. Thanks!

[HondaRidr]

We also made a new stinger out of 1 1/4 inch I.D. tubing similar to that in the picture. We did this so that the bigger engine could breath and not trap in heat. 1 1/4 I.D. stingers is what the cr500 and kx500 pipes have. Hope it helps!https://uploads.tapatalk-cdn.com/20180413/fb41f99de2d153e1397fc4a510eca111.jpg

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[fabiodriven]

I've spent a ton of time on this machine lately, more than I was anticipating it needing. Dan and I assembled this machine in 2016, so two years ago. Two years doesn't seem like that long of a time, but it was long enough for me to forget a lot about this machine. The main thing that I'd forgotten was that Dan and I got this bike together quickly with the intent of it making Trikefest that year, completing multiple runs on the drag strip, and that's it. It did just that in 2016 and again in 2017, then after Trikefest 2017 I decided to make it a rider instead of a drag bike, then the shock puked and the bike got put on the back burner.

I started working on it a month or so ago. In that time I have rebuilt the shock (my first time rebuilding one), rebuilt the forks, replaced the front wheel bearings, added a 39mm Keihin PWK, had a compression release added to the cylinder head, and I've added a very critical part, a head stay. I also removed the extended swing arm and installed a stock ATC250R unit.

The forks were wiped out and I've learned that I have two different forks on this bike. I believe one fork is 83 and one is 84, as one is longer than the other. I added a brand new set of progressive springs to them while I was in there. I had to make a seal driver for the fork seals, didn't realize these needed a special tool for the fork seals. Front wheel bearings were wiped.

I'm sure most people saw the shite-show thread which was me rebuilding the shock on this. It's all set now and installed in the bike.

MRE (Millar Race Engineering) out of Canada, eh, did the work on the compression release which is second to none. They also re-cut the compression chamber for all around improvements. Adam does fantastic work and the price was right as well. Thank you MRE!

The head stay has been absolutely critical. Dan and I did not install a head stay when we built this bike due to time constraints. What I found when I started working on this bike for the first time in a long time was, the engine was loose in the cradle and it was also cocked in the cradle. I hadn't noticed the engine being cocked before because of the length of the chain due to the extended swing arm, which was more forgiving with the long chain. When I got the stock swing arm on the bike, I realized that the chain was curving quite a bit, more than I was comfortable with, and I wasn't sure if I was up to the task of straightening the engine in the cradle, but I had to try. I ended up getting very lucky in that department. Dan was responsible for measuring and ordering all of our spacer stock for the engine mounts, and he did an outstanding job of that. The problem we had was, we put four of those spacers in the wrong places which moved the rear of the engine to the left and twisted it clockwise. It was a very simple solution to put the spacers in their correct places and therefor straighten the engine in it's cradle.

Another problem as I said, the engine was loose. We'd used the improper bolts in the two rearward most mounts due to time constraints during the initial build and because of that there was a bit of marring of the mount holes on both the engine and the frame. Not enough to be a huge deal, but they needed to be addressed. We'd used bolts that were threaded their entire length instead of shouldered bolts, and those threads were eating right into the engine cases as well as the frame tabs. I have replaced those with the proper metric shouldered bolts.

The head stay I added had to be stronger than normal because my head stay is going to take more of a load than most. My front engine mount is not of an ideal configuration when it comes to integrity. It would never break, however it could flex. A little flex eventually becomes a lot of flex and then the problem is not just the front engine mount, it becomes all of them. This engine must not move anymore, so the head stay is critical. I built it very heavy as such.

This part I'd like to share with my fellow half-liter two stroke pilots, as vibration is a constant problem for these bikes. They will shake themselves to pieces, as is proven with my 480. Inside of all of the engine mounts, I have added a special kind of silicone that I happen to have on hand here. It's specifically made for the Ford 7.3 diesel oil pan, and it's not just a sealant, it's an adhesive. This stuff is stout, it's strong. It's extremely resilient yet forgiving making it the perfect substance to cushion my engine mounts. I pumped every mount hole full of this special RTV, then slowly spun each bolt through to coat the inside of every single engine mount on this bike. The RTV cannot fail, it will not wear out, it has nowhere to go as it is trapped inside the mounts where it is and it will stay there and keep vibration down whilst simultaneously keeping the engine snug in it's cradle and all the bolts tight. I would highly suggest this method to anyone who has issues with engine mounts that like to loosen up.

I was going to make a new head pipe, but I've massaged my existing Franken-pipe to fit a bit better, and I'll find out tomorrow if it's going to work or not. I should have it running tomorrow, but I cannot ride it until my 520 half link arrives from Europe unfortunately. I have some jetting to do so I hope it arrives soon.

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I am extremely impressed with this repop chain guard. I don't know who makes these but they're great.

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Difference in fork length.

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Strait as an arrow now.

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This is the mount that is less than ideal, making the head stay that much more important.

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My fork seal driver.

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[fabiodriven]

It's almost done now. The compression release certainly is a help, but it's not as effective as the one we had on our Tecate 500. The Tecate kicked over like a 125 with that compression release on it. The 480 still is tough to kick, harder than a 250, but it is definitely an improvement. I have to see what it wants for jets, as I have the idle set all the way up now so it must be fat on the bottom. I'm still learning the PWK, so I don't know if the pilot jet has anything to do with idle or if idle is controlled strictly by an idle circuit and I don't remember if this has an air screw. I'm going to mess with it some more after lunch. Even not being able to ride it, it feels like the engine is solid in there and it feels like it has far better throttle response than it ever has.

I ended up being able to massage my Franken-pipe successfully to fit just right, so no need to make a new pipe like I was going to. So far so good!

https://www.youtube.com/watch?v=O7a4FNwmG-U

[fabiodriven]

I'm really excited for this machine right now and looking forward to the arrival of the half link so I can ride it. Started with a 52 pilot, then 50, then 48. It feels crisp and runs great with the 170 main jet, but I won't know what it's going to need for a main until I'm able to get it hot, and even then it might have to be jetted again in Indiana.

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[trikelife101]

That things friggin cool!!!