85 Tecate Plus One KX500 Motor [Archive]

BigGreenMachine

08-31-2006, 05:40 PM

Looking to make the swap before Christmas comes. I know the lower frame rails need to be changed as does the downtube but its fully within my limits to do so. What else needs to be changed to fit this motor? I assume the rear swingarm/motor mounts line up and fit just like the 86/87 Tecate/KX500?

In any case look for this swap to take place as well as a no link rear suspension swap.
James

moose 53

08-31-2006, 08:05 PM

I did a swap of a KX500 to a 85 Tecate a few years ago .You have to mod the frame ,if you have the dirt bike frame just cut out the part you need and weld it to the Tecate frame .I also had to cut the the 500 pipe so it would come out on the same side that the Tecate pipe did. Take your time and you shouldn`t have any big problems.

3Razors

08-31-2006, 08:47 PM

I would run with the 89 and later motors. They have better transmissions and more parts available.

BigGreenMachine

08-31-2006, 11:33 PM

Thanks fellas, thats some solid info right there!

Are all KX from 89 and up the same motor?

BigGreenMachine

09-01-2006, 12:36 AM

Its funny, to say that this is a hard swap isn't really true. Swap frame rails and part of the downtube and the rest is cake aside from making the expansion chamber line up. Reinforce the frame itself and use slugs at the joins between the KX and KXT frame..oh my...now the hunt for a good motor and used frame begins.

James

3Razors

09-01-2006, 02:27 AM

Yes the 89-04 motors are identical. It is a super easy easy swap. Cant really get any easier in my mind. Use the 500 pipe, making it fit in a tecate will probably be the hardest part of the conversion, unless you run with a side pipe. Build it strong because the kx motor will try and break mounts, ect. To minimize the vibration put a "bar snake" in the handle bars and use foam street bike grips. If your lucky you can find a donor KX500 for cheap. That way you will get all the other components so it wont nickle and dime you. Keep us posted cause I want to see it evolve!!

BigGreenMachine

09-01-2006, 10:20 AM

What about cooling? Will the stock tecate rad cover it or should I mount up the KX rads somehow?

BigGreenMachine

09-01-2006, 11:58 PM

For anyone interested the Tecate radiator will cool the big 500. On that note it'll be wise to run engine ice coolant as a precaution.

James

scooterroo

09-02-2006, 10:12 AM

big green, cant wait to see this thing take shape. you using an 84-85 model or the 86-87 model as your base to start off? is this something your doing to your current ride or are you getting another one to start fresh with?

BigGreenMachine

09-02-2006, 03:53 PM

Using my current 85 frame and modding/making the engine cradle fit the 89-04 KX motor. Will have the funds to buy parts in two weeks.

Big, BIG thanks to Moose53 for letting me pick his brain about the swap and having the patience to put up with a young'in like me.

l8r

BigGreenMachine

09-24-2006, 05:23 PM

Have an 88 KX500 motor paid for including all electronics and misc pieces I need. Still looking for a pipe. Will be building the cradle and I've decided I'll build a +6 swingarm out of steel rectangular tubing. Whats a good wall thickness swingarm building?

Should motor mounts be made from steel? What thickness?

BigGreenMachine

09-24-2006, 05:24 PM

My motor sitting in its old home.

http://img.photobucket.com/albums/v514/BigGreenMachine/Tecate/kx3.jpg

hadar

09-24-2006, 09:51 PM

What are you going to do about the pipe? Are you going with a custom pipe or do you have somthing in mind that will fit with a few mods? Sounds like she could turn out to be pritty mean.I got an 88 kx250 and it's power band is sweet, I love that bike. I can only imagine the kx500 I'm sure she will produce big bore horse power in a trike. :naughty:

BigGreenMachine

09-25-2006, 03:28 PM

I plan on buying the stock pipe and reworking it to fit.

Anyone have some good airbox ideas?

BigGreenMachine

10-05-2006, 03:38 PM

Heres where I am. Stripped trike that is waiting on the 500 motor. Motor should be here by the end of the month. PLan is to mount the motor, mod the pipe then work on the extended swingarm and no link rear suspension. LOTS TO BE DONE!!

http://img.photobucket.com/albums/v514/BigGreenMachine/PHOT0001-1.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/PHOT0004.jpg

scooterroo

10-05-2006, 03:40 PM

wow, are you modifying the down tube on the frame? cant wait to see this thign when its done bgm, gonna be bad ash!

BigGreenMachine

10-05-2006, 03:51 PM

Yeah the downtube and engine cradle will be taken out and replaced. Lots of work. Funny thing is that my welding course will be covering tube bending in the next few weeks so thats a bonus. Also I figure I'll be able to weld up an aluminum airbox at school as well. Want to use a BIG air filter to make the 500 breathe right.

Thanks for the complements Scoot.

BigGreenMachine

10-05-2006, 08:04 PM

Here is the swinger I plan to build. The middle will have a backbone like the pictured Cal-fab that will have three different shock mounting locations. The front will be stock ride height, then by moving to the mounts further back you can lower the ride height to match lowered forks.

http://img.photobucket.com/albums/v514/BigGreenMachine/Tecate/swing.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/Tecate/calfab1.jpg

youngbansheeman

10-05-2006, 08:10 PM

Good luck Put some pics up when you finish it Might buy 1 from you

Bigbore

10-05-2006, 09:41 PM

If your doing all the work to make a new swingarm then think about making it like the 400ex and using the 400 ex bearing carrier. The you can get new axles etc.

BigGreenMachine

10-06-2006, 06:43 AM

I would but I can't afford to. The Tecate axle is fine for now. That will be a step for the future (next year when I have a nice little income).

moose 53

10-06-2006, 09:54 AM

When you get to the brake line for your swingarm let me know .I will tell you how to make a stainless steel braided line colored to match your bike.If you have access to a lathe and press you can make it yourself for about $30 materials, very easy to make. :Bounce

maggiesboy

10-06-2006, 10:13 AM

Bigbore

10-06-2006, 10:14 AM

I would but I can't afford to. The Tecate axle is fine for now. That will be a step for the future (next year when I have a nice little income).

Yea! I know. For me, I just can't justify $200 or MORE for a tecate aftermarket axle when I can get a brand new G-Force +/- 2" for $199. And never have to worry about obsolete parts.

The swingarm wall thickness should be .125 to .187 of an inch. The dimensions should be close to 1.5" x 2.250" by the length. See if anyone around you has the rectangular aluminum stock, if not let me know. We have an aluminum supply company that sells drops and doesn't mind cutting shorter pieces. It running about $3.00 to $3.50 per pound for 6061-T6.

The one I'm making is solid with milled pockets to reduce the weight and increase the strength. It'll be a little heavier or close to the stock swingarm weight. I saw the design of yours and the Cal-Fab, looks good.

BigGreenMachine

10-06-2006, 01:03 PM

Robin I'll be looking you up for a coloured rear line when the time comes.

Bigbore, I plan to use steel for the arm unless I can get a good deal on aluminum locally and weld it all up at the college.

moose 53

10-08-2006, 09:59 AM

Here is a photo of the brake line I made for a Banshee the other day. Also a sample of other colors from Rit Dye. http://i84.photobucket.com/albums/k10/moose53_2006/DSC00319.jpg :Bounce http://i84.photobucket.com/albums/k10/moose53_2006/DSC00643.jpg:Bounce

Billy Golightly

10-08-2006, 12:36 PM

I think you need to make a thread and let all of us know how you make those :)

Tecate250

10-08-2006, 08:13 PM

I just found a score I can't refuse.
A Mint 87 kx 500 with spare motor and a complete set of plastics That have no holes drilled out yet for 800$
My friend found it and wants me to buy it.
Big green has me thinking.
And there is another tecate frame around here too.

BigGreenMachine

10-08-2006, 08:23 PM

Do it!

I found some info tonight on using expanding foam inside the bars/frame to deaden the vibrations from the big 500. Also made a deal for a used KX500 pipe that I can mod to fit.

OZQUAD44

10-09-2006, 08:38 AM

Does anyone know if a 84/85 swing arm will bolt into and 86/87 Tecate?

Bigbore

10-09-2006, 11:11 AM

Does anyone know if a 84/85 swing arm will bolt into and 86/87 Tecate?
NO. The offset is wrong.

OZQUAD44

10-10-2006, 06:14 AM

NO. The offset is wrong.

Dam

Cheers bigbore

BigGreenMachine

10-10-2006, 04:44 PM

Got your eye on that +8 chrome swinger thats listed on egay? You could make it fit by changing the shock mount location rather easily IMO.

Bigbore

10-10-2006, 09:50 PM

Its too long for me. I want a +3 or +4, I do a lot of trail riding.

3Razors

10-10-2006, 10:44 PM

OZQUAD44

10-11-2006, 07:32 AM

Got your eye on that +8 chrome swinger thats listed on egay? You could make it fit by changing the shock mount location rather easily IMO.

No there is a white one that has been listed a couple of times, plus 4 I think. Made from round tubing. It looks like a professional job.

Is the shock mount location the only difference between the 84/85 and the 86/87 swingers?

Bigbore

10-11-2006, 12:13 PM

You are going to need at least a +8 for a KX500, even still that will not be enough length to keep the front down. The stock tecate swingarm is ridiculously short. Any amount of throttle and you will be on your back:(

But I'm not running alcohol, or paddels.:naughty: I plan on 20" bandits, a mild port motor, with a pipe. With a +4 it would have nearly the same wheel base as my kx500 and I handle the front end ok.

BigGreenMachine

10-11-2006, 01:34 PM

That white swingarm is a copy of the Champion design. Very nice design. Buy it and have the UNI linkage mount moved over to suit.

Bigbore, 3razors, I'm going to test ride the 500 swap with my +2 swingarm just to see how uncontrolable it is.

3Razors

10-11-2006, 05:42 PM

Just be careful...I hate to see anyone get hurt.

On bikes the added length really isnt nessesary and most of the power is lost in wheelspin. Quad and trikes get at least 4 times the traction.

BigGreenMachine

10-11-2006, 06:19 PM

Just be careful...I hate to see anyone get hurt.

On bikes the added length really isnt nessesary and most of the power is lost in wheelspin. Quad and trikes get at least 4 times the traction.

I'll be careful, definately going to respect it.

I hate the idea of putting a +6 on this thing. Where and how I ride really calls for a short wheelbase and the ability to turn on a dime.

Think these will find traction??!!:lol:

http://img.photobucket.com/albums/v514/BigGreenMachine/Tecate/PHOT0015.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/Tecate/PHOT0017.jpg

Bigbore

10-11-2006, 09:54 PM

Where did you get the clean looking rear plastic for your T3??

3Razors

10-12-2006, 01:25 AM

Ya KX500's definately play for keeps! It'll give the spider trac's a serious workout. Nice tire choice!

BigGreenMachine

10-12-2006, 06:40 AM

The plastic is Maier. Thanks 3Razors.

Bigbore

10-12-2006, 11:08 AM

The plastic is Maier. Thanks 3Razors.
I thought Maier only had rears in a "low-profile" style?

BigGreenMachine

10-12-2006, 02:21 PM

Oh, my bad. I forgot to mention it was 86/87 style Maier fenders. They basicly fit right on there with the addition of a new fender support.

BigGreenMachine

11-02-2006, 07:34 AM

What thickness steel for motor mounts? Would aluminum hold up as motor mounts?

Bryan Raffa

11-02-2006, 08:39 AM

most all are 1/8 to a 1/4 and aluminum YES they will hold up...

ausatc70

11-02-2006, 05:39 PM

man this is going to be sweet! i used to race a 2000 kx500 and it used to bite me all the time! cant wait to see the finished product!

BigGreenMachine

11-08-2006, 05:40 PM

Motor arrived last night. First impression was how much bigger the 500 is then the 250. Second impression was how nicely everything looks to fit.

http://img.photobucket.com/albums/v514/BigGreenMachine/T5.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T52.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T53.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T54.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T56.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T57.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/T55.jpg

BigGreenMachine

11-08-2006, 05:47 PM

The rear swingarm bolt lines up perfectly. I think anyone wanting to do this swap will need to convert the bike to a no link suspension setup (will confirm this tonight/tomorrow). The bottom mount/front mount and top mount needs to be fabricated. The top bar that holds the CDI and coil needs to be removed. The kickstart and chain clear the frame with room to spare. The brake lever will need a new bend to clear the side cover. Thats all for now.

moose 53

11-08-2006, 10:52 PM

Sure would like to see the look on your face when you ride it for the first time.The combination of shock, fear ,and grins and giggles is pretty funny.:Bounce

SYKO

11-08-2006, 10:58 PM

is it me or does the bottom of the motor in relation to the frame looks like its tilting to the right some, in the rear pictures? just woundering, also what are your ideas for the exhaust? splittin the frame?

BigGreenMachine

11-08-2006, 11:23 PM

Yeah the frame/box is tipped slightly. I caught that earlier.

BigGreenMachine

11-10-2006, 04:53 PM

Lots of room for the sparkplug and cap once you remove the CDI bracket. Spent tonight lining up the sprockets and taking measurements only to take it all apart. I will start again in the morning.

http://img.photobucket.com/albums/v514/BigGreenMachine/T58.jpg

nd4speed

11-10-2006, 05:57 PM

Thank you for all the nice pics. Cool project!

Now if someone would just do the same but for the 86-87 T3.

OZQUAD44

11-12-2006, 06:07 AM

That "CDI" bracket acts as a brace for the frame, are you going to replace it with another one?

Tecate250

11-14-2006, 06:28 PM

Wow.
I can't believe how nice it really fits.
Has me thinking of my kx 500 + motor that will be here in april.

BigGreenMachine

11-14-2006, 08:30 PM

Yeah there is a load of room everywhere for the motor. I haven't checked the rear suspension linkage for fitment around the new motor but I suspect it would work.

I'm waiting on bushings to be cut by our local machinest that will center the motor in the swingarm location. After that I will make my top motor mount and then the engine cradle will be remade to allow the pipe to exit in the new location. The KX500 pipe needs to be cut and the bends changed but its straight forward and should look top notch once done.

Should add that I've picked up Argon/Co2 gas for our mig, the thinwall tubing and paper thin pipe will be no trouble to weld now. This stuff is fun with the right tools.

BigGreenMachine

11-28-2006, 06:07 PM

Quick update. Had these bushings made by a local. The aluminum pivots on the brass while the brass holds the motor in place and lines up the rear sprocket. This is the beginning of my swingarm.

http://img.photobucket.com/albums/v514/BigGreenMachine/jl.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/kl.jpg

http://img.photobucket.com/albums/v514/BigGreenMachine/kj.jpg

scooterroo

11-28-2006, 07:44 PM

damn bgm, nice write up so far.

BigGreenMachine

11-28-2006, 09:09 PM

Thanks Scoot. I'll be adding to this thread until I'm done. Things should go a little more quickly now I think.

cr480r

11-29-2006, 04:56 AM

That thing is going to be so sick. I have a special place in my heart for Big-bores and trikes. This is better than a wet-dream...

BigGreenMachine

12-07-2006, 09:01 PM

Super stoked tonight. Decided I want to ride so I'm putting the aluminum swingarm build off until spring.

Good news for us Tecate guys. The 500 motor will bolt into the rear mount, the swingarm/shock linkage will bolt up and all is well in the rear end department.

Thats where I left off. LEft to do is the top motor mount, new frame rails, bottom/front motor mounts, reconfigure the exhaust pipe, take care of the airbox
and some misc stuff.

Stoked!!

3leggeddog

12-07-2006, 09:14 PM

sweet man,looks like a nice build so far.get that thing done!!

cr480r

12-08-2006, 03:17 AM

I can't wait to see it on here. This is my favorite thread. Keep up the good work.

BigGreenMachine

12-08-2006, 03:40 PM

I'm out of welding wire, need to pick some up and still haven't gotten my 1'' diameter tubing for the frame.

Brockey

12-11-2006, 02:39 AM

How ya doing BigGreen? Where ya too in Newfoundland. St. John's here. Would love to see the project in person. Keep it up man.

BigGreenMachine

12-11-2006, 08:05 AM

Hey Brockey, its good to see another local on the forum. I'm about 3 hours out side of St.John's on the Burin Penninsula.

Tecate250

12-11-2006, 02:01 PM

Up the east coast or alond the south coast?

cr480r

12-30-2006, 06:39 AM

How is the swap coming along?

uktecate500

12-30-2006, 08:36 AM

to anybody thats interested
im using a no link pts shock in my kxt but im also using the 87 kx500 frame with ally subframe. main prob with that is the spring strenghth as its used to being a near horizontal shock. also notised that the ktm shock are very long.
how will you fix the top of the shock as theres no frame brackets?

BigGreenMachine

12-31-2006, 01:19 PM

I'll be making frame brackets to bolt the shock on end of the frames backbone.

No progress. Buying nic-nacs to help things go together smoothly. Need a KX500 frame, prefer an 87-up.

moose 53

12-31-2006, 02:46 PM

I see you have come to the conclusion the using the bike frame is the best way to go.With the KX500 you should upgrade the suspension and the swing arm anyway. Between the two I like to use as new a technology as I can.:Bounce :w00t:

BigGreenMachine

12-31-2006, 03:20 PM

I'm going to graft the 500's engine cradle/downtube onto the Tecate frame. I like new technology but this is kinda budget minded at the moment.

Got a thumb throttle bought, rear brake rotors and another T3 frame on the way. Lots of stuff that I plan to add to this bike in the near future. Stay tuned! lol

cr480r

12-31-2006, 06:52 PM

I was going to use a Kx frame for my project, but I have decided that a modified KXT frame will make for a better handling machine. I am curious to see how yours turn out, as I am doing the same thing. I am using a 250 motor though.