'83 ATC 480R Starting The Fabrication

[Bigbore]

I wasn't sure if I was going to do this or not... But some of you guys are trying to do the 480 conversion on the Gen 2 and I'll try and make it easier for you.

Anyway, My '83 R needs a new set of rings so I figured I'd work on building a set of motor mounts and spacers for a CR 480 / 250R conversion. I'll tear my '83 to make the conversion parts then put my 250 back in.

This one is a little more involved than the ‘ 82, but shouldn't be a problem. The 480 motor fits in the '83 frame fine. The lower frame motor mount bolthole can still be used. The rear mount will need more fab work than the conversion for the '82. The front mount is also going to take a little more ingenuity since the '83 only has 1 through bolt mounting to the frame. I will probably work on a small set of supports going to the front skid plate boltholes. The larger problem is the head stay mount. There isn't anywhere to mount it to.

Since the airbox isn't going to work with the new motor, it might work to make a crush bushing with a 10mm hole. Install the crush bushing in the downtube just ahead of the gas tank hold-down bolt. Drill a 10mm hole in each side of the downtube, then install a head stay bracket.

The best part is it should be a completely bolt in conversion.

I'll work on it over the next few days and post more photos of the progress.


Here are some photos of the motor resting in the frame.

[JasonB]

very informative! I would def like to buy the conversion for the 83-84 this winter to use for my cr480 drag bike if I decide to go ahead with the project. For some reason I had thought you were using the second gen as the original bike for your conversion kits, not the first gen. Good work though, and will there be any issues with the exhaust plumbing?

ps I really like those head lights! That bike looks nice man I like the accessories

[Dammit!]

I've only ridden one CR480 in my life. I was only about twelve at the time but man that thing was mean. I can just imagine how much fun that would be in a trike.

I've been trying to remember what year it was. I always want to say it was a 1984 but did they even make them that year?

[Tri-ZNate]

When you make all the brackets and such you have a money order here with your name on it :D. This is the easy way out for me. I was hoping you were gonna do this project soon :naughty:

[Huffa]

I've only ridden one CR480 in my life. I was only about twelve at the time but man that thing was mean. I can just imagine how much fun that would be in a trike.

I've been trying to remember what year it was. I always want to say it was a 1984 but did they even make them that year?

Nice fab jobs you do bigbore, what color is that frame, a grey or a silver, I like the headlights too, very cool. OH, and the PRM products too, since I just ordered them myself, the skid plate I really like, very heavy duty.

Dammit, the 480 was made in just 82 & 83 , 81's were 450's and 84 were 500 liquid cooled jobs.

[3Razors]

1985 was the first year of the liquid cooled cr500.

1984 was the only year ever of the air cooled cr500.

Cool project by the way!

[Huffa]

1985 was the first year of the liquid cooled cr500.

1984 was the only year ever of the air cooled cr500.

Cool project by the way!

Your right, then it was a 85 I had, 23 years ago I guess I can be excused for forgetting what year I had ! :lol:

[Bigbore]

Nice fab jobs you do bigbore, what color is that frame, a grey or a silver, I like the headlights too, very cool. OH, and the PRM products too, since I just ordered them myself, the skid plate I really like, very heavy duty.

Dammit, the 480 was made in just 82 & 83 , 81's were 450's and 84 were 500 liquid cooled jobs.


Thanks!

The frame is a metallic gray/silver powder coat. I wish I would have gone with the aluminum metallic instead... oh well. The headlights are 5" 55w stainless steel Pro Comp's. They were $50 each I think. The mounts were easy. PRM's skid plate's and grab bars are top rate!

[Bigbore]

very informative! I would def like to buy the conversion for the 83-84 this winter to use for my cr480 drag bike if I decide to go ahead with the project. For some reason I had thought you were using the second gen as the original bike for your conversion kits, not the first gen. Good work though, and will there be any issues with the exhaust plumbing?

ps I really like those head lights! That bike looks nice man I like the accessories

The other thread is for the Gen 1. That's the one I want for me. The Gen 2 is to help you guys out. Not sure on the the pipe yet. I'll get the mounts done then see what can be done. Sure like the hydroforming thread though.

[vegas250rr]

I like what your doing here !

[JethrowMan]

hey thats great i am going to order both! i love them air cooleds and have a 82 and 83 int he works i just hope that my ct racing custom pipe fits on that 83 480

[Bigbore]

I like what your doing here !

Do you remember the '82 250R from Las Vegas craig's list back in May for $250. It's the one I used for the '82 480r build.

[vegas250rr]

must have missed that one.... DMAN DMAN DMAN

[wizzard]

If your going to make it that easy, I guess I have no excuse not to build my own conversion.

[protraxduner]

Does the kickstarter clear the frame in either one of these conversions.

[Bigbore]

Does the kickstarter clear the frame in either one of these conversions.

On the '82, the kicker clears the frame fine by bending it alittle.

On the '83, Don't know. Haven't gotten that far yet. Just got the rear motor mounts done last night. Still working on the front mounts. I'll need to get the motor mounted in then I'll have a better idea. I need a steel kicker from a CR 450. Anybody have one?

[protraxduner]

Keep me posted I am interested in the kit. Seems like the kickstarter is usually the hardest thing to make work unless you get lucky and it just happens to clear everything. Question maybe you or someone else on the board can answer. I am wanting to build a sleeper old school 250r with 480. I have a 84 roller and assume it will ride better than the 81-82 models, but really like the old school look of the 81-82. Does anyone know what kind of work it would involve putting 81-82tank/seat/plastic on a 83-84 model. thanks

[Bigbore]

The tanks are totally different. The hold down bolts on the '82 is in from the side and the '83 is on the top of the down tube. The seat also mounts differently.

"Form over function" or "function over form". I guess if you like the look of the '82, a Works Performance shock on the rear and a rebuilt front forks with some new springs would go a long way on an '82.

The 480 conversion is easier on the '82 than the '83 but when I get done with the kits neither one should be that hard. I might have the pipe issue worked out on the '82. I just need to get everything back from the powder coater to verify. A pipe for the '83, not sure yet:wondering .

[Tri-ZNate]

Hows it commin? Any progress?

[Bigbore]

I went to Vegas for a week over Thanksgiving and was swamped in the shop before I left. I got a new press brake and ironworker. Trying to get them in place and under power.

The '83 480R... I should have all of the mounts done by Friday. I'll have more photos to post of the progress on Thursday and Friday.

[Tri-ZNate]

http://www.xsltblog.com/archives/24805BP~The-Simpsons-Mr-Burns-Excellent.jpg

[vegas250rr]

what the???? NOBODY TOLD US A BROTHER WOULD BE IN TOWN!

[Bigbore]

I know I should have said something, but it being Thanksgiving and all I didn't want to take up anyones time when everyone already has a busy schedule. Just went there to get away for a couple days. Had the wife and kids:crazy:

I'll be back for the Shot Show in 2 months

[scrawny]

cant wait to start to see it come together kewl bike!

[250rfreak]

hows it coming?

[riverrat]

Thanks!

The frame is a metallic gray/silver powder coat. I wish I would have gone with the aluminum metallic instead... oh well. The headlights are 5" 55w stainless steel Pro Comp's. They were $50 each I think. The mounts were easy. PRM's skid plate's and grab bars are top rate!

You don't have any issues running 110watts off your stator?
I am asking because on my 200x 84' the original headlamp is 60watts. I wanted to step up to dual lights like you have, but I am worried about frying the stator, or rectifier.

Same thing with my 85R, that only came with 45watt bulbs. I am sure I will need more light than that. I like to run on the ice in the dark :rolleyes:

[Bigbore]

You don't have any issues running 110watts off your stator?
I am asking because on my 200x 84' the original headlamp is 60watts. I wanted to step up to dual lights like you have, but I am worried about frying the stator, or rectifier.

Same thing with my 85R, that only came with 45watt bulbs. I am sure I will need more light than that. I like to run on the ice in the dark :rolleyes:

I got a 110 watt Ricky Stator and it runs both lights at the same time perfectly. One light is a wide beam and the other is a narrow beam. When their both on WOW!

I'll get some more done on the '83 480 swap, I've just been burried getting the shop put together and tring to get the pieces back so I can get the '82 done.

The shop is coming together nice. I have the CNC Bridgeport up and running, the press brake and the iron worker are under power. That'll be another thread....

[factoryX]

you should get the baja lights...

[xerkie]

Ive had the 83 480 engine for 2 years now trying to figure out the best way to do this. I had actually given up and was recently thinking of selling the engine and bike... Glad I didn't. You can totally count me in if you're still going to make a kit to sell. Until now, I hadn't gotten a lot a direction from people...

[Bryan Raffa]

Ive had the 83 480 engine for 2 years now trying to figure out the best way to do this. I had actually given up and was recently thinking of selling the engine and bike... Glad I didn't. You can totally count me in if you're still going to make a kit to sell. Until now, I hadn't gotten a lot a direction from people...

hey :welcome: now ya got a reason to stick around! I would be intrested Too..and I think there's another who has plans for one..

[GoodKarma]

I can't wait to hear that this is ready! I purchased a motor last year, and this will surely make me want to start on this project with a more positive outlook!:w00t:

[Bigbore]

I know it doesn't seem like it but I am working on this one too. I'm trying to get the '82 assembled and I'm wait for parts for the '83.

Here's where it is the motor mounts are done. They’re a lot more involved than the ones for the '82. I'm working on the kicker problem.

I've ordered a custom female splined shaft and a male splined shaft. Each has the same splines as the kicker. What I'm thinking is building a bracket that will attach on the kicker side under the swinger nut. The whole thing would be a bolt on item. The bracket will have a bronze bushing in it and will be able to support the kicker shaft extension. The assembly should be "clean" when I'm done.

The spline shafts where a custom order and they had to make it so I'm still waiting for it to show. When it does I should be able to get everything wrapped up pretty quick.

[xerkie]

Anyone know where I can find a extended swinger for an 84 R? Oh and the electronics for the 83 CR 480R?

[Tri-ZNate]

Anyone know where I can find a extended swinger for an 84 R?

The only thing you'll find is an old school one, or have a shop make your stock one extended

[xerkie]

Found the 480 Cdi unit, just need a coil????

[xerkie]

Does anyone know if the 82 cr 480 electronics while work for the 83 480's...Having trouble finding an 83 coil, but I'm seeing them for the 82's. And if so, will the 82 coil work with the 82 CDI or should I use electronics for the same years? I know this is a 3wheeler forum, but as soon as Bigbore is manufacturing the mounts I'm putting in the beast....

[250rfreak]

how much will this kit cost once done???????

[xerkie]

There's money burning a hole in my pocket....

[GoodKarma]

How's this build coming along? Do you have motor mounts you want to sell?:Bounce

[Bigbore]

Work has been a killer. I have 2 different gun projects that I've been working on; one new one and one that has come back to life after 12 years.:wondering

I've got the mounts 90% done. One of the mounts has a tight bend in it that I can't do in-house. So it's easier to make it in two pieces and TIG weld it together. I'll have the motor mount kit done in a week or two. The kick starter extension shaft and support bracket will come together when the company making me the shafts gets them done. So when I sell these the price is for the motor mounts and bolt hardware and NOT the kick shaft extension and bracket (that'll cost extra and I'll know how muck when I get the shafts in).

Anyone that wants a set will need to let me know and I'll get them on a list. I'm only going to make enough to fill the initial list. After that you'll need to get put in for the next run (when ever that is:lol: :lol: )

[xerkie]

Bigbore...thanks for the update. You can count me in for brackets and shaft. Just let me know when it's ready and I'll send the payment.

[GoodKarma]

Put me on the list! Tell me where and how much money to send, and I'll start selling blood to be sure this starts moving forward!

Are you able to use the rear motor mount setup from a stocker, or does it have to change too? I now see the issues with the front mount, after I placed the motor in a bare frame this weekend.

I'm EXCITED now! This will be a fun build for the summer.......:w00t:

[Bigbore]

Put me on the list! Tell me where and how much money to send, and I'll start selling blood to be sure this starts moving forward!

Are you able to use the rear motor mount setup from a stocker, or does it have to change too? I now see the issues with the front mount, after I placed the motor in a bare frame this weekend.

I'm EXCITED now! This will be a fun build for the summer.......:w00t:


:lol: :lol: :lol:
Blood! I'll let you guys know when and where when their ready to ship, 2 weeks.


Yea, the rear motor mount gets changed to fit the rear of the 480. Since the shock mount is in there, it gets incorporated into the new rear mounts also. The motor mount kit will have a new rear mount, front mount, head stay and bolts.

After the company gets the kicker shafts to me then I'll sell the kicker shaft extension and the bracket w/ bushing. The company is pretty cool on making custom shafts... Expensive though! http://www.grobinc.com/coldrolled/

[Tri-ZNate]

very cool. You got my PM correct? I want the whole package

[Bigbore]

very cool. You got my PM correct? I want the whole package

Got it.

Did you want the mounts to ship with the shaft kit or do you want the mounts first to get started? and ship the shaft when it comes in?

[Tri-ZNate]

Got it.

Did you want the mounts to ship with the shaft kit or do you want the mounts first to get started? and ship the shaft when it comes in?

Just ship everything at once, probably save on shipping and easier

[GoodKarma]

PM sent, as I would be interested in mounts if they are ready first:w00t:

[Bigbore]

PM sent, as I would be interested in mounts if they are ready first:w00t:

Got it. Mounts will be ready to go next week.

I'll get the motor in and mounted by Wednesday and post some photo's.

[83250r]

how fast is the 480 motor would it beet a liquid cooled r's ?? never heard of cr 480 until like 2 weeks ago and if you are selling a kit for the 480 motor i would like one as well

[Bigbore]

how fast is the 480 motor would it beet a liquid cooled r's ?? never heard of cr 480 until like 2 weeks ago and if you are selling a kit for the 480 motor i would like one as well

The stock 480 will walk away from a built H2O-R.

Almost done with all of the mounts. Just working on the head stay mount and tring to make it so it can be done without drill the frame.

[GoodKarma]

Many thanks for helping those of us that don't have the means to manufacture stuff in our little garages!:Bounce

[xerkie]

So is there a status update?

[laidout2times]

yeah.. curious how its all progressing. I since the start of thiese builds I feel that 480's are harder to spot. Could be in my noggin though.

[85_200x]

yea more pics!!! just put new piston and rings in my 480r tonight! cant wait to fire her up! l
looking good! GL on the build!

[xerkie]

Bigbore, did you give uo on the project? Still have everything in storage, just waiting for the mounts and maybe idea's for the exhaust...

[Bigbore]

No not really. I've just been slammed at work. I've got deadlines at the project I'm doing at the USAF Academy. So trying to get Uncle Sam done, going to the races for my kids, building their machines, and trying to get the '82 480R done I had to set it in the corner for now.

I'm wrapped up at the USAFA job in 2 weeks and the kids are done with flat track now, so I can get back into the shop soon.

Sorry to keep you guys waiting....

[harryredtrike]

that should be a mean motha trucker

[this guy]

How would an IT490 (has porting work done) compare to the CR480? What is with the Husky side kicker on those?

[Shorty]

Count me in for one of these kits. I WANT the whole 9 yards. The kicker, motor mounts EVERYTHING

[oldtoys72]

Has there been any progression with this? I am very intrested in getting the kit so I can slam a 480 in my 83 fooler!

[oldtoys72]

Still no updates?

[cr480r]

bump. curious if the 2nd gen swap worked out.

[sbjones73]

any idea on price for the mounts ? and then for the mounts with the shafts?
thanks

[Brokenmike]

Iam REALLY interested in a kicker set up. I have had a cr480 bolted up in a 84 ATC 250r for about 3 years and I came to a halt at the kicker and the pipe. The engine is all rebuilt too. That's about all I need. What did you do for a pipe?

[TheRealFatShady]

Brokenmike - can you use it, you just need it to kick forward to clear the fenders? I may cut the left side fender off to fit on my 82R......

[gumbyspeed]

Here is what i did. I extended the kicker 3 inchs out from the motor and took out and inch in the length (made it lovely to kick),and made the peg removable with a quick release pin. let me explain the peg a little better. Drill the threads out of the peg mount (the threaded part on the frame). take the peg and weld a peice of round stock in the peg bolt holes. insert the new modded peg into to the frame and drill a very small hole through bolth the frame part and the round stock part of the peg. go to home depot and get the quick release pin first. They look almost like a safety pin. If you would like to see this i did on my 84 200x with a 84 cr500 in it posting. hope this helps, if not its my 2 cents.

[Brokenmike]

My problem is the kicker hits the frame. I only need to come out about 1" 1-1/2" so the kicker will clear the frame. I have never tested it with fenders

[ATCThumper500r]

Hello bigbore, im building a ATC480r trike, and was woundering if you had the bolt up kit for this motor. Its going on a 83 ATC250r.

[xerkie]

I have a complete 1983 480R engine for sale if anyone wants to do the swap. Comes with complete top and bottom engine, carb, intake, and coil.

[motoman1012002]

147628 dont if this is it or not but found this pic today

[Williejamehufff]

Bump

Was this project finished?