Kawasaki Mocate Built

[sticker_sääp]

After i had some requests from my ATC 250R Threat i will now start a report about the design of my Kawasaki Mojave x KX250 Frankenquad...

http://www.3wheelerworld.com/showthread.php/175647-Built-from-scratch-250R

A few years ago i think in 2011 i bought two Mojave 250´s in order to get out one running streetlegal one:

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So i had one frame laying or better said hanging around...

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[sticker_sääp]

Back in that days i was away on a job in the USA in order to get that baby running at a big american electric company near Schenectady

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I used my free time in the states to find an engine for this built on craigslist...

It was an old (89) KX250 engine which i bought from a guy somewhere near Lake George:

(Don´t ask me why these guys had a bavarian flag in there shop...)

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The engine was in an excelent shape, i just had to sleeve it and did some minor welding on the case...

[sticker_sääp]

After some trouble with your trailprotrailprotrailprotrailprotrailprotrailprotr ailpro TSA guys that found minimal traces of gasoline on the engine parts in my toolbox and did the whole "terrorist program" to me i had to sent it via post from JFK airport home to me... Thats why the engine was not that great deal compared to regular european prices.

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Lesson learnt... Dont bring your engine to an american airport in times of war against terrorism:twisted:

[sticker_sääp]

While waiting for the engine i had time to disasamble the chassis and buy an dutch Van Helsing (or somthing like that) tuning pipe... Nowadays i would just built them :Bounce

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[sledcrazyinCT]

Sucks the TSA made you ship your motor instead of stowing it on the plane. Just checked out your CR250 trike build great job. Speaking of jobs if you don't mind sharing who do you work for? Thought maybe SECO Tools from your sketch pad in other thread, but then I see you came to the US to set up a robotic arm.

How close are you to Wehingen, DE? If you ever start making billet covers and side cases maybe we can work around the high freight and customs charges if you are close to Wehingen.

[sticker_sääp]

Sucks the TSA made you ship your motor instead of stowing it on the plane. Just checked out your CR250 trike build great job. Speaking of jobs if you don't mind sharing who do you work for? Thought maybe SECO Tools from your sketch pad in other thread, but then I see you came to the US to set up a robotic arm.

How close are you to Wehingen, DE? If you ever start making billet covers and side cases maybe we can work around the high freight and customs charges if you are close to Wehingen.

Thanks!

No it is not SECO Tools, i installed the robot for a Company that is called Dorst Technologys, they built large hydraulic presses for hightec applications...
But at the moment i work as a design engineer/project manager for a large german electronic manifacturing service company, where i design and plan the production lines.

There is a google maps screenshot about my distance to Wehingen:

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I think for american standarts it is close...

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Found some older pics of the trailprotrailprotrailprotrailprotrailprotrailpro up orginal frame:

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The first fitting test after the engine was delivered:

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The position of the swingarm bolt was perfect for the engine swap, i just needed to built some engin mounts, cut the pipe into pices and then somehow assemble everything together...

I hearde some storys that team green or another kawasaki race team built some of these Mocate/Tecate Hybrids as race machines, just befor the Tecate 4 came out... Has anyone infos about that?

[sticker_sääp]

I tried to use as much original parts as posible because i had them laying around...

So i just sandblasted/cleaned them and pissed a bit of colour over them:

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Design proces of the hood:

I know there is one from maier available but money was tight these days...:beer
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[onformula1]

That was the MOCAT.

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Stainless steel upper engine mount:

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Back there i made the first experiments with tig welding...

We only had a DC tig welder, so everything was built from stainles steel.

[sticker_sääp]

That was the MOCAT.

Have you got a link or some pics of that somewhere?

[onformula1]

I will try and look it up, getting late here, thanks

Sent from my SM-G386T1 using Tapatalk

[sticker_sääp]

There was no chance to use the ebay pipe without modification, so after turning that thing around for an hour i finaly cuted it into pices and welded it together again:

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[sticker_sääp]

The rear shock needed some adaption but then it fitted in great:

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View of the left side with the carb:

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[sticker_sääp]

Pipe position was freezed, so the lower engine mount were built:

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It is ugly but functional, that thing also holds the nerfbars...

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Some more pictures of freshly built and painted gizmos...

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Then it was time to paint the frame... That was a quite bad idea...

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Always test everything before you do the paint job.

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Assembling of the painted frame and the ramaining "periphery":

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[barnett468]

.
Unfortunately I can't see any of your photos but it sounds like a cool project.

I did all the development testing on those at Kawi and even built one and raced it a few times . . I also bought a nitrous kit but never got time to install it . . I thought that would have been fun.

Anyway, hope it turns out hw you want.

[sticker_sääp]

.
Unfortunately I can't see any of your photos but it sounds like a cool project.

I did all the development testing on those at Kawi and even built one and raced it a few times . . I also bought a nitrous kit but never got time to install it . . I thought that would have been fun.

Anyway, hope it turns out hw you want.

Thank you! Do you have pictures of your project?

Everything went out pretty well... The project is finished and everything works great for 2 years now.

What is the problem with my pictures? Dead link?

Has anyone the same problem?

This irritates me because on my work pc and my phone the pictures are ok...

[Yamada]

Then it was time to paint the frame... That was a quite bad idea...

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Always test everything before you do the paint job.

Pictures works for me.
Did you had to cut the frame after paint?

[Mickey Dunlap]

I'm not real sure what type of riding you are going to do with your project, back in the day we did it the other way around and put the Mojave 250 motor in the better handling Tecate 4 once we put a Funco kit on the front end so it didn't have the bad bump steer. Everyone at the time started putting the 250x Honda motors in the 250r Four Tax frame, and that was even better.

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[barnett468]

Thank you! Do you have pictures of your project?

Everything went out pretty well... The project is finished and everything works great for 2 years now.

What is the problem with my pictures? Dead link?

Has anyone the same problem?

This irritates me because on my work pc and my phone the pictures are ok...

xlnt, glad it turned out how you had hoped . . Although the stock Mojave was a little heavy, I still liked it and had fun testing it, but unfortunately, they didn't give us nearly enough time on that project to work out some of the bugs, and my guess for them doing that is because it was targeted towards the novice to intermediate level recreational riders, so if it didn't handle great at high speed in the whoops etc, kawi didn't care.

unfortunately, the tecate 4, which was supposed to be a racing bike designed to compete with the suzuki, was a disaster due to complete incompetence on the part of the original designer and their 4 foot tall, 80 lb, novice level test rider.


the mojave i used belonged to kawi r and d . . they gave it to me to do "testing" with, so I had Jerry Branch of Harley racing fame port the cylinder and had a custom cam made and used the stock piston and exhaust head pipe with a super trap silencer . . i knew it wouldn't be competitive like that and planed to do other mods including a real exhaust pipe and high compression piston etc then lighten it some and make some titanium parts for it, but other things kept getting in the way and after i raced it a couple times, i just ended up racing my friends suzuki quad.

team green also built a mojave engine and i think they put it in a tecate frame . . they had one of their guys race it at one of the mickey thompson 3 wheeler events in pomona calif which i raced at, and it was pretty fast . . i'm pretty sure dean sundahl won that particular race, but even if he didn't, he still spanked the crap out of a lot of people including jimmy white, and the team green managers were laughin about it, lol . . the team green guys actually liked dean and mike coe because they were great riders and didn't have a cocky attitude like some other riders did, plus, the team green managers were so laid back it was really laughable.

unfortunately i don't have any photos of anything because they were all lost.

[sticker_sääp]

I'm not real sure what type of riding you are going to do with your project, back in the day we did it the other way around and put the Mojave 250 motor in the better handling Tecate 4 once we put a Funco kit on the front end so it didn't have the bad bump steer. Everyone at the time started putting the 250x Honda motors in the 250r Four Tax frame, and that was even better.

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The goal was to built that can ride fast on mown meadows, it handles quite like a gocart...

I also use it in medium high snow with 4snows to have some drifting fun. It is very wide and has a low center of mass, to avoid flip overs.

I will update this threat within the next days after the christmas/new year stuff is done...

[Dustin87R]

xlnt, glad it turned out how you had hoped . . Although the stock Mojave was a little heavy, I still liked it and had fun testing it, but unfortunately, they didn't give us nearly enough time on that project to work out some of the bugs, and my guess for them doing that is because it was targeted towards the novice to intermediate level recreational riders, so if it didn't handle great at high speed in the whoops etc, kawi didn't care.

unfortunately, the tecate 4, which was supposed to be a racing bike designed to compete with the suzuki, was a disaster due to complete incompetence on the part of the original designer and their 4 foot tall, 80 lb, novice level test rider.


the mojave i used belonged to kawi r and d . . they gave it to me to do "testing" with, so I had Jerry Branch of Harley racing fame port the cylinder and had a custom cam made and used the stock piston and exhaust head pipe with a super trap silencer . . i knew it wouldn't be competitive like that and planed to do other mods including a real exhaust pipe and high compression piston etc then lighten it some and make some titanium parts for it, but other things kept getting in the way and after i raced it a couple times, i just ended up racing my friends suzuki quad.

team green also built a mojave engine and i think they put it in a tecate frame . . they had one of their guys race it at one of the mickey thompson 3 wheeler events in pomona calif which i raced at, and it was pretty fast . . i'm pretty sure dean sundahl won that particular race, but even if he didn't, he still spanked the crap out of a lot of people including jimmy white, and the team green managers were laughin about it, lol . . the team green guys actually liked dean and mike coe because they were great riders and didn't have a cocky attitude like some other riders did, plus, the team green managers were so laid back it was really laughable.

unfortunately i don't have any photos of anything because they were all lost.

What swingarms were you guys using on the Tecates ? I know CAL-FAB built a T4 swinger but I've never seen one.

[sticker_sääp]

Next step:

modification of the nerfbars...

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I can not remember from which atv they came, bought them used on ebay

[sticker_sääp]

The original mount of the front shocks was not usable so i had to cut and modify the frame a little bit...

Shocks are from a newer Raptor version (I think 2009 or some thing like that)

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Subsequently, painting the steel profile with blue two component paint in sponge technique:drool:

Always testride a project before you paint it!

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[sticker_sääp]

Frontbumper:

It is just clamped on the frame with CNC milled clamps,
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Design of the Aluminium hood:

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That will give it a more racing like style

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The pipe came back from powder coating:

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Time to rebuilt the engine:

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[sticker_sääp]

I won a "KX250" sleeve one ebay US for a few bugs, imported it and the cylinder was drilled for this sleeve,

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just to find out that it is a Tecate 4 sleeve and that therefore the ports did not fit :mad:

Some more pics of a dissasabled KX250 engine:

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