86 tecate 500 build it runs!!(pics)

[danimal95]

well the deal with my first 500 motor fell through,so ive been on the hunt for another....found 1 in nevada this weekend,which turned out to be a better motor anyway...out of a 92 KX500,fully ported cylinder,balanced crankshaft(no vibrations here)new flatslide 50mm carb,all electronics,full exhaust plus a bunch more:cool:also the motor was dyno'd whenit was in the bike to the tune of 72hp:Bounce:eek:........anyways should have it this week it was shipped today,i am tearing the T3 apart tomorrow and prepping everything,i will try to take pica as i go along.my goal is to have this together and all the bugs worked out before my annual Little Sahara Okalahoma trip in the middle of march.

[dcreel]

Can you push it back to April 17-18th? There will be a bunch of three wheelers at Little Sahara for that weekend of the Midwest Rampage. Last year there was over 70 three wheelers there. Just a thought.. If you can make it then I'll see you there..
http://www.3wheeler.org/vb/showthread.php?t=38960
a picture from last year.
http://i241.photobucket.com/albums/ff257/gdkarma1/000_0057.jpg

Pictures from last year.
http://www.3wheeler.org/vb/showthread.php?t=36992&page=2&highlight=sahara

[danimal95]

im pretty sure that is doable.......really depends on my friends work schedule,he may be back too work by then

[danimal95]

well we are slow at work so i have been woring on the swap since 9a.m. today,it is now 12:15 and im on lunch so i thought i would update....bottom line is it will be running today!!!made the front and top mounts this morning out of 3/16 aluminum plate,look stock.over the weekend i picked up an fmf K5 pipe for 30 bucks,as a sacraficial pipe to send and get duplicated for a direct bolt in hand coned piece,that may end up being a production piece,ill keep yu posted on that.however between the pipe that came with the motor and the 1 that i bought i was able to cut and section the 2 so that it fits perfectly w/o contacting anything at all and still maintains a safe distance from the bottom of the tank.it is already wired and verified it has spark,the cross tubr for plug clearance is already done,the radiator hoses are done and the carb is in and mounted,i may try to use my stock air box to retain the factory look,well see...all that i have left is to mount the silencer,throw the chain and put gas in it.....i will post mre this evening when i get home,sorry i forgot my camera at home today pics for sure tomorrow

[danimal95]

well got it fired up,brought up to temp,chain on,almost ready to ride....all i need to finish up tomorrow is the kicker modification,and the induction.the pipe and exhaust turned out really nice,fits perfectly doesnt hit or rub a thing.ill post more as i go along,as well as first ride impressions

[alexandros]

post any fotos!!!!

[danimal95]

post any fotos!!!!

no pics till tomorrow:-(

[69HemiGTX]

Good news about the 500. There's nothing like having an insane amount of power for no reason other than you can. :) On a side note, the pic from above is about 75 yards from the Snack Shack out at the dunes, across the road from the bathrooms and vending machines. My buddy owns it, and he sells fast food and drinks out of it. If y'all go this March, stop by and tell him Damon says hello from Afghanistan. Man, I really miss home!

[danimal95]

for those of yu that have done the K5 swap on your tecates....i need to know what sprocket combo you went with and where you got the rear from.i rode mine for the first time today and the gearing is all top end,i need more bottom end especially for the dunes.....2nd gear feels like 40mph at less than 1/2 throttle,thanks in advance ,i must say thogh this thing is a rocket...i will be building an induction tomorrow for it ,the stock sir box seems to be a restriction,it doesnt run nearly as clean compared to a clamp on element so that tells me it must be a restriction,i took some pics but it wasnt very good lighting so i will take more tomorrow after its all cleaned up and esdy to go

[tecat-z]

Dan, call sprocket specialists. They will make you any combo you wish, out of many diff materials too. They have very fast turnaround, esp for a biz like yours...

[danimal95]

Dan, call sprocket specialists. They will make you any combo you wish, out of many diff materials too. They have very fast turnaround, esp for a biz like yours...

thanks ill make that call today....how have you been?heading to oklahoma in march,you should try to make silver lake pales incomparison

[tecat-z]

I'm good. Went to the Rampage there last April and had a blast. Can you put off your trip till then? Cause we plan on going again. Yes, it's much bigger than S.L, but the 3 hour drive Michigan is convenient.

[JohnR.]

What gearing are you running now? It'd be a whole lot easier to take a guess at a better combo if we knew that.

[danimal95]

I'm good. Went to the Rampage there last April and had a blast. Can you put off your trip till then? Cause we plan on going again. Yes, it's much bigger than S.L, but the 3 hour drive Michigan is convenient.
that is a possibility,but that is the weekend of the wifes birthday,plus the group of guys i go with generally go back to work the week before that,damn seasonal workers:)
you are right though,it is hard to beat the 4 hour(for me )drive to SL,well have to meet up again at SL,i need to make more trips there,especially with the new combo

[danimal95]

What gearing are you running now? It'd be a whole lot easier to take a guess at a better combo if we knew that.

the combo was my first post,not sure what else i can tell you,the current gearing is 15/37,however i do have a 14T front comonig that will be here by friday so ill see if that gets me what i am looking for

[JohnR.]

Sorry, I missed that. I would have ordered a 13 and a 14. They're cheap enough and will give you some adjustability with your gearing. No biggie though, see how you like the 14 then if its not enough go to a 13 and if its too much start going up or down on the back. I'd bet one of those two will get you where you want to be though.

[nd4speed]

Gearing was always a big question I had. I would go 14 or 15 in the front. I have heard of one running 14/39 with like +6 swingarm but it was going to be changed to something steeper like 14/44. Tire size will be a factor too.
If I went steep like 14/42 14/44 I might plan to use 22" tires with a stock swingarm.

I would use what I had like 14/37 or 15/37 to see how it performs first. Dont really know what kinda riding you want to do.

This makes me want to build mine now.

I really had hoped you were going to post pictures covering all the details of the build.

[3Razors]

The smallest I would go on the front sprocket is 14T. If you go to a 13T the chain will wear hard on the guide swingarm area. Another thing on the 86-87 Tecate rear sprocket sizes other than stock are virtually impossible to find on than from sprocket specialists and sidewinder. On my brothers tecate with 500 in it we found that 14/42 gearing with 20 inch paddles was great setup for rec riding. He had to have his sprocket ordered from sprocket specialists and I believe was about $70 after shipping. I would inquire to see if they have them available in steel instead of alum. 500's wear out alum sprockets and hook the teeth in no time at all.

[danimal95]

The smallest I would go on the front sprocket is 14T. If you go to a 13T the chain will wear hard on the guide swingarm area. Another thing on the 86-87 Tecate rear sprocket sizes other than stock are virtually impossible to find on than from sprocket specialists and sidewinder. On my brothers tecate with 500 in it we found that 14/42 gearing with 20 inch paddles was great setup for rec riding. He had to have his sprocket ordered from sprocket specialists and I believe was about $70 after shipping. I would inquire to see if they have them available in steel instead of alum. 500's wear out alum sprockets and hook the teeth in no time at all.a 13 actually is too small and rubs the side of the case,thats why i went with the 14,also i called sproket specialist's and they have a steel rear all the way up tp 52 teeth,i think i am gonna go with the suggestion that T3Lopes reccomened 14/42,i may try slighly taller in the rear mabey a 44 well see,thanks for the help

[danimal95]

Gearing was always a big question I had. I would go 14 or 15 in the front. I have heard of one running 14/39 with like +6 swingarm but it was going to be changed to something steeper like 14/44. Tire size will be a factor too.
If I went steep like 14/42 14/44 I might plan to use 22" tires with a stock swingarm.

I would use what I had like 14/37 or 15/37 to see how it performs first. Dont really know what kinda riding you want to do.

This makes me want to build mine now.

I really had hoped you were going to post pictures covering all the details of the build.

i do have pics but the bike was dirty and really didnt look that well in my eyes.....since than i have washed it but havent taken any new pics yet....also the build really isnt that detailed because it really is a simple swap,i was amazed....i will post the pics i have but please dont judge till you see it cleaned up and pretty:)

[danimal95]

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500002.jpg?t=1264118562
modified FMF K5 pipe-soon too be duplicated and a production piece,should make this swap easy for anyone that can hold a wrench:lol:

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500001.jpg?
i used 1 5/8 mandrel bent tubing to build the section to the K5 stinger,i cut back the head pipe just enough to allow the 1 5/8 tubing to butt up to it perfectly and not cause a loss of flow

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500004.jpg?
this is the only part of the head pipe that needed modification not so it didnt contact the rad hose,or the bottom of the tank,both of which now have a solid 1/2 in in between

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500003.jpg?
right hand radiator hose was too tight a bend radius and was almost kinked,so i got these 2 hoses,trimmed them back and put in a 90 degree elbow to make the bend a smooth transition

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500005.jpg?t=1264119043
another view of the section of head pipe that was added,this was taken from a donor pipe that was sent with the motor,also an FMF so this piece fit in perfectly with no flow loss either

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500006.jpg?
front motor mounts,kind of hard too see,but they were made of 3/16 aluminum plate and were clearanced around every bolt that may have been in the way,once the 1st side was done i used that as a template for the 2nd side that way they are indenticle

http://i439.photobucket.com/albums/qq118/danimal95/1986%20tecate%20500/teacte500007.jpg?
this is a pic of the pipe(dusted with high temp paint)on the trike and the rear plastice slightly clearanced,only to clear the 1 5/8 stinger tubing and not just melt around it.also was able to make the K5 kicker work well,took some heat and a long bar to bend it but it clears the plastic and folds in nice,wasnt clocked right in this pic


i have changed a couple tings since wednesday when these were taken.it is coming home tomorrow so i can get the jets dial'd in and stretch its legs out on the lake:p

[alexandros]

nice fotos and even more nice build

Good work

[nd4speed]

I was interested in seeing the radiator hoses, the bumped in cross member ,and the motor mounts, but anyway- nice job. 14/42 is the gearing I was picturing. A price of the rear sprocket would be nice too. $70?

[danimal95]

I was interested in seeing the radiator hoses, the bumped in cross member ,and the motor mounts, but anyway- nice job. 14/42 is the gearing I was picturing. A price of the rear sprocket would be nice too. $70?

the left rad hose uses the stock hose,and the other is pictured,the motor mount pics arent very good i will get more this weeekend ,the bump in the cross member was minimal compared to most that i have seen done,i run a very short spark plup so mine was only 1/4" in at best,the sproket was 52.99 plus shipping,i think the totla was just under 60 bucks,if there are any other particulars that you or anyone else would like to see just let me know and i will domy best to get those pics for you

[danimal95]

nice fotos and even more nice build

Good worki am kind of embarrassed by the pics,everything is dirty because i tookm them afterthe first test ride,and it is very sloppy and wet here right now,but thanks

[jeffatc250r]

Cool! Pipe came out nice. Nothing quite like the sound of a 500 is there? Brrrrppppp

[Tyler 54]

So this is why your selling you jet coated pipe?

Looks pretty sweet. Were are you in Il?
I started on my 86 T- tonight. Already have my spare frame painted just have to re polish my swinger and do some painting on other parts.

[danimal95]

So this is why your selling you jet coated pipe?

Looks pretty sweet. Were are you in Il?
I started on my 86 T- tonight. Already have my spare frame painted just have to re polish my swinger and do some painting on other parts.

north of chicago by about about an hour,yeah thats why the pipe was being sold....now i just have to figure out a technique for starting this thing:)

[fabiodriven]

You did this really quick, man. Nice job. I will get mine together someday...

[danimal95]

You did this really quick, man. Nice job. I will get mine together someday...
thanks,actual time working on it was just under 9 hours,fairly easy swap