86 tecate 500 in progressupdated 7/13/09

[brapp]

ok guys here goes i broke the kicker on my kx500 yesterday and today i got bored and this is the up comign result. but this is what i have learned today





1. i have found out the 86 tecate 3 motor comes out in abotu 15 min .
2. the 94 kx500 came abotu in 20 minuites
3. the tecate exhaust does mount up into the kx500 cylinder but moves the mount under the tank slightly higher.
4. the only cut i will have to do is notch the frame and plate it to clear the spark plug cap
5. the carb off the tecate is only a mm smaller then the stock kx500 carb
6. the carbs has the plunger style on the kx500 and it is right up against the airbox and not accessible with the airbox on
7. the tank has to have a spacer made to rais the tank 5/8th of an inch to give a full inch under the tank between the exhaust and the tank bottom.
8. the chain line sup perfectly
9. the factory front motor mounts are off by 1/8 th inch
10. the top mount off the kx500is so close woudl have to egg out the holes slightly to make it work
11. the bottome motormount needs to be 3/ 32nds larger to acomadate a bolt that fits snug into both the motor and the frame so theres is not play.

ok the game plan


1. the swingarmpivot/ motor mount is fine where its at.
2. the botom motor mount is done also
3. the spark plug cap issue on the frame is goign to be heated and dimpled with a solid die and soem heat to avoid cuttign the frame and weakening it too much
4. the airbx issue willbe handled with a 39pwk with a pod filter on the back for the meantime until i can research the correst carb with the factory style choke set up.
5. find a tecate-4 thumb throttle or use a honda 250r throttle and cable ( i dispise twist throttles on wheelers)
6. goign to use the entire eletricals off the kx500
7. hope to sellthe kx500 extra parts to fund rebuilding front and rear shock for the tecate
8 powdercoat candy raspberry frame and motor mounts
9. find good maier front fender
10 find option 1 set of good radiator shrouds? option 2 dc plastics tank cover/ shrouds.




this is my build and my game plan for the meantime and my budget is rather low but i am excited so well see how it goes

[brapp]

here is the rough pics.

[outtaline]

:beer dude thats gonna be sick I hope you make a thread and keep us up to date.

[brapp]

this is the threaDDDDD and it is going to get worked on tillits completed.

[SYKO]

there isnt a way in hell I would use a 250 pipe on the 500 I would reconsider that homie! other then that....build away! I got a soft spot for ol kxhundeeez I had a 94 model back in 95 mmmmmm fireroad bike rite durr.

[brapp]

the clem ipe has the same bends and diamiters as the kx500 pipe be;e it or not

[dcreel]

Looks like an awesome build so far. I'm going to have to do one of these too someday. 1st gen though. Is the tranny fluid fill on the right case stock? Just curious. Keep the info and pictures coming.
Doug

[brapp]

yeah should be an easy build

[brapp]

i am debatign takign the exhaust tat wa son the kx and the tecate up to dyno port and se ewhat they can come up with for a top end screamer.

[3Razors]

This one is my brothers Tecate 500. Please don't try and use the 250 pipe, it will really hurt the performance. Modify a KX5 pipe to fit or get one custom made.

[Bryan Raffa]

FIRST OFF HOW the hell can your budget is rather low ...didnt you just sell the right to your property? wtf...:crazy: spending that money on a vett that you cant even drive to your house....:crazy: dont know dude .. but your priority's are all trailpro trailpro ....

[johnny's X]

Priorities first Brapp!!!!!!!. Screw that vet. You could have made money last week when I was at your house. Put a price on that tecate and I will come get it. I want the stock motor though not the 500

Money is better than a project!

[factoryX]

this project should not cost that much to complete.

[brapp]

well so far i have 400 into the donor kx500 and i have about 300 into the tecate and i rode the t-3 for the first time today with the 500 motor. the conversion is done i will be gettign pics tonight and workign out the bugs and a few fine tune issues.


it needs shifter lengthened or if tecate shifter will work.

the petcock rebuilt

front brakes need to be rebuilt so they work and decinitly need to find wider hubs/ wider axle. nor ofset rims to make it a more agressive stance,

need to amke mounts for the seat for the seat/fender set up i am dreamign up

new plastics.

powdercoat candy raspberry purple

and a tank skin or a nice tank and shrouds.

[factoryX]

this project should not cost that much to complete.

nevermind.

[brapp]

ok here goes! firs tpic is the dimple int he frame needed to clear the spark plug cap and the top motor mountw ehad made for temporary until the aluminum bes are machined properly and the second pic is the only real cut needed to make the pipe work with the chasis

[chris200x]

looking good bud. dont get hurt! :D

[RodKnockRacing]

coffin on wheels buddy coffin on wheels dont expect to con me to get on it like u do the zilla lol

[chris200x]

coffin on wheels buddy coffin on wheels dont expect to con me to get on it like u do the zilla lol

I guess you know Josh as well as me. dude has no fear! :rolleyes: :crazy: :beer

was nice kowin ya brapp! :D

[brapp]

yeah rod knock ther eis corby one of the good local boys i met him trough nate a while back and a good guy. and you woudl be suprised how much smother this 500 is than the 250 motor the 250 was actualy harder to ride lol

[JasonB]

looking good so far! And whats this about a vette? :naughty:

[brapp]

2008 z06 427 wil cooksey special edition #202 of 505 signed from factory. and for right now i am at a stand still i an ahvgin rear shock rebuilt and revalved for my 240lbs of fat and the +2 calfab and the forks are gettign diffrent springs and slight modifications to handle the harder brakign gogin to be required. i cant tellyou my secrets but reaktive suspension in bechtelsville pa woudl be more then willign to rebuild your stock and aftermarket suspension needs.610-367-1700 ask for al

[JasonB]

nice, I want a zo6 real bad but Im broke! keep up the good work on the tecate

[brapp]

and the vet was a joke to se ehow far i could go with it that allstarted with a big speedign ticket when i drove it to the beer distributor lol

[brapp]

the hardest part now completed. I NOW HAVE NEW OEM PLASTICS!!!!!!!!!!!! AND JUST NEED TO GET MY FORKS AND SHOCK BACK AND , GET SEAT COVER FINISHED UP AND MAKE SEAT HOOKS AND PULL BACK APART AND POWDERCOAT THE FRAME AND MISC PARTS.

[outtaline]

Dude if I ever ever do a 500 I'm doin a kawi it looks like soooooo much less work lookin good brappy.:beer :beer

[brapp]

yeah its a pretty straight forward build hardest part was makign the pipe fit .

[OZQUAD44]

the hardest part now completed. I NOW HAVE NEW OEM PLASTICS!!!!!!!!!!!! AND JUST NEED TO GET MY FORKS AND SHOCK BACK AND , GET SEAT COVER FINISHED UP AND MAKE SEAT HOOKS AND PULL BACK APART AND POWDERCOAT THE FRAME AND MISC PARTS.

Brapp where did you get your plastics from?

[brapp]

i got it privatly from a fellow board member who wishes to remain anonoumous

[brapp]

i picked up another tecate that already had the 500 conversion done at soem point in its lif ebut is now just a roller so do i smell a pair fo tecate 500's?

[MagicJames]

Hey brapp, i need a front end for a kx 250, what kind of a price do you have in mind for your whole front triple trees to brakes. Let me know if you want to sell it.

Oh yeah, That looks Tits.

[brapp]

sorry the bike is already been parted the day after the motor came out. i actualy traded the forks for suspension work i am havign done to set the bike up for my weight. sorry man.

[OZQUAD44]

i got it privatly from a fellow board member who wishes to remain anonoumous

Thats cool, I thought that maybe Kawasaki still had some in stock somewhere.

I was on a kawasaki parts site the other day and they had all this gear with prices and My heart skipped a beat thinking that I could still get all this stuff new. Stupid brain!

P.S. You mentioned that the 500 was smother to ride than the 250..... how much smoother? Could you spend a whole day in the dunes doing general riding on a KXT500 with no dramas, or is it too much of a beast for that type of riding?

I would like to flick the sleeved barrel on my 250 for a plated one to take it back to original, but for similar money I could just about squeeze a 500 donk in there. Its just that I don't want a comp hill machine, I want an all rounder. A 500 sounds a bit full on, particularly in a trike chassis.

[brapp]

well the front and rear fender you can still get oem on ebay and the left shroud too but the right shroud and headlght shell are long gone!

[brapp]

as far as power goes it hits low and pulls allthe way up trough the powerband to a strong tp end simialar to a 450 thumper or even a 650 in soem cases

[OZQUAD44]

I also ride, and have raced 450 Quads and absolutely love those things. That type of power I am very used to, no problems, having said that though it is far easier to ride a quad with balls than it is a trike.

I use my Tecate for sand mainly, I have no desire to take it anywhere else. Power is a bit too sudden at times to be much fun in the bush and the bike is too rare to be bush bashing anyway. In the dunes its a different story, in the wider open spaces and power sucking sand the T3 comes into its own IMO. It rocks out in the sand.

What is the 500 like to live with in the sand dunes. Can the motor handle being lugged or does it have to be on the pipe all the time? What's the vibration like? I know on the T3 250, if your not on the pipe you might as well pack up and go home because its pretty lame down low. 85/86 250R's are much more fun to cruise around on because there isn't that violent transition from bottom end to mid range punch like there is on the Kwacker.

Do you think the 500 is reasonable to live with as an all rounder in the dune environment?

The other option would be a later model KX250 motor, but then the price jumps again.

[brapp]

hell i ambuilding this up as a general track and trail bike and it is verry smothe power it alldepends hpw your motor is set up it makes crazy torque but is verry rideable

[the great gazoo]

looking good bud. dont get hurt! :D

As long as he doesn't have an audience, he might not:lol: :lol: :lol: :lol: :lol: :lol: :lock: :lock: :lock: :lock: :lock: :lock: :lock: :welcome:

[fabiodriven]

I know on the T3 250, if your not on the pipe you might as well pack up and go home because its pretty lame down low.

Don't beleive the hype. My 85 250 has more than enough power down low. I lug the hell out of that thing and it trucks right along.

[brapp]

yeah but i am pullign 16/35 gearign with 20 inch tires and ther eis no lack of torque.

[OZQUAD44]

Don't beleive the hype. My 85 250 has more than enough power down low. I lug the hell out of that thing and it trucks right along.

What hype? I'm talking about My Tecate, that I've had for 10 years, comparing it to other two strokes I've ridden. Namely 85 and 86 250R's.

I'm glad yours trucks right along, mine is pretty ordinary off the pipe in comparison.

[brapp]

it also depens how you have the powervalve adjusted too. but i may have found a pair of 89 kx500's today for 600 bucks so imay be building 2 500 tecates at once lol

[toocheaptosmoke]

Man that thing is gonna be sick. Was going to do a CR 500 build but you got me thinking the kawi might be the ticket. :w00t:

[3Razors]

Anybody trying this conversion may want to try out the NGK sparkplug BR8ECMIX. Its a shorter version of the BR8 series plugs that will give you 5/8 more clearance. Guys that put the KX5 in the KX250 alum frame run this plug. Might be worth a shot to avoid having to notch/dimple the frame.

[Jeremy Urban]

If you are still looking for a thumb dumb throttle , I have a honda one that is painted gold but could be polished off and look kick ass with a litttle elbow grease I would trade it for a good twister. Also, if you increase stinger size on the expansion chamber to simular or slightly larger then the kx or just combine the two pipes if you handy with a welder you could even braze it on with oxy aceteylene torch too

[Jeremy Urban]

they also make short reach header plugs for race cars ngk champions and others all make them some even have 5/8 head on them I would send you one with the thumb throttle just to check for clearence They are hot lthough maybe ngk 7 or 8's

[Jeremy Urban]

Man that thing is gonna be sick. Was going to do a CR 500 build but you got me thinking the kawi might be the ticket. :w00t:

big bro put a kawi triple cylder in one T-3 2nd gen, now tha was bad az f@#k!!!!!!!

[brapp]

i have a good twister and cable if youhavea honda throttle withthelinkagein it? where in ny are you located? and the shorty plugs dont workeither because its not theplug thats the issueits the plug cap and beignable to get a wrench on it .

[nd4speed]

what did you do for the front motor mounts?

What's it like to kick the motor over with the T3 kicker?

Does case saver fit w/ 16 tooth F. sprocket?

Where did you get a 35 tooth rear sprocket?

[brapp]

made a rough 2 piece motor mounts, but havignmy machinist make nice one piece billet aluminum mounts, the motor isnt too unbearable but better have a strong leg and i dont have a case saver on the kx500 motor?? and the sprocket was on there

[fabiodriven]

what did you do for the front motor mounts?

What's it like to kick the motor over with the T3 kicker?

Does case saver fit w/ 16 tooth F. sprocket?

Where did you get a 35 tooth rear sprocket?

I got a compression release for mine so I can kick it over. It was very easy to kick with the 500 kicker, like a 125. I had a T-3 kicker lever modded to fit on the 500 kicker base so I wouldn't have to take the plastics off or cut them to fire the thing up. The trike is apart right now, but I think it's going to work out well.

http://i146.photobucket.com/albums/r275/fabiodriven/Tecate%20500/P7220295.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/Tecate%20500/P7220297.jpg

http://i146.photobucket.com/albums/r275/fabiodriven/Tecate%20500/P7220299.jpg