30 replies to this topic

[rccarlson22]

Hello fellow two wheel enthusiasts. I in fact, do not own a complete TDM. I have a dream.

Years ago I bought a 1996 Kawasaki KLX 650, for those unfamiliar, its like the KLRs more badass older brother. Inverted forks, a slightly more powerful engine, and less weight. A couple years ago the engine (after ALOT of use and the occasional wheelie) gave out. So I put it in the shed and left it for awhile. Then I had the idea to swap in a more powerful engine but didnt know what to use. A member of another motorcycle forum offered up his TDM 850 engine that he acquired for a project but never used. Score!

So here I am, engine in hand but I need some miscellaneous parts to get it running. Ive already turned the crank by hand no problem. The head and valves are all straight. I know Im missing carbs, wiring loom, exhaust, and the rectifier I believe.

Ill uncrate the engine and take pics along with the KLX so you can see what Im getting into. The goal is to have 70HP and 70ft lbs in a dual sport.
I forgot to put that it is a 1992 TDM 850 engine

[dapleb]

Mega. Good luck with it.

Rectumfrier and exhaust shouldn't be too much bother ..a loom might take a bit of searching.

...and welcome.

[Alekre]

Hey, welcome to the forum!

 

 

There is some guy who installed Versys 650 into KLR . Maybe u can find it and study a bit so u can get some basic ideas.

 

Anyway, as u can see TDMs engine is forward inclined noticeably. I guess 21inch wheel would have problem with clearance. Plus there is radiator to be mounted that will take space. 

 

For sure, noone of projects like this are easy to build but that is what add value to such work and motorcycles. Good luck!ž

 

Sorry for crappy english.

Edited by Alekre, 22 April 2020 - 01:59 pm.

[rccarlson22]

Yes this is a mega project, but the old girl deserves new life.

Ill keep yall updated on progress as it happens. Ive already got the carbs and wiring found actually. I dont want to purchase exhaust until I mock up the engine in the KLX frame and see what my clearances are like. Radiator is another part to figure out what were going to do with.

[fixitsan]

Need to find out if the 850 engine is from a mk1 or mk2. The mk1 has a 360 degree crank and mk2 has a 270 crank, so things like the ECU are different

[rccarlson22]

How to I determine if its MK1 or MK2?

[dapleb]

I am guessing you is a Merkin....so it will be a MK1. Will have 3VD at start of enjun number.

[Favs]

Hey, welcome to the forum!

 

 

There is some guy who installed Versys 650 into KLR . Maybe u can find it and study a bit so u can get some basic ideas.

 

Anyway, as u can see TDMs engine is forward inclined noticeably. I guess 21inch wheel would have problem with clearance. Plus there is radiator to be mounted that will take space. 

 

For sure, noone of projects like this are easy to build but that is what add value to such work and motorcycles. Good luck!ž

 

Sorry for crappy english.

Not crappy.

 

@ rccarlson22 Hi & good luck with the project.

[fixitsan]

How to I determine if its MK1 or MK2?

Easy way is to remove both spark plugs and use  paper straws inserted into the bores  so that one straw  sits on each piston top and see where they synch.

A 180 degree crank has the pistons in opposition, a 360 degree crank has both pistons at TDC at the same time, and 270 degree crank has #2 piston 90 degrees behind #1, like in this animation 

 

https://en.wikipedia...haft_angles.gif

Edited by fixitsan, 22 April 2020 - 03:32 pm.

[dablik]

Well you already said in the 1st post it's a 92................so it's a 3vd innit....if your Merkin you may well be purchasing from Europe, good luck, post pics please..

[rccarlson22]

I am guessing you is a Merkin....so it will be a MK1. Will have 3VD at start of enjun number.

Yep I am from Murica.

It is a 3VD

Well you already said in the 1st post it's a 92................so it's a 3vd innit....if your Merkin you may well be purchasing from Europe, good luck, post pics please..

I bought it from a British fella that had it imported I believe


Ill get pics once my brother comes help me offload it from my trailer, for some reason I dont own a hand truck


This forum is a bit different and Im on mobile how do I upload pics?

Edited by rccarlson22, 22 April 2020 - 06:03 pm.

[Studley Ramrod]

Hi and welcome.  Regarding pics, first off I'll say that as a member you can only upload a few small sized pics, supporting members can upload up to 50MB of pics.  It costs £5 to become a supporting member.

 

Alternatively, you can link to photos posted up on another site like photobucket or similar.

 

For posting up photos onto here, click on the more reply options button below the text box, you'll then see the attach files browse button.  Select the pics you want to upload.  Then click the attach this file button to upload the pics. Then place the cursor where you want the pic to go and hit the Add to Post clicky thing.

[rccarlson22]

Hi and welcome.  Regarding pics, first off I'll say that as a member you can only upload a few small sized pics, supporting members can upload up to 50MB of pics.  It costs £5 to become a supporting member.
 
Alternatively, you can link to photos posted up on another site like photobucket or similar.
 
For posting up photos onto here, click on the more reply options button below the text box, you'll then see the attach files browse button.  Select the pics you want to upload.  Then click the attach this file button to upload the pics. Then place the cursor where you want the pic to go and hit the Add to Post clicky thing.

Thank you. Hopefully I can get it together so I can share the progress with yall.

[fixitsan]

Well you already said in the 1st post it's a 92................so it's a 3vd innit....if your Merkin you may well be purchasing from Europe, good luck, post pics please..

 

Ah.....the appearance of that info leads me to think Im drinking too much under lockdown....how did I miss it ! ? hic

[dablik]

 

Ah.....the appearance of that info leads me to think Im drinking too much under lockdown....how did I miss it ! ? hic

i wondered....

[rccarlson22]

Heres a link to photos on another thread

https://www.motohous...074#post4194074
From what I can tell I will need:

1. Carbs
2. Wiring Harness
3 Spark plug wires
4. Radiator/plumbing
5. Clutch Cable
6. Shift Lever
7.Exhaust

Thats all I got if you see something I missed fill it in

[Studley Ramrod]

Oil tank

ecu

coil

Sprocket cover

Reg/Rec

Battery

Throttle and cables.

Choke cable.

Also, not sure how you're gonna set up the speedo ?  Mk1 uses a cable conected to the front wheel.  Dunno if yours is mechanical or electrical.  Might then need the instruments.

[rccarlson22]

Does anyone have a decent exploded parts diagram from a manual? I may just end up buying a manual if I can find one

[rccarlson22]

Plenty of 4TX ecus available, would that part work or needs to be a 3VD ecu?

[rccarlson22]

Alrighty!

Got an ecu, wiring harness, recitifer, and ignition coils from a German motorcycle parts warehouse.