K-Man's 1999 Swedish Steelie

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K-Man
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K-Man's 1999 Swedish Steelie

Post by K-Man »

A big thank you to all contributors to this excellent forum as all tips, facts, instructions and walkthroughs
have been a big help to my rebuild so far!

After having had a great time on my CR last winter
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...a friend of mine told me to check my piston for cracks and lo and behold, there it was, almost an inch long from the bottom of the skirt of the cast Prox. Lucky check. Not long before this piston would wreak havoc in my engine.
Note the small inlet ports... they're about to get bigger!
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This led to a big teardown and as I really wanted a bit more revs and top-end I ported the cylinder a bit.
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Transfer ports. One raised so far
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Then I ordered a Wiseco piston and had the cylinder bored out to 89,50 mm. Now the intake is a lot bigger :twisted:
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As I plan to put this engine in my '02 CRF450 SM roller I've got, I figured I might as well swap all bearings while the engine is out of the frame and have a completely fresh one to start with.

Splitting the cases, 2 yo daughter Leia helping :) GoPro timelapse movie


and pulling the bearings and replacing them

You might see me checking out doggers excellent Engine build pictorials to speed up my rebuild.

An old rear sprocket got to serve as a crank puller and it worked like a charm


Putting the bike back together in 2.5 minutes and fitting an hour meter to keep better track of service intervals than the previous owner did.


And yes, it comes to life again and does run nicely :D I have put some bigger jets in since it's ported now and it's winter. First start with all the new parts covered in oil means a smokey startup. I probably should've done it outdoors but its cold as **** here right now :roll:


Hopefully I'll go iceracing this weekend and post some more footage afterwards.

// K-Man, Sweden
Last edited by K-Man on February 7th, 2012, 7:02 pm, edited 4 times in total.
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AlisoBob
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Post by AlisoBob »

SWEET!!!!
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Tharrell
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Post by Tharrell »

That was great.
Loved it when the kid was helping. :)
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Post by hoofarted »

Tharrell wrote:That was great.
Loved it when the kid was helping. :)
Yeah was cool! My 2 girls do the same thing. :)
The CR500 is an acquired taste. If you don't like it, acquire some taste...

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asteroid500
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Post by asteroid500 »

My little girl knows her way around a tool box .... gotta love that.
"not speeding officer".....qualifying

CR250 97
CR500 AF 99 (in progress)
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K-Man
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Post by K-Man »

I ran the engine in the other day and now I've put together a little video from that day :) Enjoy!

available in 1080-res on YouTube

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Post by Tharrell »

Excellent! :cool:

Hardcore CR500 riders all around the globe.
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Post by iggys-amsoil »

Very nice!
Trinity Racing mild porting FMF
62 pilot, EGH needle, 172 main
03 Gen III CR250 frame

2013 Dodger Charger 5.7 Hemi

http://www.prisonplanet.com

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K-Man
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Post by K-Man »

My daughter Leia sure likes motorcycles :)

'Raising my family' - Get it?

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Post by kevin_s »

Looks like Leia is already a Hoonett.Great thread and videos. :cool:
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Post by johnnytheswede »

That was a wonderful day we had on the ice there, K-man=)! I recognise the porting tools:=)!

Johnny
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K-Man
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Post by K-Man »

HELP!
Can anyone help me with a part number for the metal bushing at the back of the crankcase where the swing axle goes through? The collar on it has cracked/broken off and I can't find it in Hondas fiches.

http://www.hondaparts-direct.com/fiche_ ... &fveh=3295

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hoofarted
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Post by hoofarted »

I believe those come only with case halves....
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Post by K-Man »

I really hope that isn't so. Having to buy a case half instead of a 10$ bushing seems insane.

Went down to my local Honda dealer and we ordered Ref# 5 in the Swingarm section. He said the schematics weren't always in the exact right place. The name, BUSH, PIVOT THRUST, and look of it seems as close as can be so I ordered two (both sides)

*Fingers crossed*
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Gmbond
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Post by Gmbond »

Unfortunately it won't be what you need

Best bet would be to get the piece/pieces and get a local machinist to make you a new set. The smaller the shop the better for price usually. And I mean It's not exactly brain surgery to turn one of those on a lathe out of a chunk of steel or stainless.
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Post by K-Man »

Are you saying that the #5 piece isn't what I need?
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AlisoBob
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Post by AlisoBob »

This is the same part number , from pivot works...

http://www.pivotworks.com/ProductInfo.a ... m_id=51472

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NOT the part you want.
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K-Man
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Post by K-Man »

true. it looks way too shallow

Do pivot works have what I need? Or anyone else for that matter? Or have I broken the one piece on a Honda that can't be ordered? :?
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AlisoBob
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Post by AlisoBob »

Somebody should have an old set of broken cases somewhere... and be able to knock that suck'a out....

:?
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Gmbond
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Post by Gmbond »

Yup It's a part you can't buy separately

a 250 or 125 collar would work also.

Or as I said. Get a new one cut on a lathe. Would work just as well.
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K-Man
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Post by K-Man »

Gmbond wrote:Yup It's a part you can't buy separately

a 250 or 125 collar would work also.
How stupid is this? :evil:
I bet I can't buy one separately for 250's or 125's either?

Having one made up will be a pain as well. I think I'll just superglue the collar back on then :(
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Post by AlisoBob »

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K-Man
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Post by K-Man »

good link but $ 100 incl shipping is more than I was hoping to pay for one little bushing and could probably get one made for less.
Thanks anyway.
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Post by AlisoBob »

You dont want the WHOLE CASE..... You want the friggin' BUSHING right?

Tell the guy to knock it out, and throw it in a tiny box.

:hohum:
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Post by K-Man »

Hehe, gotcha, nice reply. But that may well render his case useless? I wouldn't want to do that if I wanted to sell the whole case. The bushings seem pretty well fixed. :?
I put mine back together with some steel epoxi. We'll see how far that will last, but at least there won't be any play an the axle and the collar can't get away from there as it sits nicely on the axle.

I followed your excellent tip and got the 59 mm bushing and now it looks like the engine will line up perfectly on the axle. I'll be cutting out the Y tomorrow and clean it up. Frame rebuild/weld is planned for this weekend. I have to continue this in the AF-forum soon :)

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