Gen 2 S/H rebuild

kevin_s · Post by **kevin_s** » August 11th, 2011, 5:41 am

I'm taking a break from my 450 project to redo this bike.It's a 01 Service Honda gen 2 that I bought from another member here.I stripped it all down yesterday to do all new bearings in the swingarm,linkage,shock,and head bearings.I did the swingarm and linkage first and man were they toast.Today I'm going to do the shock and head bearings.
I have a couple of questions:
1.Do the swingarm bearings get pressed in flush to the inner bore of the swingarm on the outboard side?or do they go in farther?
2.Do these use the 54mm and 59mm spacers like my 450?
3.I did not notice a mount for the ign box or coil,does anybody have pictures of where their's mount?
4.Is it true you have to take the outer crankcase cover off to get the engine in or out?

maddog1927 · Post by **maddog1927** » August 11th, 2011, 6:32 pm

1) IDK
2) I would guess same as gen 3 conversions. I would have to look up the sizes but they are the gen 3 125 swaped side to side. Remember this is my GUESS. SH used aluminium shims. They should have named them cr500 AS.
3)

This is the LH spar. The foam tape to the right is over where the shroud rubs the frame for reference. I had to pull the rad out of the way to get this pic. I have never had the coil off, but I bet there are tapped holes in the frame. 6mm bolts and aluminium sleeve/ spacers. You can get spaces at the home depot in the little bins in the hardware dept. Not sure if they have aluminium though. Plastic for sure.

Forgot to get a pic of the coil, but it is on the steering head behind th # plate.

4) i usually take the clutch cover only off just to help out. Back it in from the RH (kick starter) side. sometimes getting the swing arm outta the way by moving it back 3" or so helps minimize frustration.

Do a gen 3 body conversion. IMO looks better, parts and graphics more available also.

Good luck

Kuma · Post by **Kuma** » August 11th, 2011, 9:55 pm

Give SH a call, the few times I have called they have been helpfull, if it is one of their bikes, don't see why they wouldn't help.

maddog1927 wrote:1) Do a gen 3 body conversion. IMO looks better, parts and graphics more available also.

Now a little thread hijacking

what does it take to swap the body, ban I keep the gen 2 gas tank?

freeride588 · Post by **freeride588** » August 11th, 2011, 10:02 pm

Kuma wrote:Give SH a call, the few times I have called they have been helpfull, if it is one of their bikes, don't see why they wouldn't help.

maddog1927 wrote:1) Do a gen 3 body conversion. IMO looks better, parts and graphics more available also.

Now a little thread hijacking
what does it take to swap the body, ban I keep the gen 2 gas tank?

Kuma you have to have the gen 3 tank to fit the gen 3 shrouds here is a write up on the other site. http://cr500riders.com/cgi/yabb/YaBB.pl?num=1289751349 Weird the author of that thread is maddog1927 i have a gen 2 that im going to do and i wil definetly be upgrading to the gen 3 shrouds and tank.

kevin_s · Post by **kevin_s** » August 12th, 2011, 3:59 am

Maddog,thanks for the info.Yes,my frame has the flat plate welded to it just like your's for the coil mount.

Unfortunately I have already ordered new plastics from Honda,but thanks for that info

hoofarted · Post by **hoofarted** » August 12th, 2011, 6:57 am

I put mine here, using a 250 coil:

another shot:

kevin_s · Post by **kevin_s** » August 12th, 2011, 5:32 pm

hoofarted wrote:I put mine here

Thanks for that.
Where did you put your CDI box?

Kuma · Post by **Kuma** » August 12th, 2011, 6:06 pm

Pretty sure the CDI goes under the front number plate

hoofarted · Post by **hoofarted** » August 14th, 2011, 12:21 am

Kuma wrote:Pretty sure the CDI goes under the front number plate

Exactly. You may have to extend the wires though IIRC...

kevin_s · Post by **kevin_s** » August 14th, 2011, 6:14 am

Ok,thanks

kevin_s · Post by **kevin_s** » August 17th, 2011, 10:22 am

Some progress pictures..

Is this AJ's initials on the y?

Rue · Post by **Rue** » August 17th, 2011, 8:55 pm

keep the pictures coming, nice to see all the swingarm and linkage bearings replaced and repacked. Like the new plastics, she's coming back to life!

kevin_s · Post by **kevin_s** » September 3rd, 2011, 7:00 pm

Thanks Rue.
I'm back on it now after my trip,engine all completed now with fresh bore and new piston.Rue hooked me up with a complete ignition system for the bike (thanks Rue).
I tried putting on the subframe and air box but I'm thinking I have the wrong air box boot because it wont line up with the carb inlet (it's about 1/2in too low)

If I'm not mistaken the stock one from this bike should fit correct?

Rue · Post by **Rue** » September 6th, 2011, 6:44 pm

It should line up, but I never got a chance to check.

I don't think the member I got the roller from switched the boots but couldn't be 100% sure... thanks for hooking me up with the water pump cover!

seanmx57 · Post by **seanmx57** » September 6th, 2011, 8:10 pm

I have some extra 00 airboots, I can check the part # if you need it. The fit isn't the best but it is workable and I've never had one pop off.

Pics of my grafics, not the new ones.

kevin_s · Post by **kevin_s** » October 8th, 2011, 3:04 pm

Ok,the airbox was correct It just has to go on a certain way.I still need some new rims but it's good enough to ride for now.Thanks for all the advice on this.This bike really wants to wheely but turns a lot better than my 98 and it's easyer going from sitting to standing.

Mik329 · Post by **Mik329** » October 8th, 2011, 4:03 pm

Call Colin over at Faster USA when you need rims if you don't want to lace and true yourself. He's a good dude and has pretty good prices, they also do hub polishing now. I sent a pair of hubs to him this week and will post what they turn out like.

kevin_s · Post by **kevin_s** » October 8th, 2011, 6:17 pm

Mik329 wrote:Call Colin over at Faster USA when you need rims if you don't want to lace and true yourself. He's a good dude and has pretty good prices, they also do hub polishing now. I sent a pair of hubs to him this week and will post what they turn out like.

Thanks,does he have a web site?
Looking forwards to the hub pictures.

Mik329 · Post by **Mik329** » October 8th, 2011, 9:59 pm

www.fasterusa.com
I bought a set of black wheels with red hubs about six months ago and they are holding up good on my 450. Much better than that China Warp9 crap all over Fleybay. I'm doing the polished hubs and black rims for another wheel set....

gregrobo · Post by **gregrobo** » October 8th, 2011, 11:55 pm

we just bought some rims from over your way of ebay $579, dnas billet hubs over 1300 aud here. $779 landed on my door and colour hoops and billet hubs heavy duty s/s spokes good value

kevin_s · Post by **kevin_s** » October 9th, 2011, 2:46 am

Thanks for the info.

NightBiker07 · Post by **NightBiker07** » October 9th, 2011, 6:50 pm

My CDI is underneath the tank on my conversion. Much cleaner looking than under the number plate, im not sure why they didnt put them there from the factory? less wiring harness stress too.

BannedCR500Riders.com

Gen 2 S/H rebuild

Gen 2 S/H rebuild