Exnav's Gen 1 Build!
Exnav's Gen 1 Build!
I bought me an engine, and am going to look at a 98 250 tonight or tomorrow.
This is fun
This is fun
I will take pictures of the progress and upload to share. Hopefully, I can learn a thing or two during the build and maybe someone else can from it too. It was Bob and Danny's posts about what to build if you are just a normal guy and I fit that description somewhat, that made me choose to go this route.
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
Everything I have found recently has been off Craig's List and I am looking in a 2-300 hundred mile radius of St. Louis.dannygraves wrote:try craigs list, I got my running '97 for $900 off craigs list.
It would appear that I may have to be more patient and wait for the deal to come around.
Am going to check the one posted a pic of on Wednesday.
Money ain't got no owners, only spenders - Omar Little
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
while your waiting for the kit to get there, strip it down and cut off the front mounts and the x-brace. Start mock up and take care of the plumbing, wiring, etc. When the kit gets there mock it up with the front mounts and spacers installed, then off the the welder. should be done by next weekend
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
You and Bob are killing me. It's freaking cold in the garage and I haven't gotten around to buying the heater yet! Supposed to snow tonight. Excuses, excuses-blah-blah-blah.dannygraves wrote:while your waiting for the kit to get there, strip it down and cut off the front mounts and the x-brace. Start mock up and take care of the plumbing, wiring, etc. When the kit gets there mock it up with the front mounts and spacers installed, then off the the welder. should be done by next weekend
Money ain't got no owners, only spenders - Omar Little
The build is underway. I have the bike stripped tonight and the front mounts have been cut. Luv the sawzall!
Heading back out to the garage to cut the X. Had to come in and read Danny's build for a pic of how to cut the X exactly.
This site rocks.
Heading back out to the garage to cut the X. Had to come in and read Danny's build for a pic of how to cut the X exactly.
This site rocks.
Money ain't got no owners, only spenders - Omar Little
Will give it a try.
tick
tick
tick
It's now a V.
Things are going fairly well to this point. I was a little concerned with the swingarm bolt being frozen in, but it came out like butter.
I did find that some meathead twisted off the right side chain tensioner bolt damn near flush with the swingarm. I have never had much luck drilling bolts out or using the "easy outs", so I may be taking this to my friendly machinist to work some magic on it. I feel a little foolish for not seeing this when I bought the bike!
The bike had a Twin Air filter on it and when I pulled the boot off the carb there was shit everywhere in the boot and the mouth of the carb. It wasn't dirt, but more like grass and cotton that had gotten oily. The carb looked good and clean at the slide and past to the manifold/cage. Things just look like what you would expect a 10 year old bike to look like.
Time for a beer.
tick
tick
tick
It's now a V.
Things are going fairly well to this point. I was a little concerned with the swingarm bolt being frozen in, but it came out like butter.
I did find that some meathead twisted off the right side chain tensioner bolt damn near flush with the swingarm. I have never had much luck drilling bolts out or using the "easy outs", so I may be taking this to my friendly machinist to work some magic on it. I feel a little foolish for not seeing this when I bought the bike!
The bike had a Twin Air filter on it and when I pulled the boot off the carb there was shit everywhere in the boot and the mouth of the carb. It wasn't dirt, but more like grass and cotton that had gotten oily. The carb looked good and clean at the slide and past to the manifold/cage. Things just look like what you would expect a 10 year old bike to look like.
Time for a beer.
Last edited by Exnav on January 24th, 2008, 8:33 pm, edited 1 time in total.
Money ain't got no owners, only spenders - Omar Little
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
sounds good. Buy a new UNI filter. read my "twin air can suck my ballz" thread in the product forum. I cut out my entire x-brace so I would be able to remove the jug with the motor in. Check out shanmans PDF as well.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
heres shanmans gen-1 instructions as well.
http://bannedcr500riders.com/library/CR ... n-RevC.pdf
also in my thread I forgot to post up pics when I did my coolant lines and exhaust, so go ahead and ask if you need any help with that stuff.
http://bannedcr500riders.com/library/CR ... n-RevC.pdf
also in my thread I forgot to post up pics when I did my coolant lines and exhaust, so go ahead and ask if you need any help with that stuff.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Read the Twin Air thread and I have used UNI in the past on my 85'. Good info.dannygraves wrote:sounds good. Buy a new UNI filter. read my "twin air can suck my ballz" thread in the product forum. I cut out my entire x-brace so I would be able to remove the jug with the motor in. Check out shanmans PDF as well.
Money ain't got no owners, only spenders - Omar Little
Can someone post up current links to the shanman's build? These are dead.....the dreaded 404 fie found.dannygraves wrote:heres shanmans gen-1 instructions as well.
http://bannedcr500riders.com/library/CR ... n-RevC.pdf
also in my thread I forgot to post up pics when I did my coolant lines and exhaust, so go ahead and ask if you need any help with that stuff.
Money ain't got no owners, only spenders - Omar Little
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
copy and paste this link
http://pho.sunrisehvac.com/AF/CR500AF_G ... Rev_C).pdf
http://pho.sunrisehvac.com/AF/CR500AF_G ... Rev_C).pdf
Last edited by dannygraves on November 28th, 2007, 7:41 am, edited 3 times in total.
'09 kx450f 4-Poke
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
Gen-4 trail bike --SOLD--
Gen-3 badass trail/mx bike --SOLD--
Gen-1 built dunes bike --SOLD--
'05 klx110 --SOLD--
'95 pw80
- dannygraves
- Posts: 8020
- Joined: June 1st, 2007, 2:03 pm
- Location: Las Vegas, NV
http://bannedcr500riders.com/board/libr ... n-RevC.pdfExnav wrote:Can someone post up current links to the shanman's build? These are dead.....the dreaded 404 fie found.dannygraves wrote:heres shanmans gen-1 instructions as well.
http://bannedcr500riders.com/library/CR ... n-RevC.pdf
also in my thread I forgot to post up pics when I did my coolant lines and exhaust, so go ahead and ask if you need any help with that stuff.
http://bannedcr500riders.com/board/cms_ ... .php?aid=7
Sorry about that.
Well the build is stalled for the moment. The swingarm is at the machine shop getting a twisted off bolt removed. The cylinder is going to the shop to be bored or honed...whatever is necessary. Don't know for sure until the top end comes apart, but it appears that this 97' engine has a cast piston from what I can see through the exhaust port(stock?). So is Pro X the preferred piston to replace the current slug with? Opinions?
Bought a bolt for engine mount mock up. I need to find a nice zinc or stainless metric to replace the nasty black one that I bought, but it will serve the purpose.
Should I take pics of the progress and post since there have been several Gen 1 builds already?
Bought a bolt for engine mount mock up. I need to find a nice zinc or stainless metric to replace the nasty black one that I bought, but it will serve the purpose.
Should I take pics of the progress and post since there have been several Gen 1 builds already?
Last edited by Exnav on January 24th, 2008, 8:34 pm, edited 1 time in total.
Money ain't got no owners, only spenders - Omar Little