Exnav's Gen 1 Build!

Exnav · Post by **Exnav** » November 16th, 2007, 8:38 am

I bought me an engine, and am going to look at a 98 250 tonight or tomorrow.

This is fun

Post by **AlisoBob** » November 16th, 2007, 1:17 pm

SWEET!!!

Exnav · Post by **Exnav** » November 16th, 2007, 8:26 pm

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.

Post by **AlisoBob** » November 16th, 2007, 8:31 pm

Exnav wrote: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.

Glad to hear the site is helping out!!

dannygraves · Post by **dannygraves** » November 19th, 2007, 10:58 am

yup, thats what we are here for!

Exnav · Post by **Exnav** » November 19th, 2007, 3:21 pm

As soon as I find a seller that isn't hitting the pipe and doesn't want 2k for his clapped out hunk of steaming dung, then I will be ordering a kit from Danny

dannygraves · Post by **dannygraves** » November 19th, 2007, 8:12 pm

try craigs list, I got my running '97 for $900 off craigs list.

Exnav · Post by **Exnav** » November 19th, 2007, 9:03 pm

dannygraves wrote:try craigs list, I got my running '97 for $900 off craigs list.

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.

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.

dannygraves · Post by **dannygraves** » November 20th, 2007, 7:56 am

goodluck

Exnav · Post by **Exnav** » November 26th, 2007, 1:07 pm

Engine is here and damn....I forgot how freaking big these 500's are in comparison to the 250

Kit is on it's way from Danny.....time to start the swap.

Post by **AlisoBob** » November 26th, 2007, 1:10 pm

Exnav wrote:.....time to start the swap.

You should have it done by dinnertime....

dannygraves · Post by **dannygraves** » November 26th, 2007, 1:57 pm

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

Exnav · Post by **Exnav** » November 26th, 2007, 3:07 pm

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

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.

Exnav · Post by **Exnav** » November 27th, 2007, 7:11 pm

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.

Post by **AlisoBob** » November 27th, 2007, 7:13 pm

Some guys only cut out the lower portion, so it looks like this...

V

Get it ?

Exnav · Post by **Exnav** » November 27th, 2007, 7:15 pm

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.

dannygraves · Post by **dannygraves** » November 28th, 2007, 7:22 am

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.

dannygraves · Post by **dannygraves** » November 28th, 2007, 7:24 am

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.

Exnav · Post by **Exnav** » November 28th, 2007, 7:35 am

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.

Read the Twin Air thread and I have used UNI in the past on my 85'. Good info.

Exnav · Post by **Exnav** » November 28th, 2007, 7:36 am

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.

Can someone post up current links to the shanman's build? These are dead.....the dreaded 404 fie found.

dannygraves · Post by **dannygraves** » November 28th, 2007, 7:38 am

copy and paste this link
http://pho.sunrisehvac.com/AF/CR500AF_G ... Rev_C).pdf

dannygraves · Post by **dannygraves** » November 28th, 2007, 7:39 am

because of the file name the hyperlink will not work, but you can copy and paste it into the browser bar

Post by **Admin** » November 28th, 2007, 7:48 am

Exnav wrote:
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.
Can someone post up current links to the shanman's build? These are dead.....the dreaded 404 fie found.

http://bannedcr500riders.com/board/libr ... n-RevC.pdf

http://bannedcr500riders.com/board/cms_ ... .php?aid=7

Sorry about that.

Exnav · Post by **Exnav** » November 29th, 2007, 6:15 pm

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?

Post by **AlisoBob** » November 29th, 2007, 6:16 pm

Hell Ya!

BannedCR500Riders.com

Exnav's Gen 1 Build!

Exnav's Gen 1 Build!