CR500AF ignition

craigf40 · Post by **craigf40** » January 25th, 2010, 9:27 am

hi to all im new here im from south africa and have built a gen3 500af the bike is perfect but iv read posts where guys have fitted the 250 ignition.i have fitted the complete gen3 ignition and tps carb but the bike runs like shit even retarding or advancing the timing doesnt really help.does anyone know if that system can work on the 500 kind regards craig

asteroid500 · Post by **asteroid500** » January 25th, 2010, 5:04 pm

try this tread,

http://www.bannedcr500riders.com/board/ ... php?t=8044

Also try the search function to any new quiries you may have 1st

nmdesertrider · Post by **nmdesertrider** » January 25th, 2010, 10:46 pm

sounds like your stator is toast

craigf40 · Post by **craigf40** » January 26th, 2010, 9:38 am

asteroid500 wrote:try this tread,

http://www.bannedcr500riders.com/board/ ... php?t=8044

Also try the search function to any new quiries you may have 1st

thanks i check all those threads already ...the bike starts easily and pulls well into the mid but as its about to rev out it just stays flat. i have also fitted a wyseco piston and a 86 head and ported it slightly... it go's very well with the 2001 cr500 ignition but after all iv read on those posts i decided to fit the complete gen 3 250 ignition and tps carb but now it go's like shit even with the 500 carb its the same... please any ideas
kind regards craig

britincali · Post by **britincali** » January 26th, 2010, 10:33 am

Jetting?

craigf40 · Post by **craigf40** » January 26th, 2010, 10:52 am

britincali wrote:Jetting?

like i say it makes no difference wich carb i fit so i have ruled jetting out the only deference is when i fit the 500 ignition then its sweet...but from all the posts iv read i would like to get the 250 setup working....i use the 250 coil with the 500 ignition and it works well so its not the coil either

eyesky2002 · Post by **eyesky2002** » January 26th, 2010, 11:35 am

nmdesertrider wrote:sounds like your stator is toast

Or the CDI box itself....

craigf40 · Post by **craigf40** » January 26th, 2010, 12:33 pm

eyesky2002 wrote:
nmdesertrider wrote:sounds like your stator is toast
Or the CDI box itself....

do you think that the 250 timing curve could change the engine vacuum so much that the jetting is completely wrong .... i been thinking about the previous reply "jetting"

MICK · Post by **MICK** » January 26th, 2010, 8:24 pm

craigf40 wrote:...the bike starts easily and pulls well into the mid but as its about to rev out it just stays flat.

you still have the factory rev limiter installed don't you! Lookup GSS in the approved vendors section. Clyde says they have experience in this matter:

100hp honda wrote:...and the cdi box that you took apart to supposedly remove the "rev limiter"

100hp honda · Post by **100hp honda** » January 26th, 2010, 8:32 pm

yep yep. glen at GSS can remove the rev limiter then youll rev to 9000rpm

NightBiker07 · Post by **NightBiker07** » January 26th, 2010, 10:00 pm

could the cr250 ignition you received actually be defective?

craigf40 · Post by **craigf40** » January 27th, 2010, 12:07 am

NightBiker07 wrote:could the cr250 ignition you received actually be defective?

the cdi comes out the gen3 rolling chassis i used for the conversion and was working fine

craigf40 · Post by **craigf40** » January 27th, 2010, 12:11 am

MICK wrote:
craigf40 wrote:...the bike starts easily and pulls well into the mid but as its about to rev out it just stays flat.
you still have the factory rev limiter installed don't you! Lookup GSS in the approved vendors section. Clyde says they have experience in this matter:
100hp honda wrote:...and the cdi box that you took apart to supposedly remove the "rev limiter"

glen is a bit far from south africa ...the thing is i dont think the bike revs higher than 5000 so i dont think its the rev limiter but thanks for the imput...

asteroid500 · Post by **asteroid500** » January 27th, 2010, 1:05 am

Is your air gap in the stator .012 in relation to the fly wheel

craigf40 · Post by **craigf40** » January 27th, 2010, 1:53 am

asteroid500 wrote:Is your air gap in the stator .012 in relation to the fly wheel

yes i checked that ...but what i have noticed is when its about to run out of fuel then it will rev but i dont understand that some one said to me jetting ...can the 250 ignition curve be so deterrent that it changes the engine vacuum so much that the jetting is way out ...when i use the tps 250 mikuni carb the main is 380 the 500 carb keihin main is 160 and with the 500 ignition it runs perfect with that jet setting...so really im about to just give up on the 250 ignition ...maybe the earlier 250 ignition is defferent

Bean · Post by **Bean** » January 27th, 2010, 2:26 am

what year mod 250 ign?

asteroid500 · Post by **asteroid500** » January 27th, 2010, 3:10 am

To be honest youd have to re-jet the carb to suit the new ignition and that aint to hard, leave the carb settings at what they were before the ignition swap over and go from there.

craigf40 · Post by **craigf40** » January 27th, 2010, 4:07 am

asteroid500 wrote:To be honest youd have to re-jet the carb to suit the new ignition and that aint to hard, leave the carb settings at what they were before the ignition swap over and go from there.

yes i think the jetting is the big problem as i took the needle from the 500 keihin wich is thicker than the mikuni 250 carb but otherwise the same and sorted the rev problem out it also idles very well starts easily its idling of the idle skrew and responds when adjusting the air skrew which it never did before...iv read posts where guys say the needle only comes into play after idle ?? seems it could effect the idle as well..and the bike was so well tuned when running the 500 ignition regards to the idling and starting fuel consumption and overall peformance that i still can't believe how much it changed with the 250 ignition.. but thanks a ton to all you guys out there who helped and i will let you know the final jetting numbers i use...im in johannesburg which is about 1500 meters above see level
kind regards craig

Bean · Post by **Bean** » January 27th, 2010, 4:36 am

mate if it's a 02 to 07 ign the tdc mark is way out you need to mod the stator plate make it work

craigf40 · Post by **craigf40** » January 27th, 2010, 7:56 am

shaggy aus wrote:mate if it's a 02 to 07 ign the tdc mark is way out you need to mod the stator plate make it work

thanks mate i have advanced it max and it seems to work well now that iv jetted it and yes its the 02-07 mod ignition... what exactly do you do to mod the stator plate drill the holes more to get more advance or what?...and thanks for your input
kind regards craig

Bean · Post by **Bean** » January 28th, 2010, 3:26 am

you need to re-drill the slots in the stator plate to get about 10deg more advance.
set the piston at true tdc and you will see how far out the timming mark on the flywheel is to the stator plate
use a timming light to set it up, the marks should line up at 2000rpm
hope that helps

asteroid500 · Post by **asteroid500** » January 28th, 2010, 4:43 am

great imput Shaggy.

craigf40 · Post by **craigf40** » January 28th, 2010, 12:02 pm

shaggy aus wrote:you need to re-drill the slots in the stator plate to get about 10deg more advance.
set the piston at true tdc and you will see how far out the timming mark on the flywheel is to the stator plate
use a timming light to set it up, the marks should line up at 2000rpm
hope that helps

thanks mate il check it out but i think you nailed it cheers...il will let you know as soon as iv sorted it
regards craig

Bean · Post by **Bean** » January 29th, 2010, 2:03 am

ok guys
the 03 250r ignition works well
i was testing it out on the workshop driveway
now there are a few big black marks along it.....

craigf40 · Post by **craigf40** » February 2nd, 2010, 8:04 am

well guys firstly thank you for all your input i have now finished it completely and must say this is the best moto x bike iv ever owned and iv had many including a kx500...the 250 ignition conversion was the cherry on the top you were correct the timing needs some extra shifting of the stator plate which just needs some drilling or filing ...i used the 03 250 38mm mikuni TPS carb with all the wiring connected to the ignition i settled for a 380 main jet needle in the second from the top position a 30 slow jet ...it idles well it starts so easy im shocked every time it starts i also used the litle 250 fly wheel which in my opinion has made the bike vibrate less...the only other mods i have is a wiseco piston .50 the exhaust port i lifted 2mm and the transfer ports 1mm ...i also polished the exhaust port and flowed the intake ports by just removing lil bumps and nukes ...i used a thick base gasket and i have a 86 head on it ...it also has a full fmf narly pipe ..well the botom seems like iv lost a lil power there could maybe be my needle position but im really not to concerned about it the mid range is second to none just unbelievable and it revs out like never before...im really happy with this bike and thanks again to all you pros out there its a really great site to get the latest and best info on the net i could find for my cr500af thanks guy

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