Exnav's Gen 1 Build!

dannygraves · Post by **dannygraves** » November 29th, 2007, 7:12 pm

DO IT! we can't have too much info here. pistons depend on the application. If you're gonna keep it stock go with cast (oem, prox or vortex) if your going to build it up go wiseco, but find a good machinist (best to send it to glen at gss or loomis since they know 500s and use torque plates). Forged pistons are strong but expand more, if you need the strength, its worth it, but cast will run fine for a long time too and is less critical on tolerances.
I run a wiseco at .004 clearance and its been running fine for a long time, but some people don't have such luck.

Exnav · Post by **Exnav** » November 30th, 2007, 12:32 pm

Woohoo, mounts came today. I can be a mocking up em' effer'

Thanks to those that designed and commissioned the parts.

Exnav · Post by **Exnav** » November 30th, 2007, 7:45 pm

Well here is some progress. Mocked up and ready to weld.

Nasty black bolt on the right side.

Left side...nice mounts.

Front showing the "V"

Lower pic of the front.

Took my time getting rid of the old welds and mounts. Carbide bit in a die grinder kept the heat away and touched it up with a fiber wheel in the die grinder, then blended with a brown scotch brite pad.

Don't know whats going on exactly, but my tank is hitting the part of the head that the head stay would mount to. I may have something screwed up, or maybe this is a different tank, because I thought that the only tank issue on the Gen 1 was the spark plug and that was fixed by using a shorty. Any ideas?

britincali · Post by **britincali** » November 30th, 2007, 7:50 pm

You have to tweek the tank a little to clear the headstay.

Post by **AlisoBob** » December 1st, 2007, 7:50 am

Exnav wrote:
Took my time getting rid of the old welds and mounts. ....

Awesome Job!!

There was once a Greek philosopher ( from Florida) named Rhackis Denero-Jackis who made this memorable quote:

Rhackis Denaro-Jackis wrote: Be weary of other sites encouraging you to do all the work yourself. It's not easy, and not for the everyday garage guy either.

Care to comment Exnav?

I cant wait to see the finished product!

Post by **AlisoBob** » December 1st, 2007, 8:08 am

On the left mount connection, there appears to still be a gap between your washer, and the motor.

You can get half -thickness washers to fill this.

Having different washers on each side is A-Ok.

Drawing the frame together by tightening the mount bolt is not.

Looks Great Otherwise!

Exnav · Post by **Exnav** » December 1st, 2007, 8:33 am

AlisoBob wrote:
Exnav wrote:
Took my time getting rid of the old welds and mounts. ....
Awesome Job!!

There was once a Greek philosopher ( from Florida) named Rhackis Denero-Jackis who made this memorable quote:

Rhackis Denaro-Jackis wrote: Be weary of other sites encouraging you to do all the work yourself. It's not easy, and not for the everyday garage guy either.

Care to comment Exnav?

I cant wait to see the finished product!

For ANYONE with a limited amount of mechanical ability, the Gen 1 is a nice project to take on. Borrow a sawzall and a small grinder, basic metric wrenches and sockets that you need anyway and get after it. I've spent more time cleaning the frame and various pieces than getting the engine in the bike.

Exnav · Post by **Exnav** » December 1st, 2007, 8:37 am

AlisoBob wrote:On the left mount connection, there appears to still be a gap between your washer, and the motor.

You can get half -thickness washers to fill this.

Having different washers on each side is A-Ok.

Drawing the frame together by tightening the mount bolt is not.

Looks Great Otherwise!

Where would one find the half thickness washers? Fastenal?

Post by **AlisoBob** » December 1st, 2007, 8:54 am

Any "Real" hardware store you have in the area.

Some call them " Half Thickness", others call them "Light"

Regular washers are about 0.063" Half's are just that, about 0.032".

dannygraves · Post by **dannygraves** » December 1st, 2007, 8:57 am

lookin good

Exnav · Post by **Exnav** » December 1st, 2007, 8:57 am

Gotcha

Exnav · Post by **Exnav** » December 1st, 2007, 3:28 pm

Couple more pics

Thin washer in and shimmed pretty good I think.

dannygraves · Post by **dannygraves** » December 1st, 2007, 4:07 pm

good job. I made the production mounts thicker than the ones on my bike so that less shimming would be needed.

dannygraves · Post by **dannygraves** » December 1st, 2007, 4:10 pm

on the tank there is one low hanging spot that touches the headstay. just hit it with a heat gun and push it in a little, not very much is needed.

Exnav · Post by **Exnav** » December 1st, 2007, 4:13 pm

dannygraves wrote:on the tank there is one low hanging spot that touches the headstay. just hit it with a heat gun and push it in a little, not very much is needed.

That's what brit was saying too. I bought a heat gun while I was out today, so it will get fixed soon. Not going to have much time to work on the project this week, heading out to a trade show. I should send the jug off to get bored.

Exnav · Post by **Exnav** » December 1st, 2007, 4:16 pm

Just thinking and have random questions, but would 14/49 be the stock gearing for this conversion?

dannygraves · Post by **dannygraves** » December 1st, 2007, 4:29 pm

I run 14/49 or 14/47 depending on where I'm riding. 14/49 is stock

Post by **AlisoBob** » December 1st, 2007, 9:21 pm

Exnav wrote: I should send the jug off to get bored.

http://www.bannedcr500riders.com/board/ ... php?t=1336

Exnav · Post by **Exnav** » December 1st, 2007, 10:13 pm

AlisoBob wrote:
Exnav wrote: I should send the jug off to get bored.
http://www.bannedcr500riders.com/board/ ... php?t=1336

Another example of not having these resources in the fly over zone of America.

I guess I should call Glenn and pack it up.

Exnav · Post by **Exnav** » December 20th, 2007, 6:03 pm

Latest update....

Got the frame welded up and it's back on the assembly stand.

Assembled the engine top end, so it is going in the frame shortly. Glen at GSS sure does nice work, as everything went back together easily.

Have lots of parts laying around, just waiting on me.

Will take some more pics once I am further along.

Merry Christmas to everyone!!!

Merry Festivus!

Post by **AlisoBob** » December 20th, 2007, 6:13 pm

Exnav wrote: Glen at GSS sure does nice work, as everything went back together easily.

Have lots of parts laying around, just waiting on me.

Great update.... Keep us posted!

Exnav · Post by **Exnav** » January 4th, 2008, 2:51 pm

Well fellas, the time finally came to suck it up and buy a new swingarm. I am done f_ckin' around with used pieces that I am trying to cobble together. It sucks to blow my build budget, but it's time to get this build moving again.

Hopefully I get this from the UPS man and can get back to taking pictures!

I did get my plumbing figured out with a little help from Danny. Just need a damn swingarm!!!!!!

Exnav · Post by **Exnav** » January 6th, 2008, 5:49 pm

Worked on the tank interference issue today and got it to a workable point. I was surprised how much I had to massage the tank for the head stay. The spark plug was easy after all the work on the head stay. I used a heat gun and the butt end of my dead blow hammer and a 24" 3/8" ratchet extension to roll the groove for the head stay.

Here is a shot showing the amount I had to push the tank up to get clearance for the head stay. You can see where the tank horizontal point was by looking to the right of the stay bracket.

And like I said, this was easy by comparison. Leaves enough room to get the boot off and on. I don't remember my 85' being a spark plug fouler, so I don't think even if this a little tight that it will be a big issue, if the bike is tuned correctly.

HrcRacing · Post by **HrcRacing** » January 6th, 2008, 7:39 pm

Exnav wrote:I used a heat gun and the butt end of my dead blow hammer and a 24' 3/8' ratchet extension to roll the groove for the head stay.

I'm gonna' have to see that 24 foot extension......J/K Looks great man!

Exnav · Post by **Exnav** » January 6th, 2008, 8:38 pm

CR500R-G3 wrote:
Exnav wrote:I used a heat gun and the butt end of my dead blow hammer and a 24' 3/8' ratchet extension to roll the groove for the head stay.
I'm gonna' have to see that 24 foot extension......J/K Looks great man!

Me and the shift key don't get along sometimes.

BannedCR500Riders.com

Exnav's Gen 1 Build!