Engine Case Help

RichM1983 · Post by **RichM1983** » February 5th, 2015, 5:45 pm

Hello everyone. Hope all is well!

I have a problem. I purchased a 500 motor that had a busted side case where the kicker shaft seats in the case. It came with a case to swap in and fix it. I spent a few hours tearing the motor down and replacing bearings, seals, and gaskets and putting it all back together. When I go to put the cylinder on I notice a HUGE problem. The side case I swapped in has a deck height way to low and it also appears that where the sleeve inserts into the cases does not have a large enough diameter either.

I tried the motor differences sticky and the pics won't work.

It looks to me like the base on the replaced side has been milled but I don't get why? Or is it just from a different year with a different deck height?

I'm fairly certain my motor was an 89.

Pic for reference.

Sandblaster · Post by **Sandblaster** » February 5th, 2015, 6:31 pm

I believe your lower case is a 86 or older.
The higher case should be 87 or newer.
Case ID's as follows:
1984 CR500 PE02E-530XXXX
1985 CR500 PE02E-540XXXX
1986 CR500 PE02E-550XXXX
1987 CR500 PE02E-550XXXX
1988 CR500 PE020E-570XXXX
1989 CR500 PE020E-580XXXX

RichM1983 · Post by **RichM1983** » February 5th, 2015, 7:24 pm

Ok so I checked out my stator side case, the one that was NOT replaced and it is an 89 for sure.

How do I identify what year the clutch side case is?

Pics.

Here are some pics of the clutch side case that I had to replace that ended up having a drastically different deck height.

Sandblaster · Post by **Sandblaster** » February 5th, 2015, 10:26 pm

I'll bet Roost knows.... Or another CR Guru..

http://www.youtube.com/user/500bigbore · February 6th, 2015, 10:14 am

What the heck!
The short case is a 1985-86, the stator case side is a 1989+, a larger bore for the larger sleeve.
What is the engine in? what cylinder do you have?

TecRider · Post by **TecRider** » February 6th, 2015, 10:15 am

RichM1983 wrote:Ok so I checked out my stator side case, the one that was NOT replaced and it is an 89 for sure.

How do I identify what year the clutch side case is?

Since the only short rod water cooled engines were '85 and '86, that will be what you have for a clutch side case.

TecRider · Post by **TecRider** » February 6th, 2015, 10:24 am

Roostius_Maximus wrote:What the heck!
The short case is a 1985-86, the stator case side is a 1989+, a larger bore for the larger sleeve.
What is the engine in? what cylinder do you have?

Dangit, Roosti, you beat me by one second . . .

The OP posted in cr500riders under my spacer thread that he had an 89 engine with a busted case. So he swapped it with a case he had on hand and found the discrepancy seen in the pics.

http://www.youtube.com/user/500bigbore · Post by **Roostius_Maximus** » February 6th, 2015, 2:20 pm

He can order a new right hand case for a 2001 model then

RichM1983 · Post by **RichM1983** » February 6th, 2015, 3:21 pm

I purchased this motor knowing it needed the right side case replaced. It was a complete 89 motor. It came with the other case you see currently installed. Through all the work I did on this motor I didn't realize what I was doing until I was finished and ready to put the cylinder on!!! I'm such an idiot lol.

Finding a right side case is going to be difficult and expensive. Two things I don't need.

This was purchased to start a CR500AF project with an 04 CR125 frame I picked up.

http://www.youtube.com/user/500bigbore · Post by **Roostius_Maximus** » February 6th, 2015, 4:06 pm

It's 300$ or less most places and comes with all new bearings in it.

BannedCR500Riders.com

Engine Case Help

Engine Case Help