BannedCR500Riders.com

I'm in the process of assembling my 89 cr500 motor and wanted to make sure I have all the right washers in place. My question is: when installing the main and countershaft (tranny) into the right case, is there a washer that rests on the bearings? And is there a washer for the shift drum (the side that also sits on the bearing)? The reason I ask is because I pulled a washer from underneath the shift drum during disassembly but it doesnt say anything about that washer in my manual.

Parts diagrams will set you free....

On the counter shaft there is a washer that sits against the bearing in the right case and left case, the main shaft however does not have a washer against the right case bearing, only against the left case bearing. As for the gearshift drum there is no indication of a washer and i do not recall installing one. Might be worth trying to find out why it was there in the first place, or someone else might know why.

Damn I cant believe I did that, I put the motor together and left the number 1 countershaft gear out (28t). I thought it was the idle gear. I kept my tranny together but somehow that one got misplaced, DAMN! Gonna fix it tomorrow it looks like.

Also after the cases are back together shift it through all the gears three or four times before anything else. Its no fun taking it all a part again.

DesertCR wrote:Damn I cant believe I did that, I put the motor together and left the number 1 countershaft gear out (28t). I thought it was the idle gear. I kept my tranny together but somehow that one got misplaced, DAMN! Gonna fix it tomorrow it looks like.

Pick up a manual and you'll avoid these mistakes,very good thing to have

here is a PDF manual I have on my hosting space
http://pho.sunrisehvac.com/500/manual/92-96CR500R.pdf

Ok guys I've got one more question. Is there a difference in the crankcase gasket between 92 and 89? I ask because when I first put the cases together I used the 89 gasket but this time I used an extra gasket for a 92 because I wanted to make sure I used a new gasket that had never been torqued. No they looked exactly the same but I'm seeing different part numbers for them. But the cases are all the same, right? Whatcha think.

nmdesertrider wrote:Parts diagrams will set you free....

true dat. if the diagram dont show it, it aint supposed to be there. some gaskets i installed dry, but center gasket is especially critical it doesnt leak so i used small amount of hondabond for added strength

Well I've got the tranny all figured out. But what about the difference in crankcase gasket, or is there any between 89 and 92? I dont want to continue unless I'm sure that it will do.

im sure the gaskets are very similiar and will interchange. lay it on the cases and look at it. match it up with the old one also

I think honda used a different material/color gasket... all center case gaskets '87+ will work.

Thanks Danny, they look identical except the 89 is green and the 92 is yellowish. I need to get an opinion from you guys, I had my cylinder bored to 89.25 by Veys in Southern CA and just right now I was about to install the piston and top end, so I measured the ring end gap and its almost at the service limit (.019). What do you guys think, run it or ?

run it

DesertCR wrote: (.019). What do you guys think, run it or ?

Sheeiitt...my last NEW top end had a gap of .024...(Wiseco)

my last wiseco rings were near zero for some reason. so i took a dremel to open the gap and accidentally went overboard. seems like they were around .018 after i got done grinding, i wasnt going to wait for new ones so i ran them and havent had any problems so far. .014 is what i was shooting for but oh well

100hp honda wrote:my last wiseco rings were near zero for some reason. so i took a dremel to open the gap and accidentally went overboard. seems like they were around .018 after i got done grinding, i wasnt going to wait for new ones so i ran them and havent had any problems so far. .014 is what i was shooting for but oh well

I think you can get "file fit" on request. Thats prolly what happened. Usually if the gap is too tight its because your bore is too tight for that size piston. Thats the oposite of what happened to me, since I run looser sidewall clearances then the minimum...

mine were about .02 if i remember right ran just fine..

My bike ran pretty good after I welded the rings to the piston, so I think its fine...