BannedCR500Riders.com

It took quite abit of reserch for what in fact is quite a very simple mod.
This info is on the CR250-99 model stator ( Digital ) and rerquired hard wear to mate up to a CR500 motor.
The standard equipment on the 500 is Analog.

You'll need a complete CR250-99, stator, backing plate, CDI, fly wheel and wiring loom.



If you turn the backing plate over you will see in the center of the casting it is rased...you will need to machine this material away so that its flat.



Heres the same backing plate machined



I used a router as alloy is machinable with most wood working tools.



This pick shows the first cut i did, i must admit i was nervous but theres no need to be the alloy cuts away smoothly and fast.



Backing plate machined.



Now theres a spacing ring that needs to be fabricated.
some make it out of michined alloy some use an "O"ring.
I chose the "O" ring as this spacer is simply there to centralise the backing plate.
There are 2 sizes in "O" rings, Imperial and Metric.




The size that fitted best for me was the Metric R-27.




Theres also a R-27 in the imperial but this "O" ring is much thinner then the metric one.(see below)



This is the Metric "O" ring fitted (thicker) you can see this as it covers more of the screw holes.(see below)



This is the stator plate machined and R-27 Metric "O" ring fitted.
the fitting of your newly modified CR250 stator is a strait forward replacement of the standard 500 equipment.



I'd even set the timing as you would the factory 500 system as the timing marks and values are the same and the digital CDI advances and retards better then any Analog could of dreamed of.
Then when you get use to it then you may advance or retard as you feel.

This is a very simple outline of this task as i found that trying to get a simple question answered required reading hundreds of pages of hijacked threads.

Nice one, and what did you think of the results?

i cant say as ive never rode the bike with the standard 500 system....i'll ride what ive got.
im sure i'll like it.

Nice info, I like pictures

How much easier is it with a good picture.

Well done asteroid

Bob you should make this a sticky

Awesome, do you feel like routering one for me? I'm gonna scour the ebay and craigslist for a setup. BTW, couldn't you replace the stator with a rewound unit for lighting? I know the 250 has a lighting coil available, but will it work?

HI port..
to be honest any carpenter or cabinet builder would have a router bentch availible to do this job.
the whole job including the O ring selection took me less then 10 mins...

As far as rewinding goes theres many differet companys that can do this for you...the backing plate will remain the same and its this part that requires the mod.

By the way i live in Norrthern Australia so its not cost efficeant for you to send your stator to me otherwise i would gladly do it for you free of charge.

nice work

nice work

So I go to ebay to look, sure enough there is only one ignition system available, and it's some guy from the cr500riders board selling it as a cr500 kit, and he wants alot of money for it. I guess I will have to search local adds because the word is out and the price of this stuff has trippled in a few months from what I can see.

Yeah the secret's out for good I guess, 250 ignitions are coming out of the wood work for sale, and not for the $90 I got mine for. A friend of mine in ID has a snowmobile magazine with a CR500 Gen 4 (ie NOT S/H) conversion ride test in it. He says the magazine states the CR250 ignition swap is "the hot setup" I thought "ok" if they say so

Great write up asteroid, that's how EVERY tech report should be done. Lots of detailed pics make a world of difference. A good ride comparison would have been just tits though...

Ported&Polished wrote:So I go to ebay to look, sure enough there is only one ignition system available, and it's some guy from the cr500riders board selling it as a cr500 kit, and he wants alot of money for it. I guess I will have to search local adds because the word is out and the price of this stuff has trippled in a few months from what I can see.

i got mine a few months ago for 200. 01 cr250.

good luck

were tryin to get a dyno session done for the 250/500 ignition,pc,fmf,std pipes atm.any hoons willing to pitch in with some time or money would be gladly welcomed. for more info, check out the link

http://bannedcr500riders.com/board/view ... highlight=

Thanks folks,
I just wanted to do this modification in a step by step format
for all Newbies....as i'm one my self.

Theres so much info on this site but you've got to read pages and pages of
playful shit...hey i'm guilty of it,
but i'd like to see all modification threads with ALL the info on the first to second pages so if your chasing any bits and pieces the info's smack in your face from the moment you open the thread......then you can enjoy the following playful shit and dig's.

Hi Ported and polished. I'm the guy that sold that unit on ebay. I've been watching them for well over a year. It's not just us that has driven the price up, cart guys like the 01 CR250 motors. There are guys building new CR250 AFC's like SH does too cause the CR250 is extinct.......

I saw a complete unit go for over $350 a while ago. You can get analog ones cheap. The one I just sold I didn't make any $$ on it. I bought the parts seperately off ebay but I messed up and got a CDI. I'm going to give a MSD unit a run so I can do my own curve.

I think I still have a couple complete units for sale.

I know who you are talking about on CR 500 Riders site. I almost brought a motor from him. He gave me the link you http://cgi.ebay.com/ebaymotors/2000-200 ... soriesjust showed me. He got $225 for it I got the link from him then I Brought 1 for $80 and did the mod myself. It is easy. I fastened to my bench and took a plunge router and set the depth. It only took 10 min as he said. I had an O-ring from all the nail gun parts I have. Oh he was also charging for the mod on top of the price of the ignition. He is a nice guy just wants a lot of money for his parts. I spoke to him on the phone.

$30.00 to machine the backing plate is VERY reasonable....
If you went to any engineering workshop you'd be charged a hell of alot more then that i can assure you.

Unless you can get mates rates....
A router bit required to do this job cost atleast $60-90 dollars.

Prices on anything in life are based on supply and remand.

Hey it's all good men, I don't expect anyone to give the stuff away. So who can post up what years are good to use? So far I hear 99, 01, and 02? Any other years worth a crap?

roosty seems to like his 88 set up, plenty like the 93 - 96 direct bolt on. I figured digital is better especially cuase I can program a MSD. vortec or what ever they are are very expensive for the softwware. MSD software is free.

No extra wires to fool with on the 99 - 01. I'm trying to get the curves mapped on the 00 and 01's as well as the 500 late model CDI's so I have a good start point on the MSD.

Bruce-J wrote:I know who you are talking about on CR 500 Riders site. I almost brought a motor from him. He gave me the link you http://cgi.ebay.com/ebaymotors/2000-200 ... soriesjust showed me. He got $225 for it I got the link from him then I Brought 1 for $80 and did the mod myself. It is easy. I fastened to my bench and took a plunge router and set the depth. It only took 10 min as he said. I had an O-ring from all the nail gun parts I have. Oh he was also charging for the mod on top of the price of the ignition. He is a nice guy just wants a lot of money for his parts. I spoke to him on the phone.

Hi Bruce, U R certainly welcome to buy new parts.........

You obviously want things for rock bottom prices. Just don't complain when they crap out.

How's your build going?

I have a lead on an '00 ignition system, I offered the guy 150 plus shipping, we will see.

i found a programable 250 unit with 4 curves. now if i only had $500

CR250-97-to current are Digital
CR250-97to98 has the power jet carb there for on your 500 application you get a spare wire and plug that run from your CDI box and would other wise got to the carby.
Aparently it does not effect the 500 having this lead going nowere as it's simply there to activate the solinoid to add extra fuel at a certain RPM range.

Sean I do want to thank you again for the link. You are a hell of a nice guy. I guess I have an opinion. I am finishing the bike up I have to put my $80 ignition in.http://cgi.ebay.com/ebaymotors/ws/eBayI ... OTORS:1123
Re jet the carb and it needs fork seal and I'm done. I don't pay full price for anything or even close to it. I guess if you don't have a plunge router I guess it is worth the $30. Not to me. I own a business and I imagine you are in it to make money but go easy on us please. I guess we have the choice not to buy. I might even get to ride it It's cold here unseasonably cold for NC nothing like Hew Hampshire cold. I'll post some pics when I'm done.
Happy CR-ing
Bruce