BannedCR500Riders.com

Picking up my case half tomorrow from drain thread repair (WASN'T ME!), then back together it goes.

I'm going all out.

you gonna polish that exhaust port and match it to the manifold?

before



during



after



not perfect, but perfect enough for me.there was another fella on this site that did the same thing but opened up the whole port abit more.i left the port opening as standard
metal polish, emery cloth, cotton rags and an electric drill will be your best friend during this process.

stuz thats some fine work . what else did you do ?

WOW! you have got too much time on your hands.

Looks very sexy!

100hp honda wrote:stuz thats some fine work . what else did you do ?

i didnt do much else. just cleaned out the other ports a bit, polished the dome and piston crown, and did a full rebuild on the engine/box/clutch. i didnt feel the need to extract more power cos its got plenty as is.im more playing with gearing and suspension these days. im running 14,46 which actually lets me use the power in 2nd and 3rd and get traction.i can lug it in 3rd ,give it full throttle and it wont even bog. pulls hard like a 4poke with any load in any gear and the wind out is much better.5th gear bogs but i never get to see it.love it. i just cant understand how people use 14/51 gearing. ive tried it on a mx track and its unusable power unless your in 4th or 5th. its the fastest bike at our local track (hardpack) but im looking forward to taking it down to some of the pro tracks to see how it goes against the pro 450 racers in the softer stuff.hopefully in the next few weeks now ive run in this seizco.
mods are;
gnally
rad valve
01 250 ing

CR500R7 wrote:

WOW! you have got too much time on your hands.

too much time is a good thing,gives me time for the finer things in summer and polishng engines lol.





i got a job where i work weekends and get the weekdays off still pull the same weekly wege too cos i work 12 hr shifts on o.t. rates. one month on, one month off rotating roster.
its one month of 7am-7pm weekends, then one month of 7am-3pm weekdays.

and once youve polished cases by hand, an exhaust port isnt much.

Xylicon wrote:Picking up my case half tomorrow from drain thread repair (WASN'T ME!), then back together it goes.

I'm going all out.

(sorry for the hijack)
make sure you use bearings made in japan for your engine. some will try sell you std taiwanese bearings, but only the ones made in japan are of transmission quality.
are you doing anything to your cases, polishing,painting,blasting? glen howell gets a real good finish using walnut shells for blasting(think thats what it was).he put up some pics on here somewhere, comes up kind of like dull polished alloy.looks sweet.i would of had my ports,barrel and cases blasted that way if i had of known prior..

hey bud, that looks like a 90mm wiseco you got there. you couldn do me a favour and weigh that puppy for me could ya? piston only(no rings or pin)
just wanna get a comparo to the 90 vertex i got.

http://xylicon.com/box/otherstuff/CR500 ... _small.jpg

Its a 90.50mm, do you still want it weighed? I have a used 90mm sitting right here, has some carbon on it, I could do that one too.

Only OEM Honda parts get used in my engine, (:

thanks mate. yeah if its no trouble both would be great. are they both wisecos?

the 90mm and the 90.50mm Wisecos look like they weigh exactly the same at 16oz, but my scale isn't state of the art.

Just picked up the case half from drain bolt repair, it came out really nice!

so whats on the "must do " list for your engine?
just the main/gbox bearings or you doing the crank?ballancing?ign,etc?

Xylicon wrote:the 90mm and the 90.50mm Wisecos look like they weigh exactly the same at 16oz, but my scale isn't state of the art.

you can bet your ass the larger piston will weigh slightly more, albiet a negligable amount.

damn, piston weighs a whole pound!

Xyclion has the new " Improved" CR500 Wiesco piston....



The CRF450 piston.


16 Oz = 473 grams ( A pound is 454 grams!)

....this weighs 261 grams

Update:





Shiny new parts

shouldnt the crank be in the other half

it would be alittle easier to flip the case half over?

Don't forget the other bearing for the shift drum and the other dowel!

fastkart wrote:Don't forget the other bearing for the shift drum and the other locating dowel!

Thanks for the dowel pin reminder I totally would've forgot!

The shift drum bearing is the one bearing I forgot to order, hopefully it arrives today or I'll be

Good work!

**Update**


It went together nice and easy thanks to my super awesome Tusk Crank Installer tool. 50 bucks well spent.

Started up on the second kick warmed it up took it up the street to verify correct transmission operation and its all good!

I just have to work out a few minor issues, like re-indexing the kick starter and my clutch is sticking a little bit, could be the BIG ASS GROOVES in the basket

blownbillybob wrote:shouldnt the crank be in the other half

it would be alittle easier to flip the case half over?

with every 2t ive built/rebuilt i always put everything in the counter shaft sprocket side. makes it way easier to put the other half on. i also built a nice little box for the engine case to sit on so i dont have the crank snout hitting the table....

Well the way he has it now it would be easier if the crank was on the same side as the trans.

I guess you could assemble it either way it's the same thing but the book says to assemble everything in the clutch basket side of the cases so when you install the adjoining half you put your bolts in and tork them down and your done? Your way sounds like you have to put some bolts in upside-down then flip it over to tork the bolts so I don't see how that could be way easier

I put my case half on two big steel parallel bars so none of the shafts touch the table

But what ever works for you???

yep half of one...six of the other