Cr 500 af

[RamRod]

Post up a vid when you can! I wanna see it launch you to the moon!

 

[SuperBuickGuy]

this is astounding, I ordered from Bike Bandit yesterday (they're in Idaho), and received my order this morning.... wow.

 

[SuperBuickGuy]

Time to start dialing this in.... after the motor, I'm going to do some suspension work - after riding for 4 hours, the suspension seemed to lose all compliance - more specifically, the rear shock. As I used the shock from the cr500; it wouldn't surprise me to find out I need to swap that for the crf shock... especially since I think I overheated the fluid (the reservoir was pretty warm).

anyway, today's job
the pipe is cracked


the pipe has been welded a few times.


the replacement, a FMF Gnarly pipe... this pipe is for more bottom end and is well suited for the riding I do - also note the Q muffler/arrester. It's quieter than my other one, and should keep me from getting a noise ticket... something I should be concerned about with the old muffler



pulling it apart


so here's where I'm at tonight - dry fit. I need to get high temp silicone and I have to cut on these brand-new pipes.... ugh, the joys of modified bikes


I'm ordering a carb for it as well, a bit larger and brand new

 

[SuperBuickGuy]

dont' get jiggy with the side grinder... d'oh


all is good now


​

 

[SuperBuickGuy]

Despite the resounding silence (hehe, punny),
And because stock is just too reliable, I present the new, larger BY 1.5MM carb (feel the power)

​time to jet

 

[SuperBuickGuy]

ugh, ignorance was bliss... this clutch was worn with a capital worn

the bike


apart


aren't those teeth worn into the clutch basket pretty? you can see the pressure plate as well is worn past usefulness.


I measured the steels and frictions - they were all substantially under minimum tolerance

even the push rod was worn


ah well, it will be all better than new when I put it back together - but like the discovery, it stopped me for at least a week.

 

[SuperBuickGuy]

new parts comparison new v. old




this one wasn't easy to find...


it looks pretty good inside, and that the case has been apart (like my brother said)


Hinson basket




to take old apart, you have to grind the rivets off - which went pretty easily, actually


press the old gear out, heat the basket to 400* and freeze the gear.... it drops in place - some rotation is required (which Hinson didn't say in their instructions...no worries, though)


​

 

[RamRod]

Looking good, I bet the thing is a rocket

 

[Cyouincourt007]

:agree:

 

[SuperBuickGuy]

and now new and improved with clutch

 

[RamRod]

Whats this!? No rear brake petal!

That confirms it! you ar ae mad man!

 

[SuperBuickGuy]

huh? it's right there under the clutch cover

 

[RamRod]

huh? it's right there under the clutch cover

Ah I see it now, didn't think that was the petal when I was first looking at it!

 

[SuperBuickGuy]

so I spent some quality time diagnosing electrical
but first, a bracket I've been meaning to weld on

and I got to test out my new torch, it works slick - I honestly can't believe how light it is, but still is a 250 amp torch.

so, according to the book the stuff inside the crankcase is fine as is the kill switch (a common failure)


which got me to the coil, and, according to the book, it's supposed to give a good, bright-blue spark.... uh, no, occasionally it gives a pissant white spark - so a new coil is on order... I best get this going, the season is almost upon us.

 

[backcountryislife]

Season is here man... you better quit messin around!!!

I'm looking at buying my first NEW bike... buying a timbersled snowbike setup, but the 300 isn't quite enough to push that thing, so new 4 stroke it is (for snow use only, I won't emberass the rocks around here with the presence of a 4 stroke )

That's a sweet setup man... I'm way tempted to give a 500 a try.

 

[SuperBuickGuy]

I should have updated.... I've launched it

the coil was shot, as was the plug (fortunately, I had tried another plug before I bought the coil).... now it makes sweet noise and moves right along.

there was even the possibility that I was going to buy a snowtrack for it... who knows, I may still....

 

[backcountryislife]

They're fun, lots of my buddies have switched from sleds to bikes lately. I took one out a few days ago, pretty interesting

Would have been more interesting on a 500 though

 

[SuperBuickGuy]

we had no snow, zero, this year (as opposed to a normal year which has 10 feet on the ground at this time of year)... so I'm bit reluctant to buy a snow machine... that said, I'm seriously considering going riding Sunday (it's a bit of a commute).

 

[RamRod]

If I didn't move to the coast I think I would have sold my Sled for a bike & track combo as well (instead of just selling the sled).

Makes total sense to have one toy that can ride both seasons without much compromise

 

[SuperBuickGuy]

from all I've heard, there really isn't a comparison between the tracked bike and a snowmobile... they simply go different places. And there's the biggest rub of getting a track for my bike; everyone I know who does motor sports in the snow either do 4x4s or snowmobiles - and it's kind of boring on your own.

 

[SuperBuickGuy]

I started the bike on Sunday, then when I went to ride it... it wouldn't start (sorry Taylor). I ordered another flywheel - I'm going to learn about magnets and rare earth magnets, hopefully I can replace the magnets that are on the flywheel with more powerful ones and make this beast easier to start.... crossing fingers

 

[twinmill28]

Just read this thread all the way through---hadn't seen it previously and have been looking for stuff on dirt bikes as they've become my new interest.
The amount of work you've put into this build is impressive, what's more impressive though is that you've stuck with it and didn't shelve the project like so many people that deep into it would do.
It's funny to look at where you started and the small amount of money you put in at the beginning--once I read about the new exhaust then the new clutch I began hearing more dollar signs. These damn bikes will eat your wallet alive mercilessly.
I just picked up a '12 KTM 500EXC as my first real jump into a dirt bike (had a Honda CRF230F that I rode around my neighborhood for awhile until I traded it). Jumping from the 230 into the 500 has been a wake up call, especially after improperly adjusting my rear suspension last week and making it a wheelie king by accident. I'd never tried to pull a wheelie before, but one blip on the throttle in 1st gear and up it went---and I don't just mean a little bit either, but not enough to kick the ass out.
I want to drop the $1K to get a suspension tune done for a fat guy, along with having it lowered an inch or two in the process. I also want to get a steering stabilizer on it before I get too much further on riding it in the dirt--those can be the difference between a great day of riding and ending on a sour note. I'd also love to put a Rekluse clutch kit on it, but my wife is about to kill me for what I'm into it already.
The best part of owning a dirt bike for me is actually having it---I can let it sit for days or jump on and go for a short ride to relax.
Thanks for posting this up-----

 

[SuperBuickGuy]

All in on my bike, I can sell it for what I've got in it - including the $1000 or so the upgrades cost.... it really helped that the motor was free, I made some bucks selling unused parts, and all-in on the bits beside the motor was $1300. What really makes me smile, though, is if you're not in a hurry, you can build a pretty good bike from the stuff on ebay.

But yes, the are a lot of fun. My friend rides a 575exc (I think, it's a exc) - he told me he can't catch me on the 500 because the bike is so much faster than his (though how much of that is his reluctance to really grab some throttle could be a factor as well), but he says it's okay since I only hit him with rocks for the first 10 or so seconds - after that, he's out of range

I wish I lived in a desert where I could really open this thing up - where you live now would be absolutely perfect.

 

[taylorblake831]

I started the bike on Sunday, then when I went to ride it... it wouldn't start (sorry Taylor). I ordered another flywheel - I'm going to learn about magnets and rare earth magnets, hopefully I can replace the magnets that are on the flywheel with more powerful ones and make this beast easier to start.... crossing fingers

Ha it's all good man I'm sure I'll come up with some reason to come back down and ride it then also make something in your shop you have just about everything I'd ever need in there! Now I know why you have so many projects on your hands it's to easy to get wrapped up with things in there!


-TEXAS FOREVER-

 

[backcountryislife]

FYI... the bike & sled are different for sure, but we've been riding with sleds & bikes together, and it works pretty well. The bikers can go where the much higher end sledders can go in the trees, without anywhere near the difficulty, but we seem to enjoy the day pretty well.

Speaking of WA snow conditions I've got a snowbike kit coming from Farmington WA in a few days... getting a darn good deal since the whole NW got STIFFED this year.

As to bike, I'm a 2 stroke guy, but imo the 300 isn't enough, seems like the 500 is. I'd really like to run a 5 on the dirt... must be a hoot. Around here the 300 is king, but I'm getting a 15 husqy 501 for the snow.


twinmill, good call on the step up man, I started on a 230 (TTR... but same gig, low power 4) and been through 6 bikes since then, last couple have been 300's... that 500 is a beast!

Google "x bushing KTM" for lowering, the lack of drop links is my biggest bitch about the PDS setup. Pretty stoked the Husqy has linkage, so dropping for my midget legs will be easier