South Africa's First and Only 2-stroke Forum

Hello again. Joined here to gain some knowledge and help my my recently acquired playmate.

The meat...
1999 CR500. Picked it up for a song... I think. The bike has not worked very hard in its life as far as I can tell. Firstly because I know the owner who had it for the last 8 years. Secondly, the plastics and the frame says so (yes, I know you can get new plastics).

What I have learnt thus far:
Header has a small (5cm) crack in it.
Chainslider at the front of the swingarm is gone (some chafe on the arm, but nothing too bad.)
Needs tyres, chain, sprockets, tubes and a good service.

I plan to make it my project bike, get it back to stock spec and play my little heart out.

Some Pics...





A little video...

YouTube Link

It flashed up on the 5th kick. First 3 doenst count because the choke wasnt pulled.


Any info or advice from you guys would be appreciated.
I will keep this thread updated with my progress.

Nice.....

Keep the aircleaner in good condition... ONLY run distilled water and Antifreeze... They are bulletproof.... If it was mine.... Porting and the whole lot....

Cool Another 500.....

Have a look at the other cr500 post and see what 573V0 with the help of BVH on the porting have created. and trust me it moooves, I've had the privilege to ride it.

good luck with the project. and get hold of 573V0-NW on this forum for any help with parts n stuff. he might have some stuff for you.

Gav

Thanks guys. I will prolly start stripping tonight and formulate a required parts list as well as a wishlist.

As it stands at the moment:

Required (known):
*Airfilter
*Chain Slider on swingarm

Wishlist:
* FMF stainless header and Powercore rear
* The full port/blueprint job you guys are all into (although I do not know if I can handle all the horses - been more than 10 years since I've been on a 2smoke, and that was a CR125).



BTW, I have read 573V0-NW's thread twice already. Very nice project. Definitely something for me to aspire to!

(07-05-2010 04:48 PM)Berm_Rooster Wrote: [ -> ]Thanks guys. I will prolly start stripping tonight and formulate a required parts list as well as a wishlist.

As it stands at the moment:

Required (known):
*Airfilter
*Chain Slider on swingarm

Wishlist:
* FMF stainless header and Powercore rear
* The full port/blueprint job you guys are all into (although I do not know if I can handle all the horses - been more than 10 years since I've been on a 2smoke, and that was a CR125).



BTW, I have read 573V0-NW's thread twice already. Very nice project. Definitely something for me to aspire to!

Hi there Berm

Cool another CR500

I have a full scanned 1996 owners manual for you if you require it, send me a pm, it's a big file........

With regards to the pipe, I do have the old FMF Gnarly header that came with my bike originally, we repaired it however, it requires more work at the cleat/bracket that is used too bolt it on to the frame.
I also have what I guess is an old FMF silencer that may only require repacking, I will check if I have the old chain slider and rollers

I work up here JHB, I have transfered the bike and parts to Klerksdorp, I am only going to KLDP the 16th of July

Let me know what else you might need. Note some the parts were purchased off eBay

Enjoy

S

Love rebuilds like these!! Those things must be sick to ride!!!! What kinda power do they push once done?

(07-06-2010 08:45 AM)ozosborne Wrote: [ -> ]Love rebuilds like these!! Those things must be sick to ride!!!! What kinda power do they push once done?

Service Honda pushes 80HP with minor mods.... They say with the CPI pipe its already 69hp...

You can push 100hp out of these motors.... The guys in the US do this for hill climbs....

I have only one thing against these CR500, they vibrate to much....

My last project bike was a 1969 Vespa. I finished it approximately a year ago and you can read about it here.

I recently acquired a ’99 CR500R, the original Monster! The feared Widowmaker. The sound of which will loosen children’s bowels and cause the elderly to involuntarily spit out their dentures.

So here my project for the year starts. In the Vespa thread I had the job completed when I made the thread, this time it will be ‘Post as you Go’.

Chapter 1 – The Stripdown

Last night I lost myself in the garage for a couple of hours. One thing I have to say about a plastic is that it is super simple to work on. For the stripdown as pictured below I only used 10 and 8 sockets. And a Phillips for the hose clamps.

The official ‘BEFORE PHOTO’.




Slightly cracked header.




Slightly chafed swingarm.




Some other random pics.






Thus far, I have learnt the following:
*Cracked header
*Gaskets needed allover. Case, Carb (incl all the seals)
*Cylinder doesn’t look too bad through the zorst port, but I think I am going to ream and install ring (as a minimum).
*Frame looks relatively good, but I am considering a fresh powdercoat. What do you think?

Parts list so far:

*Chain guide plastic insert
*Chain slider
*Rear internal mudflap
*Set of new grips
*Front brake lever
*Clutch lever incl. perch
*Clutch cable
*Some sort of header pipe protection
*Sparkplug
*Ring


For the immediate future I will continue to take it apart and make the call on whether I need to powdercoat the frame. I don’t like the rusty slurrey that came out of the cooling system, so I think I wall take it all for an acid bath at a radiator shoppe. I will have to take the head and barrel off to make a call on the sleeve and piston. Plastics are all good, but faded, so I will do the sanding paper & heatgun trick.

I am also posting this on another forum here. I need as much assistance as I can get, so please share your wisdom, comments, tips, advice, concerns and guidance with me.

I plan to use the bike as a plaything, because I find that I am subjecting my HP2 to too much abuse wheelying, powerlsiding and all the rest. It will be my “morsbike” like my SWAMBO said…


"Baby, ek het vir my nog n bike gekoop..."
"Watse Bike?!"
"Daai een van *Koos, die arme ou het geld nodig toe dog ek ek help hom uit..." :
"Is dit n Morsbike?!"
"Haha, ja my engel..."

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Forum only allowed me 10 hosted images, so here are the rest...

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(07-05-2010 08:33 PM)573VO NW Wrote: [ -> ]Hi there Berm

Cool another CR500

I have a full scanned 1996 owners manual for you if you require it, send me a pm, it's a big file........

With regards to the pipe, I do have the old FMF Gnarly header that came with my bike originally, we repaired it however, it requires more work at the cleat/bracket that is used too bolt it on to the frame.
I also have what I guess is an old FMF silencer that may only require repacking, I will check if I have the old chain slider and rollers

I work up here JHB, I have transfered the bike and parts to Klerksdorp, I am only going to KLDP the 16th of July

Let me know what else you might need. Note some the parts were purchased off eBay

Enjoy

S

Howzit S

I have sent you a PM. Please, I will take as much as I can get. Manual would be great too!

Regards
D

Die header lek nie olie waar hy kraak nie, so dalk het net die versterker plate gekraak..... Check dit uit... Ek sou anyway gaan vir n nice aftermarket pyp...!!

100HP on a 2 wheeler!!! EINA!!!