ATC500R build thread

[JasonB]

whats that you say?!?!?! TIME FOR UPDATES? HELL YES IT IS!



Rads, groments, and other misc goodies that showed up from Manbearpig my buddy in california. not sure if hes on here, Paul Proctor.


Rads and groments in place.


My mint 86 seat showed up from manbearpig, and I just took a pic of all the seats in my garage because I feel like a hoarder lol


Last night we moved the bike to the garage since it will be too big to get out of my shop soon. Installed the rebuilt/revalved/resprung shock. Starting to look like a real bike

[JasonB]

Flexx bars. And they came with grips and universal bar mounts



the seller of the Flexx bars (ATVGALAXY on ebay) took 12 days to ship my bars and as a 'thanks for the patience' i got 15 bucks off another item from their store. so why not buy a new MX ONE Industries pair of pants and jersey from them?! Thanks to an awesome ebay seller


Parts arrived with the outfit this morning from usps/ups. KFX400 master cylinder and lines with lever so now I will have rear brakes. T3 throttle cable that Liz Harvey at SmartCarb suggested i run with the 38mm cast I have coming from them. Also pictured are items from Magnum (eric bought) such as two sets of pipe springs, one of the Uni filters (the other is on back order), clutch perch and lever, gallon of my favorite 2 smoke oil, and a new clutch basket.


fun item i found when i was painting the motor; inside the old clutch cover is a handful of info scratched into the cover to date parts replaced etc. They stuck a new clutch basket in this thing in 1989 among other things. From the list of items and the second sleeve in the cylinder im guessing this 88 motor was run hard and enjoyed by someone once upon a time. Lord only knows the kind of abuse its about to see from the current owner

[JasonB]

New shock. Just a used shock for the ATC 310 to use since I stole the revalved resprung shock for the 500 to run


The old clutch basket had to have the rivets ground off so I could get the ring gear off and the center gear. I have no clue what the correct terms are for those parts so bear with me. Shot below is after I took a grinder to the rivets and popped the gear off the back of the old basket.


Gear on new basket. Installed the baffles (little black rubber inserts). I had to use my heat gun on the old basket to get it super hot and hammer out the center gear. To get that big gear into the new basket I stuck the gear into the freezer for an hour and heated the new basket up with my heat gun for about 10 minutes and then that gear just slid right in with a few good hits from the hammer. drilled out the holes on the tin cover for the new screws to secure the gear to the baket, Little bit of loctite on the screws and away we go!


This part is something I overlooked. Went to install the Rekluse into the new Pro-X basket and got hung up on this part. its the top hat (throw out bearing part), I didnt realize i needed to upgrade this to the newer style clutch. I have an 88 motor but had to update to 90-2001 basket, 90+ right side crank case, and 90+ clutch cover for the rekluse to fit and function. The 90+ clutch uses a throw out bearing that utilizes a newer top hat with flat bearing and washer instead of the one im holding that utilizes this top hat and a bearing inside. Jumped on partzilla.com after i figured that out yesterday and ordered up the correct throw out bearing and associated washers and new push rod etc.


Not pictured here is the KFX master cylinder. The banjo bolt from the line to the caliper just bolted right on to the master cylinder, no size difference issues. Bolted right up to the frame with some special spacers I had (some shiney nuts I had laying around). The push rod is right where it needs to be for the brake lever and little arm to line up and work perfect. For anyone in need of a new rear master cylinder the KFX and z400 masters work! I bought an 03, only found limited info to confirm it worked but went ahead and bought one anyways. fits like a glove.

[JasonB]

Exhaust manifold showed up last week.


Jason Hall packaged and sent my forks 3/12/14! Fedex says they will arrive today 3/14/14. Pictured below are the rebuilt, shortened CR125 Forks! In the package he sent should have these, my 450R foot peg adapters to fit them to my atc250r frame, and the new machined tripple trees to hold the inverted forks. Pretty stoked about that!


Clutch parts showed up two nights ag; new push rod, throw out bearing, c clip and associated parts and washers. Rekluse Z Start Pro should be installed this weekend or Monday depending on prior obligations. I LOVE HONDA FRESH OEM PARTS

[JasonB]

all for now. I meet up with my powdercoating guy at lunch to give him my rear 10" wheels and a pound of gold urethane powder, he has my front 10" wheel already at his house. Liz at APT sent my smartcarb out EXPRESS MAIL yesterday i should have it today! So hopefully by monday I will have powdercoated gold wheels back from my buddy Bryan Melguin, and the bike mostly completed and on its own 'legs' ready to be started. Cant wait to hear the 500 come to life!

[kb250r]

Cool man,this is an awsome build...looking forward to the next update...

[udontknowme]

do you plan to use your stock airbox somehow or try a pod filter ?  your reed spacer looks pretty thick thats why i ask.  for years ive known about the intake problems of the cr500 .  reed cage blocks off the boyesen and boost port. with a rad valve it makes the problem even worse.   i thought about using a spacer but i wanted to keep the stock airboot and box. plus i figured there might be issues with the carb hitting the shock spring, so i never put much thought into finding a good solution for the 500 intake issue.

[JasonB]

I have an airbox in place. i prefer them, no chance of issues when riding if things get wet. I ran a coupler because the motor sits like an inch or two farther forward than stock, but everything fits nice now. The reads are cut like that to mock the vforce2 design coupled with a torque spacer. This is supposed  to put the reeds right where the fuel and air mix will be picked up just right. Im told.

Shes in one piece and headed to Little Sahara to ride this week. abotu 40 or so of us going to ride tomorrow through sunday. COME JOIN US



While finishing up the Rekluse Z Start Pro clutch install I figured out I have 7 friction disks instead of 8 like I need. The 86-89 bikes had 7 friction disks, I upgraded to the 90-2001 clutch so I could run the rekluse. That means I went w the updated right side case, new clutch basket, new throw out bearing and push rod w assbly, and somehow I overlooked that there is one additional fric disk and drive plate. I ordered one new friction disk from honda since the 7 I have are within spec already for thickness.

shots of the wheels durring powdercoat. The front wheel done and one of the rears

[JasonB]

[JasonB]

Starting to resemble a rocket powered 3 wheeled atv.

[JasonB]

These shots show a few items I havent had time to fix yet. The rotor is on backwards. Beer+working too much at once=mixed results. Front tire is flipped around, didnt have time go back to the no mar place and have them flip it.

[JasonB]

[JasonB]

Need to address fork guards and brake line holder.



Brake. Had a local shop zip the shaft welds off the brake lever and basically popped it into the other side and welded it back up. I had to grind a little off the lever so it would clear the peg. Could be angled a little differently but its functional and im happy with it. And the kicker shouldn't hit it anymore either so my goal was met.

[troybilt]

Big group of us on R's will be down at the LS this week, we'll be there Thursday thru Sunday, hope to catch up with you there.

Awesome build, love the 500R!!!

[JasonB]

hell ya man! We are staying up in the cowboy camp, we have pretty much half the big lot reserved lol. Look for a crap load of 3 wheelers. Cant miss us. Where you guys camping? PM'ing ya