Honzuki SVCR500S - Page 2

Erin_S · January 5th, 2009, 07:56 PM

That's awesome!

What's the maitenence like on a CR500 motor? How long between top end / bottom end rebuilds? I hear you need to be more careful about warmup and it has a funky powerband, that true?

Awesome. Engine swap sounds like a perfect next project for me. ^_^ You're inspirational!

BlackKarma · January 5th, 2009, 07:57 PM

Very Cool project Dude!...Can't wait to see a video of her running!

TheDuck · January 5th, 2009, 08:02 PM

Quote:

Originally Posted by Erin_S

That's awesome!

What's the maitenence like on a CR500 motor? How long between top end / bottom end rebuilds? I hear you need to be more careful about warmup and it has a funky powerband, that true?

Awesome. Engine swap sounds like a perfect next project for me. ^_^ You're inspirational!

Well, I know of some people that have had their CR500s for 10+ years ride them nearly every weekend and never rebuilt a top end. So I guess this all depends on your maintenance and how badly you rag on the thing. Top ends can be rebuilt in 2 hours or less and even if you replace the piston it can be done for $100 to $200 (depends on where you shop and forged vs cast pistons)

As far as mileage, I dunno, depends on how you gear it and how hard you ride it, what kind of oil you use, etc etc etc. We'll see!

Warmup on these bikes isnt so bad, they warm up real quick, in fact they tend to run a little hot anyways.

The powerband is extremely PEAKY. You will suddenly SPIKE in HP at VERY LOW RPMs. If you're not careful you end up sitting on your ass with a front fender in your mouth! All because you turned 1/4 throttle, lol.

Erin_S · January 5th, 2009, 08:15 PM

That's awesome. Talk about peaky!

Aluminum frame, 17" wheels, 70hp, yet about the same weight as my bike. o.o I'm so jealous.

Viper-Byte · January 5th, 2009, 08:16 PM

Nice work Duck, I see you have put many hours of work into this! It was a really good read.

Please do keep us posted and with pics, also feel free to include some pictures of these stray women modeling with the bike

TheDuck · January 5th, 2009, 08:18 PM

Quote:

Originally Posted by Erin_S

That's awesome. Talk about peaky!

Aluminum frame, 17" wheels, 70hp, yet about the same weight as my bike. o.o I'm so jealous.

Yeah, now compare that to a factory SV power curve, lol.

TheDuck · January 6th, 2009, 05:40 PM

Some people wanted to see a good comparison between SV650 and CR500 power curves. I overlapped 2 plain vanilla dyno charts of each here:

Erin_S · January 6th, 2009, 05:56 PM

Thank you sir, that's pretty nifty.

Mind if I ask how you chose this particular engine?

kkim · January 6th, 2009, 05:58 PM

Quote:

Originally Posted by Erin_S

Mind if I ask how you chose this particular engine?

...it chose him!

Erin_S · January 6th, 2009, 06:02 PM

I'd be willing to believe that if it was a hemi he got for only a few hundred dollars with historical significance.

Nicely played though. o.o

TheDuck · January 6th, 2009, 06:26 PM

Quote:

Originally Posted by kkim

...it chose him!

In soviet Russia, engine chooses you!

TheDuck · January 6th, 2009, 06:39 PM

Quote:

Originally Posted by Erin_S

Thank you sir, that's pretty nifty.

Mind if I ask how you chose this particular engine?

Well, I wanted 2-stroke street bike for the last 15 years, so this HAD to be a 2-stroke. I would be riding an NSR, an RGV, RG or an Aprilia RS250 but they are just too damn expensive or hard to find! One day I may still get one or SEVERAL of the above, we'll see!

I started to look at dirt bike engines. I wanted something with parts readily available, something with a record of being reliable, and something BIG AND POWERFUL with a history of hurting people.

So the CR500 was a natural choice.

I've also noticed that people are putting CR500 engines into all sorts of things. Karts, AF CR250 chassis, ATCs ATV, you name it. But no street bikes! Then one day while I was doing some research I came across someone else with the same idea, he was putting one into a korean United Motors bike. He did have lots of problems, but he was doing silly things like drilling carb parts to *fix* things. Bad news.

I also looked at KX500 engines, but they seemed a little more complex with the exhaust power valves, and there aren't as many of those around and are much more expensive to rebuild.

2-stroke single-cylinder engines are narrow, so I needed to find a narrow sports bike chassis. I4 bike frames are WAAAAAAAAY too big! But the CHEAP V-twin SV with a blown engine was the perfect choice! They've been around 10 years, has a long list of aftermarket support, its lightweight aluminum and is a rather all-round popular bike that is easy to upgrade.

But I have a big box of all sorts of parts, master cylinders, grips, wires, chains, shocks, swingarms, brake/clutch levers and cables etc etc. I haven't had to buy hardly anything yet because I've been diving into my own parts bins and making things work!

TheDuck · January 11th, 2009, 03:54 PM

Put the engine up on the bench today to remove the kickstarter shaft for lengthening by my local friendly machine shop!

First I drained the oil. I should have done this while the engine was still mounted it would have been MUCH easier! I just kinda forgot.

The oil was very sticky and yucky. This bike hadn't been run in a long time, thats a fact!

I had problems with the clutch dragging, so while I was in there I checked it all out. The sticky oil was gumming up the discs and plates. Even without the pressure plate and springs installed the clutch STILL dragged every bit as badly as with. I examined and cleaned each disc and plate and reassembled. The clutch looks good with very mininmal wear. The bolts and such don't even have any evidence that they ever had a tool put on them. I was told this engine hadn't run in years, has very low hours, and was never opened up... Now I believe it!

Clutch bastket:

Clutch plates/discs:

And lasty I removed the kickstarter shaft, cleaned it up so I can put it in my pocket to take to the machine shop on the way to work on Monday.

Skeeter watched:

Bone_Head311 · January 13th, 2009, 01:12 PM

Now all you need to do is supercharge that badboy.

Guinss · January 13th, 2009, 02:16 PM

great project!

a 500cc 2-stroke with kick-start, isnt that a little dangerous? Must be easy to break a leg :P

TheDuck · January 13th, 2009, 03:38 PM

Quote:

Originally Posted by Bone_Head311

Now all you need to do is supercharge that badboy.

Its already supercharged!

Thats what the expansion chamber is for.

Conventional super(or turbo)chargers don't work well on a 2-stroke as they just blow the excess pressure out of the exhaust port.

Quote:

Originally Posted by Guinss

great project!

a 500cc 2-stroke with kick-start, isnt that a little dangerous? Must be easy to break a leg :P

This engine HAS been known to break peoples' legs!

I know my little 4-stroke XR200 chinese clone that I had was a bitch to kickstart at times. I twisted my ankle slipping off the kicker once, ouch!

This thing is gonna be funnnnnnnnnnnnn hurtin' myself on!

kkim · January 13th, 2009, 03:48 PM

I'd rather kick start a 2 stroke than a 4 stroke any day, though I have heard those 500cc two strokes can be tricky to start.

Guinss · January 13th, 2009, 03:50 PM

thought so.

Iv'e heard about people hurting themselves on rs250's so if you slip on that 500cc kick, mmmm...!

but its sure worth it, when you think of the power and weight saving!

TheDuck · January 13th, 2009, 04:03 PM

Quote:

Originally Posted by Guinss

thought so.

Iv'e heard about people hurting themselves on rs250's so if you slip on that 500cc kick, mmmm...!

but its sure worth it, when you think of the power and weight saving!

I've heard of CR500s firing halfway through the kick stroke while a little skinny sh!t had all of their weight on the kicker and got launched into the air over the bike, lol.

Guinss · January 13th, 2009, 04:09 PM

Quote:

Originally Posted by TheDuck

I've heard of CR500s firing halfway through the kick stroke while a little skinny sh!t had all of their weight on the kicker and got launched into the air over the bike, lol.

lol

take no chances, go for a rolling/running-start as often as you can

Erin_S · January 13th, 2009, 05:48 PM

Quote:

Originally Posted by TheDuck

I've heard of CR500s firing halfway through the kick stroke while a little skinny sh!t had all of their weight on the kicker and got launched into the air over the bike, lol.

Oh wow.

Now I know never to get anything with a kick start... o.o That's frightening.

TheDuck · January 16th, 2009, 04:20 PM

Quote:

Originally Posted by Erin_S

Oh wow.

Now I know never to get anything with a kick start... o.o That's frightening.

Haha! Even worse trying to kick over an older Harley. I've heard many sad stories there, too.

Sailariel · January 17th, 2009, 05:35 PM

It`s all technique. My 08 Ninja is the first bike ever for me with electric start. Been riding since 1958.

sprale · January 17th, 2009, 08:52 PM

Quote:

Originally Posted by Alex Allmayer Beck

It`s all technique. My 08 Ninja is the first bike ever for me with electric start. Been riding since 1958.

Not nearly as many riding years here, but the Ninjette is also my first bike without a kicker. took a while getting used to. Also the bike I learned to roll-start, because of the 'missing' part...

TheDuck · January 17th, 2009, 09:01 PM

Quote:

Originally Posted by Alex Allmayer Beck

It`s all technique. My 08 Ninja is the first bike ever for me with electric start. Been riding since 1958.

Well I'll be doggy dicked, I never thought you to be that matured. I figured myself to be one of the older guys on here, and I only started riding in the very early 80s, lol.

GreezMunky · January 17th, 2009, 10:30 PM

Quote:

Originally Posted by TheDuck

Well I'll be doggy dicked

What the hell?

And I thought I had heard everything when it came to strange expressions, lmao.

TheDuck · January 17th, 2009, 10:43 PM

Quote:

Originally Posted by GreezMunky

What the hell?

And I thought I had heard everything when it came to strange expressions, lmao.

Link to original page on YouTube.

You haven't heard much until you spend a little time with me, haha. After that, you have heard it all.

GreezMunky · January 18th, 2009, 06:56 AM

Oh Good Lord, I am left speechless..

Ahahhaahaha, awesome.

January 18th, 2009, 07:43 AM

Ahhhhhhhhhhh hahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahaha hahahahahahahahah!!!!!!!!!!!!!!!!!!!!!

I'm in tears here!!!!!

TheDuck · January 19th, 2009, 05:47 PM

Its light!

Link to original page on YouTube.

January 19th, 2009, 07:18 PM

Sweet doggy-doing-a-duck that's light. Or you now have a hernia

. You're ginna have to weigh in after you get the motor re-installed.

TheDuck · January 19th, 2009, 07:28 PM

Quote:

Originally Posted by Bluevitz-RS

You're ginna have to weigh in after you get the motor re-installed.

Yep! This thing is gonna be lots of fun! Super light, yay!

Criomega · January 20th, 2009, 08:04 AM

Man thats going to be some fun! At least if you get tierd of kicking you can push start it. I have 3 87 quadzilla 500's (little disapointed you didnt go with a suz 500 but understand a deal on something is a deal) When we go riding with my quads like with my wife and others that can't kick over a 500 I have to kick all 3 and let me tell you 1 is stock and the other 2 have high comp pistons and by the time I'm done starting 3 cold 500's ....I'm to dam tierd to ride! LOL

Cant wait to see this thing running!

TheDuck · January 20th, 2009, 08:37 AM

Quote:

Originally Posted by Criomega

Man thats going to be some fun! At least if you get tierd of kicking you can push start it. I have 3 87 quadzilla 500's (little disapointed you didnt go with a suz 500 but understand a deal on something is a deal) When we go riding with my quads like with my wife and others that can't kick over a 500 I have to kick all 3 and let me tell you 1 is stock and the other 2 have high comp pistons and by the time I'm done starting 3 cold 500's ....I'm to dam tierd to ride! LOL

Cant wait to see this thing running!

Haha, I guess I could understand all that.

I did consider finding a quadzilla engine, but there seems to be less aftermarket and OEM parts support. I also couldn't find one for the life of me! They stopped making those things almost 20 years ago! A more recent CR500 engine with much more information on the internet about it and parts availability made a better choice.

Besides, now I can call it a Honzuki and have people's heads turn.

Criomega · January 20th, 2009, 09:01 AM

that is true.

TheDuck · February 13th, 2009, 08:12 AM

Before:

After:

And then I installed it, it fits perfectly!

Criomega · February 13th, 2009, 08:17 AM

Nice work there. So.....how fast does it go, have you dragged knee on it yet, stand up wheelies?

LOL How long till you get it in and started?

TheDuck · February 13th, 2009, 08:28 AM

Quote:

Originally Posted by Criomega

Nice work there. So.....how fast does it go, have you dragged knee on it yet, stand up wheelies?

LOL How long till you get it in and started?

Maybe this weekend, I will keep everyone posted!

Criomega · February 13th, 2009, 08:43 AM

Forget everyone else! Just worry about keeping me posted!

LOL j/k

February 13th, 2009, 11:54 AM

They did a good job on that starter shaft. It looks factory. Have you fabricated a supported for it yet?

January 5th, 2009, 07:57 PM	#42
BlackKarma ninjette.org member Name: Ronin Location: East Tennessee Join Date: Dec 2008 Motorcycle(s): 2004 Chrome Yellow Ninja 250 Posts: 50	Very Cool project Dude!...Can't wait to see a video of her running! __________________________________________________ Well, either you're part of the problem, part of the solution,.....or you're just part of the landscape. - lndeed. "Hatzofeh Lifnei Hamahaneh"

January 11th, 2009, 03:54 PM	#53
TheDuck Da Duckman Name: Duckman Location: Pensacola, FL Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480	Re: Honzuki SVCR500S - Update #6 Put the engine up on the bench today to remove the kickstarter shaft for lengthening by my local friendly machine shop! First I drained the oil. I should have done this while the engine was still mounted it would have been MUCH easier! I just kinda forgot. The oil was very sticky and yucky. This bike hadn't been run in a long time, thats a fact! I had problems with the clutch dragging, so while I was in there I checked it all out. The sticky oil was gumming up the discs and plates. Even without the pressure plate and springs installed the clutch STILL dragged every bit as badly as with. I examined and cleaned each disc and plate and reassembled. The clutch looks good with very mininmal wear. The bolts and such don't even have any evidence that they ever had a tool put on them. I was told this engine hadn't run in years, has very low hours, and was never opened up... Now I believe it! Clutch bastket: Clutch plates/discs: And lasty I removed the kickstarter shaft, cleaned it up so I can put it in my pocket to take to the machine shop on the way to work on Monday. Skeeter watched:

January 13th, 2009, 01:12 PM	#54
Bone_Head311 ninjette.org member Name: John Location: Jensen Beach, Florida Join Date: Nov 2008 Motorcycle(s): 09 250 ninja Posts: 31	Now all you need to do is supercharge that badboy. __________________________________________________ Yoshimura full CF Exhaust, K&N R-0990 filter using stock air box intake tubes, DJ rejet kit, Targa fender eliminator

January 20th, 2009, 08:04 AM	#73
Criomega ninjette.org member Name: Ron Location: Detroit, MI. Join Date: Jan 2009 Motorcycle(s): 2 2008 ninja 250r's, 2002 Hayabusa, 2008 M109R to name few Posts: 20	Man thats going to be some fun! At least if you get tierd of kicking you can push start it. I have 3 87 quadzilla 500's (little disapointed you didnt go with a suz 500 but understand a deal on something is a deal) When we go riding with my quads like with my wife and others that can't kick over a 500 I have to kick all 3 and let me tell you 1 is stock and the other 2 have high comp pistons and by the time I'm done starting 3 cold 500's ....I'm to dam tierd to ride! LOL Cant wait to see this thing running! __________________________________________________ Lifes journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways, totally worn out, shouting "HOLY ****..WHAT A RIDE!"

January 20th, 2009, 09:01 AM	#75
Criomega ninjette.org member Name: Ron Location: Detroit, MI. Join Date: Jan 2009 Motorcycle(s): 2 2008 ninja 250r's, 2002 Hayabusa, 2008 M109R to name few Posts: 20	that is true. __________________________________________________ Lifes journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways, totally worn out, shouting "HOLY ****..WHAT A RIDE!"

January 5th, 2009, 07:56 PM	#41
Erin_S ninjette.org member Name: Susan Location: Fredrick, FL Join Date: Jan 2009 Motorcycle(s): Gix Posts: 80	That's awesome! What's the maitenence like on a CR500 motor? How long between top end / bottom end rebuilds? I hear you need to be more careful about warmup and it has a funky powerband, that true? Awesome. Engine swap sounds like a perfect next project for me. ^_^ You're inspirational!

January 5th, 2009, 08:15 PM	#44
Erin_S ninjette.org member Name: Susan Location: Fredrick, FL Join Date: Jan 2009 Motorcycle(s): Gix Posts: 80	That's awesome. Talk about peaky! Aluminum frame, 17" wheels, 70hp, yet about the same weight as my bike. o.o I'm so jealous.

January 5th, 2009, 08:16 PM	#45
Viper-Byte ninjette.org sage Name: David Location: Wellington, New Zealand Join Date: Dec 2008 Motorcycle(s): 08 Ninja 250R in Green! (Sold) Now 2011 Triumph Daytona 675 SE Posts: 564	Nice work Duck, I see you have put many hours of work into this! It was a really good read. Please do keep us posted and with pics, also feel free to include some pictures of these stray women modeling with the bike

January 6th, 2009, 05:40 PM	#47
TheDuck Da Duckman Name: Duckman Location: Pensacola, FL Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480	Some people wanted to see a good comparison between SV650 and CR500 power curves. I overlapped 2 plain vanilla dyno charts of each here:

January 6th, 2009, 05:56 PM	#48
Erin_S ninjette.org member Name: Susan Location: Fredrick, FL Join Date: Jan 2009 Motorcycle(s): Gix Posts: 80	Thank you sir, that's pretty nifty. Mind if I ask how you chose this particular engine?

January 6th, 2009, 06:02 PM	#50
Erin_S ninjette.org member Name: Susan Location: Fredrick, FL Join Date: Jan 2009 Motorcycle(s): Gix Posts: 80	I'd be willing to believe that if it was a hemi he got for only a few hundred dollars with historical significance. Nicely played though. o.o

January 13th, 2009, 02:16 PM	#55
Guinss ninjette.org guru Name: Simen Location: Norway Join Date: Jan 2009 Motorcycle(s): 2008 250R (Black) Posts: 298	great project! a 500cc 2-stroke with kick-start, isnt that a little dangerous? Must be easy to break a leg :P

January 13th, 2009, 03:48 PM	#57
kkim Join Date: Nov 2008 Posts: Too much.	I'd rather kick start a 2 stroke than a 4 stroke any day, though I have heard those 500cc two strokes can be tricky to start.

January 13th, 2009, 03:50 PM	#58
Guinss ninjette.org guru Name: Simen Location: Norway Join Date: Jan 2009 Motorcycle(s): 2008 250R (Black) Posts: 298	thought so. Iv'e heard about people hurting themselves on rs250's so if you slip on that 500cc kick, mmmm...! but its sure worth it, when you think of the power and weight saving!

January 17th, 2009, 05:35 PM	#63
Sailariel ninjette.org certified postwhore Name: Alex Location: Belfast, ME Join Date: Jul 2008 Motorcycle(s): 2010 Honda NT-700-V, formerly, Green 2008 Ninja 250R Posts: A lot.	It`s all technique. My 08 Ninja is the first bike ever for me with electric start. Been riding since 1958.

January 18th, 2009, 06:56 AM	#68
GreezMunky ninjette.org guru Name: Tor Location: TX Join Date: Dec 2008 Motorcycle(s): 09 250r (sold), 2010 Daytona 675 Posts: 301	Oh Good Lord, I am left speechless.. Ahahhaahaha, awesome.

January 18th, 2009, 07:43 AM	#69
Bluevitz-RS Guest Posts: n/a	Ahhhhhhhhhhh hahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahaha hahahahahahahahah!!!!!!!!!!!!!!!!!!!!! I'm in tears here!!!!!

January 19th, 2009, 05:47 PM	#70
TheDuck Da Duckman Name: Duckman Location: Pensacola, FL Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480	Its light! Link to original page on YouTube.

January 19th, 2009, 07:18 PM	#71
Bluevitz-RS Guest Posts: n/a	Sweet doggy-doing-a-duck that's light. Or you now have a hernia . You're ginna have to weigh in after you get the motor re-installed.

February 13th, 2009, 08:12 AM	#76
TheDuck Da Duckman Name: Duckman Location: Pensacola, FL Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480	Re: Honzuki SVCR500S - Update #7 Before: After: And then I installed it, it fits perfectly!

February 13th, 2009, 08:17 AM	#77
Criomega ninjette.org member Name: Ron Location: Detroit, MI. Join Date: Jan 2009 Motorcycle(s): 2 2008 ninja 250r's, 2002 Hayabusa, 2008 M109R to name few Posts: 20	Nice work there. So.....how fast does it go, have you dragged knee on it yet, stand up wheelies? LOL How long till you get it in and started? __________________________________________________ Lifes journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways, totally worn out, shouting "HOLY ****..WHAT A RIDE!"

February 13th, 2009, 08:43 AM	#79
Criomega ninjette.org member Name: Ron Location: Detroit, MI. Join Date: Jan 2009 Motorcycle(s): 2 2008 ninja 250r's, 2002 Hayabusa, 2008 M109R to name few Posts: 20	Forget everyone else! Just worry about keeping me posted! LOL j/k __________________________________________________ Lifes journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways, totally worn out, shouting "HOLY ****..WHAT A RIDE!"

February 13th, 2009, 11:54 AM	#80
Bluevitz-RS Guest Posts: n/a	They did a good job on that starter shaft. It looks factory. Have you fabricated a supported for it yet?