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Cr500 Find now starting the build

wwillf01

wwillf01

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So I have a Ktm 300 I am going to use this year but...... I found a blown up 97 cr500 for a couple hundred that I could not pass up..

From What I read this is the path to go:

Send to Eric gore for Port and decomp (Anyone doing big bores with the snow kit?) Or any other recommended people?
Smart carb 38mm with heat jacket (Ordered)
Desert Tank
Service Honda digital ignition
Ame heated battery powered grips
Rekluse Zstart T balls and high engagement
Heaviest fork springs available? (I am 220)



ANY OTHER RECOMMENDATIONS OR BETTER OPTIONS WOULD BE GREAT... I AM LOOKING FOR RELIABLE POWER.... SOME OF THE BIG bores look interest but there are a lot of custom parts that make me nervous....
 
Fyi I did confirm that Turboboyz in Utah has turboed cr500s for the snowbike application with success... it would cost similar to the boondocker... I am getting excited here!
 
The list is a start. I'd skip the SH ignition. The ignition itself works ok but the stator is a pile of junk. I burned up one and that was enough. I saw on ebay there is a 200 watt Eline stator up for grabs. I'd bid on it and expect to pay. They made a bunch of those but they are getting very hard to find and spendy. Honda did make a factory CR500E (Australia version only) that had this stator. Eline and Baja kinda ripped it off I believe lol. I ran the Honda version and it was bulletproof and enough power to power all your needs. It retains the factory stator/ignition and then a dual 100watt coil that is external. A battery is not needed really unless you run HID lights/helmet lights. This is the only worthwhile solution. I paid 700 CDN from a friend that had two sitting around.

I think Gorr still does some good work. If your in Canada I'd only send it to Adam Millar. He is a 500 know it all and does his famous TWIRP porting. Now I don't want to start a porting war but I did see a dyno where Gorr motor made 1hp more than Adams but Adams trounced the Gorr in the torque department lol. Take it for what it's worth. I sure like my Millar motor. It's has power ! Get a decompressor installed while ur at it.

I think a coolant heated carb is a must which has been taken care of with Avids new setup. The CR500 does have a dual outlet head which will need a solution when using tstats. Either 2 stats or a single out head etc. Also the outlet hoses are only 15mm compared to the 19mm of most other brands. I tried two 55C KTM stats that seemed to not heat the motor above 90F. I believe they let to much coolant by when closed. Need a true closed/bypass system IMO. Just food for thought.

The Smarty works well but needs a primer for cold starting. Either the factory APT primer bulb or some other primer. It takes care of the jetting and runs very very good. Some of the issues (including my own) that I have seen come from trying to re needle it before trying it etc. I went to a 76 needle because of some deto issues I was aware of and after trial and error I went back to the stock 80 needle. I take care of my deto with a little race or Maxima Hi Test. Works perfect. I'm sure the deto comes from the porting, as a friend with a KX500 also had a little deto as well in the same spot. Both ported and both ran Smartys.

I did notice on certain days I'd get a little slide sticking from carb ice when my KTM heater wasn't working or keeping up. The coolant is the answer.

Overall the 500 is the power house of the snowbike world. Seems like all the 4 strokes I have tried are a little flat in the power dept. I've never tried a turbo yet but it seems like unless your in the right gear with the right boost it would be a pain especially in the tight stuff. Also motor wear on a normal aspirated motor seems bad enough, I'm sure the turbo is hard on cams and valves etc. One thing I did notice on the turbo dynos are they seem to lack torque. I've seen some as low as 34ft lbs. I thought it would be better since the hp was up in the 90's. It's interesting.

If the 500 had electric start it would be more or less perfect lol. But knowing what I know now, I 'm sure I'll kick a little less next season ! Cheers
 
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I have gone through many of your posts and appreciate the info... I live in Utah and did check Adams pricing but at 1200 for the Twirp package I am a 3rd of the way to a turbo? That was my thought process.. According to the shop they said the upkeep would be tracking your compression and throwing a top end every year if you stuck in the 6 psi realm... now I know they are trying to sell their product so I take it with a grain of salt... I also am waiting for a few more questions to be answered. How much hp\tq do you think you gained with yours?
 
I'd sure like to see some pics of their 500 turbo kit. I wonder how they fuel it ? The Smarty would probably work well for that since it fuels what the motor demands. I couldn't imagine trying to fuel it with a stock carb unless you like chasing jetting. Would be neat to see for sure.

I've seen some dyno sheets for Adams motor but have not dyno'd mine yet. Maybe this fall. I'd hate to throw out numbers without proof. I have 4-5 dyno sheets including the one between the Gorr KX500 and a Millar CR500.

The TWIRP porting is spendy but it's because you get more than just the cylinder work. Adams stuff is beautiful and no BS. He is a excellent resource for more than just porting and is easy to text and call which is huge IMO. He has a ton of experience making power, big HP hill climbers to salt flat 500's. I talked to the salt flat guy and he told me "that boy builds a mean motor" lol. I'm glad we have such a great 500 guy in Canada. Adam also builds AF frames like Service Honda.
 
I have asked for photos of the system... I will post when I get them... I will really have to think hard about Adam.. your not the only person to swear by him that I have talked to... I start riding around 10000 ft so for me a turbo would be benificial...
 
I like the idea. It only really gains you low temps on the trail. Prob not as important as getting a little temp in the motor in the deep imo. In a perfect world id like to see 100-120F all day all condition for a 2 stroke. And obviously zero carb ice.
 
Sent head and cylinder off to gss porting in Ca..... I talked to him at length and felt he knows his stuff... the downside is I will not see it back till Oct. He is so backlogged.... that will give me time to get the rest of the bike in order..
 
Here you go looks legit.... They are using an Aero turbo here but they said with the smart carb and advances in fuel control that there are all types of good options... Man these hobbies are getting expensive;)

image.jpeg
https://www.dropbox.com/s/m6v1z8i5lkugkf8/image1.jpeg
https://www.dropbox.com/s/q4h8spvh65s6a0a/image.jpeg
image1.jpeg
 
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GSS does good work i hear. Who is making that turbo kit ? Do they have any video of it working ? Wonder how they take care of the crank seals. Millar was telling me he has made seal retainers for the 500 seals for higher case pressures. Wonder if they do the same.
 
The turbo kit picture is from turbo boyz in Utah ... that will be an addition for me next year.... the one pictured was made a few years back with an aerocharger. He said now there are much better choices plus having the smart carb should help...
 
wwillf01 said:
Summit boy would you run into the same crank seal problem with nitrous?
Click to expand...

Not likely to the same degree as a turbo. While nitrous does go in under pressure its not like a turbo, its supplying the extra O2 in a liquid or vapour depending on your system which basically allows you to add more fuel. Whatever boost you are running on your turbo blow through system gets applied to the whole motor. My old Rx1 used to blow the half moon seals out of the head after about 10 lbs boost if they weren't glued in.

M5
 
summitboy said:
I'd sure like to see some pics of their 500 turbo kit. I wonder how they fuel it ? The Smarty would probably work well for that since it fuels what the motor demands. I couldn't imagine trying to fuel it with a stock carb unless you like chasing jetting. Would be neat to see for sure.

I've seen some dyno sheets for Adams motor but have not dyno'd mine yet. Maybe this fall. I'd hate to throw out numbers without proof. I have 4-5 dyno sheets including the one between the Gorr KX500 and a Millar CR500.

The TWIRP porting is spendy but it's because you get more than just the cylinder work. Adams stuff is beautiful and no BS. He is a excellent resource for more than just porting and is easy to text and call which is huge IMO. He has a ton of experience making power, big HP hill climbers to salt flat 500's. I talked to the salt flat guy and he told me "that boy builds a mean motor" lol. I'm glad we have such a great 500 guy in Canada. Adam also builds AF frames like Service Honda.
Click to expand...

Did you find after your porting your bike was easier to start... Gss said that I should not need a decomp valve because with his porting starting it will be like a 250.


Sent from my iPad using Tapatalk HD
 
Decomp is the only way to go. My bike needs lots of fuel to start. The Smarty choke doesn't pull enough to make the mixture rich enough for easy starts on a 500CC imo. My porting is a lot different than GSS. The cylinder is prob similar but the TWIRP is different. I'd like to see some pics of the GSS after you get it back. Be interesting to compare his work to Millars. PM me some pics if you want/can.
 
summitboy said:
Decomp is the only way to go. My bike needs lots of fuel to start. The Smarty choke doesn't pull enough to make the mixture rich enough for easy starts on a 500CC imo. My porting is a lot different than GSS. The cylinder is prob similar but the TWIRP is different. I'd like to see some pics of the GSS after you get it back. Be interesting to compare his work to Millars. PM me some pics if you want/can.
Click to expand...

Will do... Will not have it back till Oct... But I will get it over then...


Sent from my iPad using Tapatalk HD
 
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