BannedCR500Riders.com

Courtesy "Roostius_Maximus".....

Ok, its not a manual, but I've worked outa bunch of diagrams that explain the misconceptions of the engine, and Interchangeability,

































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awesome thread! Thanks front BC

Very, very nice!

hopefully this will prevent someone else from losing money on the wrong parts. awesome job!

http://rapidshare.com/files/107737872/H ... _Years.pdf

Someone let me know if they can download this OK. It is a PDF document of the diagrams Bob posted above.

Great thread

nice work

hey, nice to see this is helping some hoons, I've got more some are crappy. Anybody got requests I'll work on it!

I've done updates to these...

What about the main cases? Seems like you da man to ask. Any differences after 89?

only the paint changed

I've been staring at the first pic showing the clutch covers. The wording makes me think that an 87 clutch cover will fit on an 86 case. Is this true?

I will be a pig in shit if it is.

B440 wrote:I've been staring at the first pic showing the clutch covers. The wording makes me think that an 87 clutch cover will fit on an 86 case. Is this true?

I will be a pig in shit if it is.

yup,bolt on and go

kkvslayer wrote:

B440 wrote:I've been staring at the first pic showing the clutch covers. The wording makes me think that an 87 clutch cover will fit on an 86 case. Is this true?

I will be a pig in shit if it is.

yup,bolt on and go

X2

shedding some light on the case question, specs to follow, but these should help for now. Chevk out how even til '88 they machined the case the same as an '86, but gave it the taller deck, theres windage room cast in it that was filled in newer cases.

88 lh


91 lh


88 rl


91 rh

I am currently machining out my 88 case to accept a 2001 cylinder, it really isnt that big of job, i will have to put longer studs in for the base but other than that it should be done late tomorrow, here highlighted in red are the areas that have to be milled out. also the edges of the sleeve have to be rounded a little.

In attempting to remove the studs from a junk case i stripped the threads, now scared to wreck good cases i use a 1" x 10" endmill, reach past the jug and top the boss a the back to match the '86-'88 cylinders, i also cut the sleeve down so i can use it on cases that have been previously assembled without having been bored. There is enough thread on the 89-01 rear studs to use the old jug height if i need to switch it

when you say you cut the sleeve down, about how much do you cut and do you mean the length or the diameter of the sleeve cause i thought about just milling the sleeve till it was the same as the 88 but it looked like it would be stronger if i just milled out the case and left the sleeve thick .

i left the lenght, and cut the od by using a boring head with the tool to the inside, made it fit a case that was assembled, but needed a jug

here it is. After taking 3.5mm off each side its a perfect fit with the 01 jug
the front base studs will work as is but the rear two are flush with the top of the hole. so now i guess i gotta order some studs for a 01 case.
this mod was tottally worth it though as this jug is a std. bore and newer jugs are way easier to find than the 88's. i will post better pics after its a little purtier.

as i mentioned, i'd cut down the cyl instead of trying to remove the case studs, the ones i tried in junk cases stripped the threads from the case. I'd cut the back of the jug down and it'd work on either length stud

I couldnt find a way on the mill to cut the flanges down without cutting into the water jacket i dont have any small bits , so i broke out the flex shaft and used a dremel cutting tooth bit and it seemed to work great.

that'll work huh

What about the change in port timing by putting the late cyl on the early case? Are they reasonably close to the same IO-IC and EO-EC?