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  #11  
Old 05-12-2016, 08:36 AM
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JMV JMV is offline
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+1 on the loctite.
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  #12  
Old 05-12-2016, 09:09 AM
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That model CR 500 is a blast, probably the most fun to ride of all the CRs, IMHO. I raced one for several years, they are just a hoot to ride just be careful with the "whiskey throttle."

I just checked, East Toledo Honda has a new oem cylinder for your bike for $365.00.
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  #13  
Old 05-12-2016, 05:40 PM
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Bearing spin is a common problem with 500 cases. The Loctite
bearing retainer is a good solution as others have suggested. If
you go to the Loctite website, you will see they market several
"colors" of the retainer ranging from mild to permanent. Stay
away from the more extreme grades (and "fixes" like JB Weld),
because they truly are permanent and you are going to have
to replace these bearings again at some point in the future.

You don't have much of a choice except to fix what you have in
this situation. Buying brand new cases from Honda (if that was
still possible), would net you brand new spinning bearings. I
have had to remove the bearings from many new cases and
Loctite them. What's more important here is checking the
cases for cracks. Check the area around the CS bearing on the
Right side case and radiating outward from there. If it's not
cracked, consider yourself lucky, especially on an abused
engine like you have there. There are a couple of ways to NDI
the cases. I use a specially designed aerosol that seeks cracks
and then highlights them under a black light. Kits are available
from aircraft supply stores. Another is to immerse the cases in
oil overnight, remove and clean them in a solvent bath, then
dry with compressed air. Then place the "clean" case in an
oven at 350 degrees for an hour. If there are any cracks, the
oil will find them and soak in. The oven will outgas the oil and
the cracks will become evident as smoke sources.
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  #14  
Old 05-12-2016, 06:53 PM
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Thanks guys! Sounds like I'll give some loctite bearing retainer a shot and just clean up those other seats a bit. I've got a massive OEM parts order on the way, but if anyone know's where I can get some medication for my OCD I'd love to find some

I've sent the crank and piston off to crankworks for balancing too so we'll see if they can stick to their 1-2 week turnaround they quoted me. I'm still on the fence about getting the new stock cylinder plated since they are still available and relatively inexpensive. How many hours do you think I can get out of a new unplated cylinder before having to get it bored? Conservatively, since I know there are a ton of variables.

Dogger, thanks for the reminder about the NDI to check for cracks. I remembered reading about you having that issue in your 500 build so I actually ordered that aerosol kit last week. Still waiting for it to show up.
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  #15  
Old 05-13-2016, 08:19 AM
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Since you already sent your piston to crankworks, you are going to want to use that piston regardless of what cylinder option you choose. Hope you didn't send them a 2 over piston and decide you are going to run a new, 89mm bore. That totally negates the purpose of the balancing.
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  #16  
Old 05-13-2016, 10:00 AM
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Haha, nope, I sent in a brand new 89mm wiseco piston with the crank. That's why I was curious about the durability of the new stock cylinders, since I will want to stay with the same size piston every time I have to change one.
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  #17  
Old 05-13-2016, 10:27 AM
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So you are going to have to either buy a new cylinder or sleeve the one you have. you can run it unplated until it needs a bore, than plate at that time.
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  #18  
Old 05-18-2016, 04:11 PM
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Did a little pre-cautionary NDI using the Magnaflux Spotcheck on the cases last night per Dogger's suggestion. I think the suspicious areas look ok from what I can tell. I'll be testing the transmission gears today.


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  #19  
Old 05-19-2016, 01:34 PM
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I'm pretty stoked about this. I've been working with Wes over at Throttle Jockey on some 95 era team Honda graphics. Those guys are awesome! He basically redesigned the layout to match the 250's and tweaked the red a bit to match the UFO fenders a little better. I'll be going with yellow number backgrounds too. Can't wait to see them in person.

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  #20  
Old 10-20-2016, 02:13 PM
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Wow, apparently I got distracted for 5 months and didn't do much of anything on this project. Finally got motivated a couple weeks ago and built the engine.

I had ordered all new hardware, new cylinder, head and Wiseco piston, Hinson basket and a bunch of other stuff. Also had sent the crank off to crankworks to have it balanced. I vapor blasted the cases and even the new cylinder to smooth out the finish a little. The casting was really rough out of the box. I also cleaned up the ports a bit too. I ended up replacing several of the transmission gears and all the washers and clips just to be safe.

It feels good to finally make some progress with this thing.

The clutch basket was toast so I replaced with a Hinson.



Powder coated the side cover.



Rebuilt and balanced crank from Crankworks


Brand new cylinder and piston



All built up




Frame powder coated and ready to start bolting parts on
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