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  #1  
Old 06-25-2005, 11:14 PM
CLM CLM is offline
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Default 1991 cr500 top end rebuild needed?

Greetings and Salutations ATM and Ex-XDB friends,

It`s been a long time since I have posted amongst this great group of people, but I have a question and need to pick your brains

I just picked up a 1991 cr500 last week out at then dunes for a great price, It had spun off it`s clutch nut so the basket was loose, probblem fixed, clutch works great.

It needs the rear shock rebuilt, a front brake line, and an air filter (It has an intact one but it`s old) and it has two very nice parts, a "GP STABILIZER" steering damper, a flywheel weight, new chain+sprockets, oh and a new paddle I am going to swap out with a nice gnarly knobby tire(I like knobby tires in the sand for some reason on bikes )

However my issue is, I don`t think it has enough compression, granted it has more then my 250, and deffinatly more then my friends 250, It just doesn`t have that "Will support 180-200 pounds without moving" type of compression I have heard these bikes were supposed to have

It makes it very hard to get a complete kick being as the kick start lever is very long and getting up to that altitude to get a full kick is a bit difficult and tiring without something to stand on currently as pressure on the kickstart lever generally ruins the "full kick". I figure with that kind of compression it was supposed to have I could almost use the kickstarter to get the "altitude"

Currently this bike is a pain to start and once started doesn't seem to have much of a discernable "hit" I hope that means a top end job, and that this rebuild will make it a bit more eager to start.

Thanks Chris Mckay
2004 TRX 450R
1993 CRM 250R
1991 CR 500R
1986 WMX 500
1981 YZ 465
1985 XR200 engined YZ80
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  #2  
Old 06-26-2005, 12:03 AM
Michael Parker's Avatar
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Default Re: 1991 cr500 top end rebuild needed?

it seems to me that your rings are worn out too far and the whole top end should be replaced. do it before the blowby caused by worn rings ruins the bottom end
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Old 06-27-2005, 11:26 AM
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Default Re: 1991 cr500 top end rebuild needed?

Run a compression test on it. 150 or better is good, if it has less than 140 it is time for a topend. Also pull the exhaust and inspect the front of the piston for cracks, the stock type cast piston will crack if allowed to rattle around in a worn bore.

I don't find the newer (89-up) Cr500's hard to start, the older ones were a major pain though with their high kickstarters.

The stock Cr5 power is low to mid, so you are not going to get a mid or topend hit like on smaller bikes.
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Old 06-27-2005, 06:23 PM
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mtk mtk is offline
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Default Re: 1991 cr500 top end rebuild needed?

Quote:
Originally Posted by PowerFiend
The stock Cr5 power is low to mid, so you are not going to get a mid or topend hit like on smaller bikes.
Unless you have a little porting work done on it....
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Old 06-27-2005, 08:11 PM
CLM CLM is offline
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Default Re: 1991 cr500 top end rebuild needed?

Well it's pretty much certain the top end is in need of freshening up. If I end up keeping the bike, which I'm leaning towards right now, I'll schedule that for after the shock rebuild (So I don't kill myself riding the bike with a blown shock... *BOUNCE*BOUNCE*BOUNCE*)

Any reccomendations on a place to send them for a basic rebuild semi-inexpensivly?

Chris
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Old 06-28-2005, 08:52 AM
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Default Re: 1991 cr500 top end rebuild needed?

Quote:
Originally Posted by CLM
Well it's pretty much certain the top end is in need of freshening up. If I end up keeping the bike, which I'm leaning towards right now, I'll schedule that for after the shock rebuild (So I don't kill myself riding the bike with a blown shock... *BOUNCE*BOUNCE*BOUNCE*)

Any reccomendations on a place to send them for a basic rebuild semi-inexpensivly?

Chris
I recommend a revalve at the same time, it is usually not much more since they have the shock apart anyway. As far as who, just get someone well known.
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Old 06-28-2005, 07:34 PM
CLM CLM is offline
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Default Re: 1991 cr500 top end rebuild needed?

I was just wondering because I remember back before these forums there was a board member who did suspension, but I've been doing other things for ages so I don't know anymore

Chris
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Old 06-29-2005, 12:21 PM
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Default Re: 1991 cr500 top end rebuild needed?

Quote:
Originally Posted by CLM
I was just wondering because I remember back before these forums there was a board member who did suspension, but I've been doing other things for ages so I don't know anymore

Chris
I think his user name is Shocknut and his site is [Only registered and activated users can see links. ] if I recall.

You can also check around [Only registered and activated users can see links. ] for CR500 tech.

Pull the reed cage out and check the piston on the intake side. That is where they form cracks when they get worn to or beyond the service limit. I have a few pictures of my original Honda piston with over 4 years on it that was worn to the service limit and it had some cracks (from running a bit lean on topend too) in my photo gallery if you want to look.

You can get rebuild parts pretty cheap from [Only registered and activated users can see links. ] or just send it off to Eric Gorr.

BTW, that easy kick you feel is partly from the decompression ports Honda used in the late model CR500's to aid in easy starting.
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Old 07-07-2005, 12:01 AM
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Default Re: 1991 cr500 top end rebuild needed?

Ya what 2K said;
You don't want this to happen do you!

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