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Old 03-29-2017, 05:38 PM
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Default 86 cr500 clutch cover swap 01

     

Hey gang i"m the FNG to site working on 86 cr500 clutch 2001 swap i read some where i have to change coolant line and brake lever it any on has some more details maybe some pic would be really help full thanks again run it like a rental!!
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Old 03-29-2017, 05:56 PM
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Take a look at the photo and note the orientation of the hoses going into the water pump, in 1989 the water outlet on the cylinder changed location as did the configuration of the water pump. You'll just have to come up with a custom hose for your particular application.
As for the brake pedal, since the outer case is slightly wider on the 90+ you'll either need to bend the brake pedal to clear or use a small shim to move it out slightly. Shimming it may cause issues but yours being a drum brake rear model should be easy enough to overcome.
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Old 03-29-2017, 06:08 PM
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yeah i see your coolant line mines right above the carb but i cant shim the break pedal because it sits on the inside of the frame thanks for the help
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Old 03-29-2017, 06:27 PM
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Quote:
Originally Posted by 86CRchuck View Post
yeah i see your coolant line mines right above the carb but i cant shim the break pedal because it sits on the inside of the frame thanks for the help
That's not my motor, though I wish it was... that one belongs (or did) to dogger315. What you should key in on is the angle of the pipes coming out of the water pump, on your bike the rearward port is angled back a bit and on the newer ones it's vertical.
Wasn't aware the brake pedal was inboard mounted on those bikes... that could create a whole new set of issues. I'm wondering if you could cut and weld a small piece in to get it to clear properly.
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Old 03-29-2017, 07:17 PM
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That's a clean engine there the kick start is cherry
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Old 03-29-2017, 09:22 PM
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the break pedal rides really close to the frame i was just hoping someone has done this on the 86 let me know please i think shimming will make it rub

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thanks for your help i will keep posted on the out come
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Old 03-30-2017, 09:13 PM
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Well we pulled the engine topend and clutch cover today here's some pics for those who like pics and to keep record cause our memories aren't getting any better



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Old 03-31-2017, 08:34 AM
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Nice!

Looking foward to more pic's of the progress.
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Old 03-31-2017, 10:41 AM
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We will get into the lower end next Friday I also think we will be tearing down my 89 I was getting it ready for a trip to the dunes a few years back and had no coolant in the radiators I pulled the water pump cover screw and nothing came out saw a little mushy rock blocking the hole so I pulled the water pump cover and it was all nasty gummed up.

I've pulled my head and the water jackets looked clear I haven't drained my oil yet but if there's water in there which I won't be surprised it's tear down time I can't be chasing chuck around on a quad that would be no good well keeep the pics and updates going on his I'll start a new thread if and when we dig into mine
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Old 03-31-2017, 01:55 PM
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BEAUTIFUL !!
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Old 04-02-2017, 07:03 PM
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Does anyone have any information on doing the 86 to 01 clutch cover swap I see we have 115 views and only one reply I figured I would get some help here on this site so throw the word around please .
Run it like a rental !!!
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Old 04-02-2017, 11:06 PM
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Sorry,
i am usless on helping you on this one !
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Old 04-03-2017, 10:04 AM
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Quote:
Originally Posted by 86CRchuck View Post
Does anyone have any information on doing the 86 to 01 clutch cover swap I see we have 115 views and only one reply I figured I would get some help here on this site so throw the word around please .
Run it like a rental !!!
Not really a lot to discuss, it's bolt on and go other than the previously mentioned water hose routing concern. I did see recently on Facebook a gentleman who is modifying newer outer case halves to have the older style water hose routing for a true bolt-on install, no idea what the cost was though.
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Old 04-05-2017, 12:41 PM
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Well I took my 89 apart and as I vegly remember it has the rot also case half should be here tomorrow the water pump rebuild kit came today moose racing from Dennis Kirk. I've done a little reading and the newer aluminum case halves are wider so my 89 maybe need some tweaking on the rear brake lever chucks 86 will need some with it being a rear drum bike I haven't found any pics for a reference so once we get too that I'll post some up.

Here's a few pics of my junk and the kit that came today I'm going to rattle can my new cover with some roll bar frame paint I have it should hold up if not o well it's a dirt bike.






Last edited by zachwrench; 04-05-2017 at 01:21 PM.
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Old 04-16-2017, 03:24 AM
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To make the newer cover work with the older 6 plate clutch bikes (85-89), take the new cover to a machinist and remove material from the clutch cover mating surface on the new right case cover so that the width of the new cover matches the one you removed. Then you don't have to worry about brake pedal clearance.
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Old 04-19-2017, 10:59 AM
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That's a good idea we might go that route at the moment the 86 cylinder is out west getting bored and port work with a member from bannedcr500riders can't remember his name we'll post his work and info up once the cylinder comes back.

I have all my parts to put my 89 back together decided not to paint my clutch half cover and went with a new clutch cover to off set the silver and black lower end and cylinder the new clutch cover is a mix of silver and black.

Not much else going on collecting parts and slowly getting these bikes back up and going again
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Old 04-19-2017, 12:36 PM
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Quote:
Originally Posted by zachwrench View Post
That's a good idea we might go that route at the moment the 86 cylinder is out west getting bored and port work with a member from bannedcr500riders can't remember his name we'll post his work and info up once the cylinder comes back.

I have all my parts to put my 89 back together decided not to paint my clutch half cover and went with a new clutch cover to off set the silver and black lower end and cylinder the new clutch cover is a mix of silver and black.

Not much else going on collecting parts and slowly getting these bikes back up and going again
Must be blownbillybob unless you sent it to Canada land.
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Old 06-29-2017, 10:21 AM
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Chucks cylinder came back we put the engine back in and there's no clearance issue with the brake lever. There was a clearance issue with my 89 with the newer clutch cover half I just took the die grinder to the brake lever here's a few pics of both bikes with the newer clutch covers installed 86 is the red frame 89 black frame

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A few more pics of some progresss hope to be riding soon

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Old 06-29-2017, 08:45 PM
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Quote:
Originally Posted by cowboyona426 View Post
Must be blownbillybob unless you sent it to Canada land.
Yup he sent it too blownbillybob
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Old 10-14-2017, 09:25 PM
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Update the 86 is up and running had a issue with a set of aftermarket rads fitting returned them and installed a set of gpi racing rads from eBay no issues bolted right up.

Well as mentioned earlier no clearance issues with the kickstart and brake lever on the 86 with the newer cover installed the only clearance issue we found was at the water pump hose and the stock pipe (expansion chamber ) we test fitted it a few times made small adjustment as needed with the hammer I'll get pics later
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