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Old 08-07-2012, 05:52 PM
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Default CR500 refresh and questions

     

I recently aquiered a 96 cr500 in a trade,
re: Trade my crf450 for cr500?

Im going to fix a few things and ride it before going through it this winter.
A few questions for now....

Carb has a few issues, the choke wont stay up. Ive not inspected it yet but what causes it to not stay in the up position?
Also with the carb, the pin that holds the float in place, there is a ton of play in it, mostly in the carb body where the pin ends sit. Tell me theres a way to fix this? I tried a 3mm drill bit, not to drill out but to replace the stock pin, but 3mm is too big, I need a 2.75mm or so to fit the current hole size (carb body)
I suppose I should drill it out to 3mm but theres not a lot of material there. If someone has done this Id like to hear about it!

The bike has a crusty looking PC pipe and a dinged up fmf silencer. Im going to replace them both but with matching brands. Which is the better exhaust system to go with? (fmf or pc)I dont care about a big change in the power band but jetting friendly would be great.

Thats it for now, I will be asking more ?? as I go along.
thanks!
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Old 08-07-2012, 07:42 PM
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The choke has a little notch cut around the rod that the knob is attached to. Under the rubber boot there are plastic "fingers" that catch in the notch when you pull up on the knob. I have remedied this problem by putting a twist of safety wire around the "fingers" to tighten their grip. I would get a new one when the budget allows (some of those chokes are $40). As far as the float goes, are you sure it has the correct pin. I would only drill as a last resort. I have noticed, while changing some rear suspension bearings, that some of the needle bearings happen to be the same size as the float pin in some carbs.
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Old 08-07-2012, 08:52 PM
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THanks for that. My pin is 2.45mm. Your right, it could possibly be wrong, because it has so much play on both the carb body holes AND the brass tube on the float "frame".
I have a spare carb off a 91 250 I can check, cant remember if its a keihin or not.

thnx

---------- Post added at 06:52 PM ---------- Previous post was at 06:23 PM ----------

Nope, opened up a 250 carb, same pin size and acceptable amount of play.
The 500 carb is worn....
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Old 08-07-2012, 10:16 PM
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Trying to repair a worn out PJ comes under the category of "penny
wise and pound foolish". That's a sixteen year old dirt bike carb
that wasn't very good when it was new, time for a replacement.
Prices range from $175 for a new PWK to $45 for a newer (hope
fully not also worn out) used PJ.

Pipe brands for a 500 come down to personal preference. Both
the PC and FMF do a a good job of toning down the delivery
compared to the stock pipe. The main advantage for going
aftermarket on this bike is to lose the bazooka length stock
silencer, and it's attendant weight.

Here are some thoughts on your other questions:
Quote:
the brake petal is worn pretty good, but is that enough reason for it to interfere with the kicker? Or could something else cause this?
I plan to replace the petal
From the picture, I'm guessing the pedal was tweaked in a crash.
Replace it.
Quote:
Can I use a newer front brake master of a crf, bolt right up?
Also crf footpegs?
Yes, and if you get one from an 07 or newer, you'll get a quantum leap
in front brake feel and performance. You'll have to stick with pegs for
the 500. CRF and CR250 pegs don't work.
Quote:
Does it look like a stock tank or aftermarket?
Aftermarket. Probably a 3.1 gal.
Quote:
Do you know of a resource or guide to jetting, or any tricks to carb setup...
Once you get a decent carb, use this for a baseline: 170, 55, 1368 2nd, 1 1/2

The bike looks to be a solid foundation for a resto. Hope you do it up
right, and give it a good home.

dogger
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Old 08-07-2012, 11:26 PM
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Thanks for that dogger. I new the carb was going to need replacement, with both the choke and float issues. Im going to try and fix it for now, nothing to lose.
So what years/models can I find a newer carb from? PWK the better choice?
The carb is currently at 175/55/1368 (a/s not sure) and needle #3 pos.

I found that the kicker is worn too far where it swings open to kick it, is beyond 90, and interferes with the petal. As mentioned before, both will need replacing.
Great news on the front master, but I cant believe the 500 pegs are model specific!

Ill be fixing it up to be a solid runner, not as impeccable as yours but a 9/10 anyway. I am picky, and cant stand riding any bike that feels loose or worn. Its going to take time.

thanks

---------- Post added at 09:26 PM ---------- Previous post was at 09:16 PM ----------

From a little reading around here it looks like the PWK airstriker is the carb of choice...
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Old 08-08-2012, 09:08 AM
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Quote:
So what years/models can I find a newer carb from? PWK the better choice?
The carb is currently at 175/55/1368 (a/s not sure) and needle #3 pos
Yes the PWK is the better carburetor. They came stock on 99 and 00 CR250s.
Unfortunately, the words out and good deals on used ones are few and far
between. If you opt for a new one, I recommend the 99 CR250 version. It
can be purchased from Service Honda for $175 jetted and ready to bolt on.
Your current jetting looks to be on the rich side.
Quote:
I found that the kicker is worn too far where it swings open to kick it, is beyond 90, and interferes with the petal
Not surprising, and not uncommon on a 500.
Quote:
I cant believe the 500 pegs are model specific
I found this out back in 97 when I first switched over to Ti footpegs. Of
course nobody supported the 500 even then, so I used a pair for the 250
thinking they would bolt right up - wrong! Your frame design dates back
to the late 80s, so items like footpegs would be common to 250s of that
time 89-91.

I'll see if I can scounge up some pictures of my 500 from that year.

dogger
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Old 08-08-2012, 10:41 AM
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Thanks again. I could live with the stock pegs, however mine are worn at the pin, no surprise there.

FWIW: I sent EVO-mx pics of my 500 swingarm decals and they are going to replicate them. So I'll have those and the rad decals coming soon. Thanks to those who posted about that company, they seem like good people!
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Old 08-11-2012, 11:05 AM
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I took it out for a quick ride yesterday, Ive got an issue with it dieing near idle. Other then that it runs really strong, doesnt seem overly rich. Starts on 1-2 kicks.
Riding a 4 stroke for the last 5 years, now I really see why the 4 stroke is easier to ride. The main difference is traction. The 450 just hooks up, the 500 is wheelspin everywhere if your not careful with the throttle! It was a blast but will take a while to get used to.

My brakes certainly need some upgrading!

Question of the day is, I know the big bores have vibes....but how much is normal. THis thing had a lot of vibes on the footpegs, and a little on the bars.
Is this normal for the cr or is it excessive?

thnx
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Old 08-12-2012, 08:44 AM
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Quote:
Is this normal for the cr or is it excessive?
500s can vibrate pretty good, some more than others.
What you're describing sounds about normal. Make
sure all the motor mounts are torqued to spec.

If you want to lessen it to say the level of a 250, get
your crankshaft balanced and isolate the handlebars
with rubber mounts.

dogger
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Old 11-04-2012, 10:24 PM
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Quick question on a replacement front master...locally an 08 yz125 is being parted out, will its front master work with the cr500 hose/banjo bolt and is it as good as a newer crf fr master?

thanks
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Old 02-23-2013, 05:12 PM
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Ok I went to clean up and install the airstriker I bought from 'seanmx57' and not only was it missing the cable holder, now I noticed its missing the idler adj. screw and spring.

Can I order this screw from my local honda shop, for the 2000 cr250? I need this ASAP.
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  #12  
Old 02-23-2013, 08:05 PM
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Yes all those parts are available from your dealer:
2000 Honda CR250 OEM Carburetor (1) | MotoSport
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