cr500 in a 250r frame

[RZBansheeMan]

Today ( Thursday ) Some kid that I know, He knows about both of my projects going on with my Banshee and the TRX 500, was telling me about seeing a really nice Red TRX 500r at Silver Lake. He didn't say when, but he did say it was really nice and really fast. I kind of assumed it was yours.

Mike

[RZBansheeMan]

Thanks for all the pics.

Correct me if I'm wrong but it looks to me like you have your pipe solidly mounted to the frame. I am planninon building some rubber isolated mounts for the pipe on my project. I was thinking of running the pipe mount from the engine cradle so the pipe is in harmony with the engine and not being confined to the frame.

By the way, did you say that you used the 86 style intake ?
What is that pipe and did you modify it ?

Mike.

[rsss396]

It could have been me I was up there the weekends of the 14-15 and 28-29.

Here are some pics of my pipe mount, I am using the factory rubber mounts, but have been thinking of adding a little more isolation.
Not sure how mounting the pipe off the motor mount would work but hey give it a try maybe it would work better.
I have been thinking about a exhaust ball joint in the header pipe like they use on snowmobile motors.

I do run the 1986 boot and I dug up my 93 boot and I told you wrong it doesn't go toward the shock it goes the opposite way toward the frame just like yours.
So buy a 86 style and your carb issues will be solved.
The stock air cleaner will work but it has to move forward I think about 1/2".
I think I just zip tied the back of it on and still used the boost bottle (1988 style)mounting hole toward the front.

[rsss396]

My exhaust pipe was made by CPI, mike is the guy to talk to.

The way you have your motor mounted with swingarm bolt threw the rear mount makes the exhaust flange almost exactly were the 250r exhaust is.

CPI has a 250r in there shop and he made a pipe to fit it. But I did have to cut the pipe in 1 spot and rotate it along with rotateing the header pipe.
Then I had to reweld the exhaust spring mounts so the springs would line up with the holes on the exhaust flange.

I have a extra pipe that I bought and never used that I would let go for $75.00
It is used and I have no idea who made it but it does fit a TRX frame.
I am no pipe expert but I would say it was designed for bottomend power because it only has a 1 1/8 outlet pipe and most cr500 pipes are 1 1/4
But this would keep heat in the pipe for excellant bottom end power.
It is a hand built cone style pipe that was built for a 500 conversion not just a
250r pipe modified.
I can bring it to silver lake on the 25-26 if you want to take a look at it.

[RZBansheeMan]

I noticed also on yours that it has a huge amount of expansion chamber volume, Is your motor ported ?
Also how does the power come on ?

Most 500 conversion I have seen pics of have a pretty long and more narrow of a chamber, more along the lines of a bike pipe. Right now the way I am mentally planning and designing it, a stock 2001 CR 250 kick start should work and clear the brake lever. What I am trying to come up with, is an extra TRX 250r clutch cover and an extra CR 500 clutch cover. The plan is to either have an extra kicker shaft made about 1" to 1 1/4" longer, and then cut the bearing support boss off from the 250r cover and welding it to the 500r cover. It is going to be be some quite involved work into this thing and there is going to be a lot of attention payed to all the details to make this thing work properly. The 250r kicker shaft has the same diameter as the 500 so it should fit perfectly as long as all goes well.

Could you take some pics of your extra pipe ?
Also what is that piece that you mentioned about exhaust ball joint ?

I also wonder how " hilpp's " project is coming along.

Mike

[rsss396]

I am ported pretty heavy compared to stock 196 on the exhaust 130 on the transfers. Stock is about 182exhaust 122 transfers.

I have a custom pipe from AAEN performance that is the long and narrow style he built for me last year. It worked very good with the stock porting.
The CPI pipe is a larger volumn pipe but is also pretty long even though it may not look like it.
It is expected to make peak power around 8200rpm but I normally see 9000 rpm with it.
It is very strong in the upper midrange.
I need to get it to a dyno to see its power curve.
I do run a 15oz flywheel weight with a bolt head welded to it so I can start it with my remote starter

There is a aftermarket exhaust ball joint sold threw dennis jerk but I was hopeing to find a nicer factory piece, just haven't had the time to research and find find one

I have to dig the other pipe out and will take pics sometime this week.

[rsss396]

I think your kick starter idea may fail because I have seen a few broken cases that did not break on the clutch cover side but on the center case half.
I think all the leverage from a longer made shaft is going to compound the problem.

I do have a compression relief on my motor done by accuproducts in Ohio.
Rick is the guy that owns it and is on E-bay.
It does work pretty good but I still have issues starting it but I believe it is because of not enough kick starter rotation.

I plan on addressing this in the off season but for now I am using a remote starter.

[RZBansheeMan]

Right now my 500 ports are stock, but how would you say that yours holds up to piped, ported and smaller stroked Banshee's ?

My builder for mine said that with the Rocket pipes that I have I should be puttin down a solid 75 horse and witha custom set of Shearers I would be in the low 80's ball park.
I know the 500's have a tremendous amount of torque, but I don't think that they can twist 11,000 to 11,500 either.

[RZBansheeMan]

On the cases that broke, was it because of an extended shaft ?

I was hoping that with adding the longer bearing boss from the 250r engine would help support the added stress of a longer kicker shaft. I was also thinking on adding some triangular gussets to the back side of the case where the kicker shaft is bottomed.

[rsss396]

thats a tough question the bike has only 2 trips this year and I see such a difference in banshee power, I use to run with or beat alot of ported & piped banshees with my 265 but then got smoked by alot to!
I am a solid 8 bike lengths faster than my 265 was.
But I was getting beat this year by some banshee's and three wheelers on alcohol the first trip before I changed the porting on that I $400 for.
I do believe I am faster now but then hardly anyone was at silver lake on the 28-29 trip that I could compare to.

The cases that were broke I do believe were stock

I really think the compression relief valve would take off allot of stress nomatter what you do.

Aluiminum welding is tough and the cases are pretty thin but it sounds like a better plan then just making the shaft longer.

But if you were to get a metal kicker like mine you can bend them alot to fit what you need and they are still pretty long after you bend it. Just make sure its off a larger cc bike so it will be long to begin with. I tried lengthing a steel trx one but the meatal was to soft and would bend after a few kicks