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Afastcar CR500 Pilot Engine CSI
http://www.pilotodyssey.com/PO/viewtopic.php?f=25&t=3948		 Page 1 of 4
Author:  hoser [ Sun Feb 03, 2008 4:12 pm ]
Post subject:  Afastcar CR500 Pilot Engine CSI
I was not going to start this project for a few more weeks but since Afastcar was asking me questions about his Engine and researching the CR500 cylinder and head I thought I would do a very preliminary investigation so he could continue his data acquisition, I didnt have this thing cracked open for only a few minutes and seen a few things that can possibly hoserized depending on his research and budget.


Reworked stock CR500 head, the machine work was very rough and a sharp edge and angle left on the transition area between the squish ban and the bowl.

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Author:  hoser [ Sun Feb 03, 2008 4:12 pm ]
Post subject: 
With the head off and the piston cleaned I can see they use a wiseco and its a 1mm over bore.

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Author:  hoser [ Sun Feb 03, 2008 4:13 pm ]
Post subject: 
Burn pattern before cleaning the piston, looks like its a low hour piston so far.

Head gasket looks stock Honda, I am assuming at this point, its metal 3 pieces and has the black coating like the stock Pilot gasket.

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Author:  hoser [ Sun Feb 03, 2008 4:16 pm ]
Post subject: 
Some pics of the cylinder wall, see the scuffing above the exhaust bridge, I assume at this point I will find matching scuffing on the piston and the exhaust bridge was not properly relieved, heck it might be missing the cooling holes too.

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Author:  hoser [ Sun Feb 03, 2008 4:19 pm ]
Post subject: 
I measured the exhaust port width so Afastcar can ask the CR500 experts how wide you can go and still use a CAST piston, I have heard to go wider you have to run the wiseco pistons, I will explain this in great detail later in this CSI once the cylinder is off and the piston out.

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Author:  hoser [ Sun Feb 03, 2008 4:21 pm ]
Post subject: 
Intake manifold and reed cage removed, it uses a FMF reed cage.


Notice the puddle of oil at the bottom I don't like this, I hope the oil was not falling out of suspension...

Their is a huge gap between the sides of the reed cage and the cylinder, read on.

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Author:  hoser [ Sun Feb 03, 2008 4:23 pm ]
Post subject: 
The top reed cage is the CR500 FMF cage but the reed area is NO bigger than the other reed cage that is off a ATC250R, the cage in the pics has been hoserized, actually I am emulating the same style stuffer shape and design as FMF and Honda uses.

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Author:  hoser [ Sun Feb 03, 2008 4:33 pm ]
Post subject: 
The ATC250R cage held in place, WHY did Honda (Afastcar you ask the CR500 gurus) make a over sized reed cage opening then only use a reed cage with the same surface area as a 250R ?

Here is where I see all kinds of room for hoserization, you have TWO options here ONE would be to fill the GAPS around the reed cage with Devcon epoxy this will stuff the bottom end and build a higher primary crank case compression option TWO would be to modify the ends of the reed cage and ADD 2 more reed petals (one each end) like the Pyramid reed valve has http://www.duncanracing.com/ctgy/28

See the width difference (pink arrows) the extra reed petals on the end of the cage would flow nicely into the boysen ports (blue arrows)

So its either stuff it for add more flow research is needed here.

More on this CSI in a few weeks.

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Author:  Stoneman [ Sun Feb 03, 2008 5:31 pm ]
Post subject: 
I am glad to see this thread. It has motivated me to breakout my 500 setup that has been behind the bedroom door for 4 yrs.
I was told by Jay at pcp that you cannot run a prox piston in a 500 jug that the ex port has been modified. So that only leaves a oem or Wiseco piston?
Afastcar, can you tell me what size carb and the jetting that's on your 500 setup? Whats the history of you motor (( Internal Combustion Engine ? ))?
Author:  afastcar [ Tue Feb 05, 2008 1:27 am ]
Post subject: 
This is a new to me project it has been sitting for seven years I don't know much about it other than it seems to be a kit from ATVR racing, it has a Mikuni carb and I don't know what the jetting is. I just hope it turns out better than the last fiasco..........
Author:  Monkey [ Wed Feb 27, 2008 4:36 pm ]
Post subject: 
Soooo, Can you mount a CR500 cylinder and head on a stock FL350 bottom.
Author:  hoser [ Fri Feb 29, 2008 3:43 pm ]
Post subject: 
A closer look at this CR500 Engine.

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File comment: See how they grind clearance into the cylinder
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Author:  hoser [ Fri Feb 29, 2008 3:44 pm ]
Post subject: 
Clutch is wider than my holder I think the clutch is adjusted too wide for the Honda belt

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Author:  hoser [ Fri Feb 29, 2008 3:45 pm ]
Post subject: 
D ring messed up because it was not assembled correctly

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Author:  hoser [ Fri Feb 29, 2008 3:48 pm ]
Post subject: 
Grooves cut on the end of the crank bolt to act as a tap???

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Author:  hoser [ Fri Feb 29, 2008 3:50 pm ]
Post subject: 
Filling the bolt hole with grease before installing the puller works every time.

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Author:  hoser [ Fri Feb 29, 2008 3:51 pm ]
Post subject: 
Look close, the washer is junk it has a deep groove.

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Author:  hoser [ Fri Feb 29, 2008 4:07 pm ]
Post subject: 
The cylinder and gasket over hangs into the transfers horribly dunno why this was not matched up.

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Author:  hoser [ Fri Feb 29, 2008 4:08 pm ]
Post subject: 
To provide clearance between the starter and the intake manifold they grind the starter housing down then seal it with gasket sealer?

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Author:  hoser [ Fri Feb 29, 2008 4:09 pm ]
Post subject: 
The exhaust manifold was leaking bad.

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Author:  hoser [ Fri Feb 29, 2008 4:10 pm ]
Post subject: 
The new cool head next to the old.

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Author:  hoser [ Fri Feb 29, 2008 4:11 pm ]
Post subject: 
The piston is like new and cant have only a few hrs use, the piston to cylinder clearance is .006

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Author:  hoser [ Fri Feb 29, 2008 4:12 pm ]
Post subject: 
The exhaust manifold is matched about as well as the cylinder

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Author:  afastcar [ Fri Feb 29, 2008 5:01 pm ]
Post subject: 
hoser wrote:
The exhaust manifold is matched about as well as the cylinder


at least the head port is smaller than the manifold, the other way around would be worse.
Author:  hoser [ Sat Mar 01, 2008 2:05 am ]
Post subject: 
afastcar wrote:
hoser wrote:
The exhaust manifold is matched about as well as the cylinder


at least the head port is smaller than the manifold, the other way around would be worse.


Both directions is bad, look at the animated gif below, when the returning pulse wave from the pipe is trying to stuff the fresh air fuel mixture back into the pipe... Every ATVR Engine I look into their is all these details that are over looked, they must save all the highly detail work for the engines they put on the dyno?


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