Looks like a great project is ahead.
Maybe I can help with some questions.
THe pipe looks to be the one ATVR had Power Pros make for them to install on the 500 conversions but in pic 29 the expansion chambers flange doesnt look to mate with the exhaust flange very well??
yes correct the exhaust flange to chamber is not sealed at all, it spews out goo from running way rich,if I need to replace the flange is that a ATVR only flange or readily available for like CR500 jug?The flange is still available and according to Partzillas part number, 18352-KA5-691, the flange will fit all year CR500s(NOTE: paragraph I wrote at bottom of this post)
Now is the flange correct for the CR500 or is the expansion chamber flange too big, My pipe's expansion chamber flange measures right about 2-3/16" ID, so the cylinder's exhaust flange would be just under that measurement, you can measure both and compare to my measurement to see which is wrong. According to CR500 motorcycle riders, the CR500's engines have a tendancy to vibrate quite a bit and break the springs that hold the expansion chamber to cylinder exhaust flange ( I also have experienced this), maybe yours has been loose and wallered out the expansion chambers flange causing it to be extremely loose??
Is there any "ATVR" engravings on the jug or head?
None I can see, usually they engrave it big and large,nothing I can see other then a large "a" that was written on the head with pen or something. I will be taking the Engine out and sending it to Hoser for a CSI in the coming months if he has time, he has 2 engines right now from me he rebuildingI bought my ATVR LT pilot used and it came with two heads with ATV carved in them. I forget the cc but one was for pump gas and the other for race gas (maybe A and B and the A on your head is for pump gas??), but the one for pump gas still gave me over 180lbs static compression , too high for pump gas, also Hoser doesnt like ATV heads so I went with the CR500 Pro Designs cool head, theyre still available new on Ebay, it comes with a 63cc and 66cc interchangeable dome, got my compression down to 165 with the smaller dome. The intake looks different from my ATVR's but still could have been fabbed by them. The carbs angle you asked about is angling towards the opposite from the factory Honda CR500 motorcycle so I think that bend is in the "boot" and maybe for the air cleaner "set up" to fit?? It should run straight back so that the carb can attach to the factory Pilot airbox boot.
The pulse outlet on the jug for the fuel pump looks like my ATVR jug.
Is that the Pilot radiator?
Yes, Pilot radiator with all the stock OEM sensorsYou can still see the bump steer tabs!
The stops are bent were the bolt screws in but they can be fixed no problem. I might install a YODA kit on this in the front and a set of DC rear LT SHOCK BRACKETS with Fox Airs in rear.One of my stops was broke loose from ATVR's crappy weld job?!? I wonder if the Pilot was used for racing since it has a Fire extingusher or maybe just a smart rider attached it
The previous owner was paralyzed from the waist down, the seller did the wrenching on it, it has a water system on it that provided water on demand to drink when a switch is activated, so I am thinking it was raced somewhere in the Utah area at some point If the trans has been leaking might want to check the torque clutch for slippage, I bought a PIlot where the PO ran the trans dry and I had to replace the cork plates in the torque clutch.
The ATVR heads I have seen have the two outlets cut off and one welded in like yours.
I will take some detailed pictures of the Engine after cleaning, it is totally covered with spooge and such but again so far nothing ATVR on anything!!spooge spooge spooge!!Keihin made the PWK39 so not sure about your carb but if you remove the carb and intake don't be surprised when you see the some of the starter ground down so that the intake and reed cage can fit
Was that the norm back in the day? Is there anything else that owners did on these conversions to the Engine or frame I should look for StixIll keep your post in mind and when and if I think of anything else related to the LT CR500 conversion Ill be sure to post it here, some notes below to help you find parts.
that's all I can think of for now...