Well as our story begins, it is late fall 2004 and I am just finishing up doing the last (or so I thought) bit of maintance on the two machines I am going to take to the Fall Jambo at Litte Sahara

I have checked all the fluids and given both my Stock FL400 (wifes ride - or so called) and my Bad500 (My LT Pilot with a 400cc Cylinder Punched out to 500cc) the 10 point check over...

It's a nice fall evening and I've already done a couple of plug chops and everything is looking great.
I decide to take the Bad500 for a little spin around the farm and down the country roads...

I return about 15 minutes later and the Pilot is running great - One last pass to the top of the hill and I'm going to load it on the trailer for the trip. As I aproach the top of the hill, running about 50 MPH the Engine slowly dies... I immediately reach down and pull the choke hoping that if I did get it hot I would be able to cool her off as I coast to a stop...

I hop out hoping that something simple happened like a) plug wire came off b) I accidently hit the kill switch c) the plug unscrewed itself (hey it's happend before) but everything looks normal...

After letting it cool down for about 10 minutes I try to give it a little pull via the start rope - Nothing doing - AH CRAP - At this point I'm guessing 4 point seizure.

Anyhow with very little time left before the Jambo I decide to push it in the garage and take my Work-in-progress FL670R instead... (In hind sight I'd guess I'd rather it blew before I loaded and halled it 8.5 hours to a ride area)

MAN I MUST BE A WORDY GUSS...

Anyhow - here it is today (or so) and I have finially started tearing into the BAD500 to see what happened.

NOTE:
For those of you that didn't know the BAD500 has been my adopted experimental project since I bought it - no one seems to know its origin or who created such a beast. Many such as ATVR have said that they never punch out a FL400 to run the CR500 piston. CW Racing has admitted to doing this mod to some Pilots but claims his all have his markings on them...

It's been two years since I have had to tear into this machine so I (an others I assume) are kinda interested in seeing what has been going on...

Enjoy the Picts - Any/All thoughts are welcome...
Dennis

The bad 500 running yet?

Pics of the old rod bearing, pin and cage?

Yep Shes's about to be loaded for the Trip south to LS...

I have some picts at home - if I remember I'll post them tonight...

Dennis

Cool glad to see it is running again, how is the 670 any changes since the last trip?

Evaluate your suspension on both your LT Pilots, have others follow you (Lightspeed) and
see how they work, figure out what springs your using if you can Pilotman is still trying
to get his setup right so were looking for data to work with I think both his rear springs
are #100.

Haven't done much to the 670 yet since last falls trip...
I want to make a few changes
Addition of a rotary valve oil resivior (kept boiling the oil last time)
Drop to single Exhaust with a Good Silencer
Reloacate the radiator mounts (to close to my head)
Swap out the rear springs for a set of #100 (to stiff)
Add a better heat sheild/firewall (so I can install my soft beard seat)
Add electric start (yea baby)

I have all the parts now just need to find some time...

"Evalute my LT suspension" - Don't have to - THEY ARE STIFF AS HELL

I believe both my LT have the same springs - 125 tenders and 150 mains
Unless others who have tried it say different I think I'll drop the 125 to the main spot
and buy some new 100's for the tenders...

I do have have Axis on one machine and Fox on the other...
(So Pilotman is running 100 tenders and mains - Does it ride like a Cadillac...)

Anyhow below are some picts of the BAD500 lower end parts

PS
One day I'll get around to working on the basket case - I HOPE...

Later
Dennis

Since I had the lower unit torn apart and sent out to be fix I also decided to send the upper unit to Bore Tech to have them treat it...

Some picts of their work below...

I am seriously considering selling this pilot...

It will be at Little Sahara in Oklomaha from 5/16-5/20 if anyone is interested...
After that it will be back home in Lincoln Nebraska

I'm looking to get $10K for it and I'm not interesed in trades...

Its got just about every darn option available for the Pilot...

You can contact me at dennis@mindvision.com for details and pictures after I get back
from LS if it has not been sold yet.

Dennis

I am currently running 100#s over 125#'s springs on my LT Pilot. I still think it is too stiff over the rough stuff. I am going to try backing off the lock rings to where the springs are just loose sitting still. If that doesn't work, I will be ordering another set of 100#s for the lower springs. I have a set of 150#s for sale if anyone wants them (doubt it unless you are stadium jumping). It did make a huge difference on the Axis shocks to go down to the 125#'ers but being I am only 160#s soaking wet.... I either need to gain weight or lower the spring weight....

Pilotman

I'm certainly not experienced with the LT setup, but based on what Radical did, and since 100s over 125s still feeling stiff, makes me think that part of the problem is too much compression damping.

Dennis, try my LT out this week at LS, you may be suprised how it rides now. I can give you my valving specs and such. Heck, we can revalve it there in an hour or so. I got my N2 tank and shock tools packed in the trailer already.....

i use 80 over 100 and extensive work on the pistons