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PostPosted: Tue Feb 22, 2005 1:57 am 
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Joined: Sun Dec 21, 2003 11:30 pm
Posts: 476
Location: Nebraska
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


Attachments:
File comment: Here you can see some of the porting work done to the intake
IntakePorting.JPG
IntakePorting.JPG [ 84.42 KiB | Viewed 1997 times ]
File comment: Here you can see the piston has some slight scuffing on it - This scared the hell out of me about a year ago when I was checking my reeds and saw it but after talking with many knowledgeable people about it. It was confirmed that this was only a piston co
IntakeJug.JPG
IntakeJug.JPG [ 131.71 KiB | Viewed 1997 times ]
File comment: parts is parts right - anyone know who made that stuffer ?
IntakeStuff2.JPG
IntakeStuff2.JPG [ 77.48 KiB | Viewed 1997 times ]
File comment: I'm not sure if this is a 90 FL400 reed Cage or a CR Reed Cage or ? - Any Ideas
IntakewReeds.JPG
IntakewReeds.JPG [ 138.19 KiB | Viewed 1997 times ]
File comment: Custom Stuffer - Fits intake boot very well
CustomStuffer.JPG
CustomStuffer.JPG [ 129.92 KiB | Viewed 1997 times ]
File comment: Notice that this is not a FL400 intake boot
It is center mounted - Did someone have a part number for this ? It fits the 39mm carb very nicely

IntakeBoot.JPG
IntakeBoot.JPG [ 133.16 KiB | Viewed 1997 times ]
File comment: This is a new one for me - Check the pict closely and you will see that the air leak is actually walking up the base stud threads
I could not believe it - These were brand new stubs and hardware two years ago
Will Thread lock stop this ?

AirLeak.JPG
AirLeak.JPG [ 142.34 KiB | Viewed 1997 times ]
File comment: Bonus points if you didn't read the Subject and can tell me what you are looking at ?

I pressure tested the Engine she held 6lbs for about 10 minues - I did find one small leak (Check Next Pict)

WhatIsIt.JPG
WhatIsIt.JPG [ 183.27 KiB | Viewed 1997 times ]
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 Post subject:
PostPosted: Fri May 13, 2005 4:04 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22077
Location: Chicago
The bad 500 running yet?

Pics of the old rod bearing, pin and cage?


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 Post subject:
PostPosted: Fri May 13, 2005 10:52 am 
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Joined: Sun Dec 21, 2003 11:30 pm
Posts: 476
Location: Nebraska
hoser wrote:
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


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 Post subject:
PostPosted: Fri May 13, 2005 6:14 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22077
Location: Chicago
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.


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 Post subject:
PostPosted: Sat May 14, 2005 12:06 am 
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Joined: Sun Dec 21, 2003 11:30 pm
Posts: 476
Location: Nebraska
hoser wrote:

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


Attachments:
File comment: Nice new ProX 500 Rod
500Rod.jpg
500Rod.jpg [ 124.18 KiB | Viewed 1872 times ]
File comment: Freshly assembled lower unit via PCP Offroad
AssembledLower.jpg
AssembledLower.jpg [ 146.35 KiB | Viewed 1872 times ]
File comment: These are the lower unit parts that were replaced
LowerUnitParts.jpg
LowerUnitParts.jpg [ 122.83 KiB | Viewed 1872 times ]
LowerRod2.jpg
LowerRod2.jpg [ 105.2 KiB | Viewed 1872 times ]
File comment: Lower rod bearing was Toast
LowerRod1.jpg
LowerRod1.jpg [ 112.61 KiB | Viewed 1872 times ]
LowerRodPin1.jpg
LowerRodPin1.jpg [ 107.46 KiB | Viewed 1872 times ]
File comment: They looked great
CrankBearing2.jpg
CrankBearing2.jpg [ 121.87 KiB | Viewed 1872 times ]
File comment: Here are the two Crank bearings - both appear to still be in excellent shape
CrankBearing1.jpg
CrankBearing1.jpg [ 125.77 KiB | Viewed 1872 times ]
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 Post subject:
PostPosted: Sat May 14, 2005 12:19 am 
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Joined: Sun Dec 21, 2003 11:30 pm
Posts: 476
Location: Nebraska
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...


Attachments:
File comment: WHA - HOO - LETS RIDE
Bad500Done.jpg
Bad500Done.jpg [ 144.06 KiB | Viewed 1870 times ]
File comment: What's missing here ? - no not the seat
SomethingsMissing.jpg
SomethingsMissing.jpg [ 132.55 KiB | Viewed 1870 times ]
File comment: How about that nice new ProX piston - pretty isn't it...
CermicCoatedPiston.jpg
CermicCoatedPiston.jpg [ 127.74 KiB | Viewed 1870 times ]
File comment: Cermic Coated Cool Head Dome
CermicCoatedHead.jpg
CermicCoatedHead.jpg [ 124.34 KiB | Viewed 1870 times ]
File comment: Cermic Coated Exahast Port
CermicCoatedExhaust.jpg
CermicCoatedExhaust.jpg [ 106.14 KiB | Viewed 1870 times ]
File comment: Another shot - Notice how thin the cylinder walls and sleeve is in this beast...
CarbonBoreCylinder2.jpg
CarbonBoreCylinder2.jpg [ 118.82 KiB | Viewed 1870 times ]
File comment: Bore Tech applied the Carbon Bore Process to the cylinder
CarbonBoreCylinder.jpg
CarbonBoreCylinder.jpg [ 99.83 KiB | Viewed 1870 times ]
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 Post subject: BAD500 For Sale ?
PostPosted: Sat May 14, 2005 12:27 am 
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Joined: Sun Dec 21, 2003 11:30 pm
Posts: 476
Location: Nebraska
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


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 Post subject: Springs
PostPosted: Sat May 14, 2005 10:45 am 
Online

Joined: Tue Dec 16, 2003 7:22 pm
Posts: 386
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


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 Post subject:
PostPosted: Sat May 14, 2005 2:22 pm 
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Joined: Fri Mar 19, 2004 12:18 am
Posts: 137
Location: MI
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.


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 Post subject:
PostPosted: Sat May 14, 2005 2:56 pm 
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Joined: Mon Dec 22, 2003 3:44 pm
Posts: 32
Location: Texas
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.....


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PostPosted: Sun Dec 22, 2013 6:14 pm 
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Joined: Mon Jan 16, 2012 8:56 pm
Posts: 550
i use 80 over 100 and extensive work on the pistons


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