atc 500r build

[circafwsk8r86]

heres my progress of the rebuild of my act 500r. my main question is exhaust. it looks as if the cr 500 gnarly pipe with fit right it with no mods. is this true? do you guys usually use cr500 exhaust with atc silencer? also whats the best way to do the cooling lines. i would like red hoses but i probably have to buy a couple kits to piece together. any input would be appreciated. or if you have any parts for me let me know. ill keep updating as build goes on.:crazy: 162226162227

[Maniac76]

When u get this built I'd like to c it that ought to b a kick but build

[circafwsk8r86]

yea should be done in a few more weeks depends how fast i get the rest of the parts. still need exhaust chain radiator hoses. but yea its a sweet machine. thanks for the interest

[circafwsk8r86]

got the dura blue today test fitted that and put a wheel on to see how it all fits up. heres some pics

[circafwsk8r86]

162495162496:naughty:

[gomer202]

Is it just a stock frame?

[circafwsk8r86]

no a dead give away is the head mount when u use the stock frame u have to cut the head mount shorter. this frame has 500 basket in it but it looks real close to stock

[Mr350x]

I am also building a 500r.. From what i have read you have to cut, rotate and reweld the cr500 pipes to make them fit.. I am having cpi pipes here in utah build me a custom sectional in frame drag pipe.. I would pm Kasey though he will be able to answer all your ??'s about the 500r

[Mr. Clean]

no a dead give away is the head mount when u use the stock frame u have to cut the head mount shorter. this frame has 500 basket in it but it looks real close to stock

Are you saying the head stay on the frame has to be cut? My conversion frame which was done by Billy Golightly did not have to mod that bracket, just require some fabbed stay brackets.

http://i280.photobucket.com/albums/kk179/miked1957_photo/DSC_6572.jpg

[Audio_Phill]

you should sell me this when youre done lol.

[circafwsk8r86]

no mr clean yours is done similar to mine with a cr500 basket welded in. the question was is mine the stock frame? which is no its not it has the cr500 lower basket welded in. if u use stock frame u have to cut the cr500 head mount shorter plus do something were the down tube y's it wont clear exhaust.

[circafwsk8r86]

thanks mr350x im buying a gnarly pipe either way i think i can get it to fit without any welding. but if not its no big deal to cut near the mani and spin it up a little if need be. but the 250r frames aren't much dif from a cr500 frame in general. i used to have a drag pipe that came out of the side but sold that dam thing.

[Mr350x]

No worries.. ya i would hve sold the out of frame drag pipe also, not my thing! Your build is looking good so far keep the pics rollin!

[loshe191]

Nice, good luck on your build.

[circafwsk8r86]

i got the gnarly pipe the other day. didnt really fit the way i wanted it too. the bends are pretty accurate. the engine sits back off the front of the frame more than the cr 500. i had to add about an inch right at the manifold. also the rear mount hits the frame so I'm gotta move it back or forward. probably move it forward b/c its very tight getting the pipe in. i bought a newer style pipe b/c i like the look better. but my engine is an 88. all in all not too much work and if you went w a new pipe it wouldnt be bad b/c were u add material u cant really see anyway so u could salvage the finish. i bought a used one b/c i wasnt sure if i had to refinish it. ill try to post pics tomorrow so u can see what your in for if you havent already been there.

[circafwsk8r86]

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[circafwsk8r86]

if anyones interested i have the plus 10 swing arm in picture 2 i will sell with extended brake line. also have good axle carrier to go with. i can powder coat any color pretty cheap. let me know. thanks

[whtcamaro]

Wow that is starting to look really nice. Are you going to make it to Trikefest this year?

[M1A1]

Wicked build. It looks good. Keep us updated.

[Cassmanbearcat]

Great work keep them pics coming...

[circafwsk8r86]

yea im gona have about 3500 into it when its all done. but def one of the best atc 500's ive ever seen. did i mention this is a duncan built engine.when this trike was set up for sand drags with the +9 swingarm and wheelie bar nothin could touch it. now with stock swingarm I'm gona have my hands full. were and when is trikefest?

[circafwsk8r86]

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[circafwsk8r86]

my intake setup seems a little vulnerable. what do you guys think? run with it?

[trike savior]

yeah better stay out of mudpits and deep water. but if you dont ride in those places much. go for it

[JasonB]

Looking stellar man! Everything looks fantastic, very nicely put together. Intake will be fine unless you like to go mudding. I have almost an identical set up interns of it being an open element set up with just an outerwear on it.


Trikefest is the weekend after fathers day in June in Indiana. It occurs at a quaint little place known as Haspin Acres where around 300 trike riding fanatics take over for a week to pillage, loot and partake in general debauchery. Very worth your time t check out. It's a blast!

[kevink]

That trikefest sounds like a blast but so far away...

[shockwheeler]

Bike is looking good!

[circafwsk8r86]

MODERATOR NOTE: Video removed because rider not wearing a helmet.

[circafwsk8r86]

MODERATOR NOTE: Video removed because rider not wearing a helmet.

[circafwsk8r86]

couple little vids beforei tore it down to rebuild. not easy to take hard corners with this setup. it was strickly a drag setup.

[circafwsk8r86]

got the pipe welded and mocked up looks like its gonna work. had to do some massaging to get it to clear the coolant line from pump to head. gona get silencer welded up then i should be able to get it back outside and finish it up. i couldnt really find many answers about exhaust so i tried to show my travels as best as i could. all in all not that bad. i would recommend keeping exhaust matched to the year of your engine. mine was a pain b/c of cooling lines, really tight fit. i used a newer style exhaust will an older style engine.

[circafwsk8r86]

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[KASEY]

wow you intentially smashed that pipe in??????? that rear cone is pretty inportant to sound wave reflection,, and now ,,, hmmmmmm,,,, i think you did alot more harm than good on that ,,,,

[circafwsk8r86]

pipe already comes with a dent there my friend i just helped it a bit. guess well see when i start it up in a few weeks. i know im not losing any sleep over it. hammer is my favorite tool :crazy:

[JasonB]

Finish it up!

[KASEY]

pipe already comes with a dent there my friend i just helped it a bit. guess well see when i start it up in a few weeks. i know im not losing any sleep over it. hammer is my favorite tool :crazy:
LOL !!! so if your building the "BEST ATC500 YOU HAVE SEEN" why in the hell would you short cut and just smash the pipe with a hammer instead of cutting and fitting it properly? sorry but i have seen alot better 500's than this one... and its real simple to fix that resivour bracket also ,,, hose clamps? really.... and one more thing.. if i was a mod here i would pull your videos,, for no HELMET!!

[circafwsk8r86]

let me rephrase that one of the nicest atc500 ive seen. somebody should pull my vid cuz my trike looks likes a pos. in those vids anyway. its my life i live it how i want. i dont tell anyone else how to live their lives. where i dented it you cant see when its on. welds u can see i didnt wana change the factory look of my pipe. i love hose clamps and if you like pickn my bike over why don't you post pics of trikes under 3 grand that have the power and look as nice as mine. you have a lot of negative things to say and i can guarantee you what i did to my pipe wont affect a thing. i build a lot of 2 stroke vehicles from jet skis to motorcycles to go carts. trailprotrailpro talkn so minimal changes these things do to exhausts its not even worth bringing up. what happens to the guy on his cr500 when he wipes out on exhaust side and dents the hell outta it. he picks it back up starts it and takes off. but like i said well see when i get it running. Ill be sure to post some 50mph wheelies w no helmet.

[circafwsk8r86]

you know trailprotrailpro kinda going back on yourself if you look at my pipe. if your cut and rewelded the way you would need to, to clear that hose, your either losing or gaining material that wasnt there. if that dent will affect the sound wave reflection. dont you think changing the overall length is just as bad. i already added and 1'' to the manifold. so i was trying to keeo that exhaust as close to fmf engineering as possible. if you know anything about metal you know by beating it or forming it you never lose material you just change shape. also the pics look a lot worse than it is. but anyway its my opinion and everyone has one. can we try to keep these posts positive. we can argue all day till people line up with each other at the dunes and really see what happens. :twisted:

[KASEY]

if you like pickn my bike over why don't you post pics of trikes under 3 grand that have the power

where do you want me to start? here is 3 out of my own trikes.. pretty sure i could find alot more... seriously you should study pipe design and you would see how bad you are robbing alot of power with your percussion tactics on that pipe!!! there are alot of ways to make it fit without adding or subtracting volume .. and bashing it in like that isn't one of them.

http://i1141.photobucket.com/albums/n592/KASEYII/DSC01899-1.jpg

http://i1141.photobucket.com/albums/n592/KASEYII/A250R1.jpg

http://i1141.photobucket.com/albums/n592/KASEYII/DSC02326.jpg

[KASEY]

oh by the way the last one is a cr500 motor,, and it was built 11 years ago still running strong too...........

[Louis Mielke]

Hi. I am a part of a moderator team and Kasey is right. We have a no helmet = no video policy on this message board. I'm removing your videos for the time being. Please make some new ones with you wearing a helmet. You're welcome to post those.

Also, I understand you've built plenty of stuff but you'll find that there are LOTS of people that have built LOTS of stuff on this message board. I would recomend you not rock the boat as you are new to the board.


I will also add Kasey is a long time and highly respected member here. His post might be a bit abrupt but he is a good guy and a skilled builder FYI.

[circafwsk8r86]

very nice trikes but which one of those is a atc 500?

[circafwsk8r86]

i see your post now the last one is a 500. hard to tell with that pipe must be home made does not have the larger manifold bend that your typical 500 pipes have. yea cr 500 engines are very reliable my was built in the mid 90's. when i get it all together ill post a pic of my compression after 13yrs or watever its been.

[Cave Rider]

I did not have to modify my pipe or upper mounts,or the downtube to make it fit !?!? Just the silencer...did I get lucky !?!? Im being serious not sarcastic... I had NO problems...

[Cave Rider]

Sorry about the small pics. But im using my phone.

[circafwsk8r86]

you have a newer engine it looks like. my engine i believe is around 85. i bought and exhaust off a 97. from my experience the newer engines have bigger water jackets and are a bigger engine all together bc of that. your engine probably sits closer to the down tube than my 85 which is a smaller overall engine. ive never seen a cr 500 engine fit in a stock frame without cutting the engine mount on the head shorter. i find it hard to believe that you didn't have to cut anything on the engine to get it to fit properly. more info would be nice on your engine year and frame year. and exactly what frame you have. i have an 85 era engine and an 85 atc. 250r frame with cr 500 basket. bc my engine sits lower and was rocked back more made my exhaust manifold sit further back from the down tube hence the 1" i had to add. i wish it was as easy as yours unfortunately not. looks good tho anyway. send us more pics of the exhaust close up and your engine close up how you mounted it. what length is your swing arm? im running stock. i see very few running stock length.

[circafwsk8r86]

seems like everyone on this forum is all secretive about there 500's. i came on here for one reason and that is to share my setup with people that are building them. i have no secrets and like to show my troubles. there are many of ways to go about these builds. if you are right cave rider about your setup being a direct fit. share your specific years of parts and that would be the easiest for people to build.

[Louis Mielke]

I have 3 500s and have done quite a bit of swapping parts years to years. It's not that anyones all that secretive it's mainly that this topic has been beat like a dead horse on other areas of the board. If you did a search on atc500r's you'd find lots of info on it.

Specifically cave riders machine, I'm pretty sure that one of the frames Billy Golightly built and grafted in completely new lower frame rails. This allowed the engine to sit in there with out a lot of fuss. It's a well known fact that with some custom mounts and some minor modifications you can get a cr500 engine into a stock atc250r frame but replacing the lower cradle does seem to make it simpler.

I have two CR dirtbike conversions and one atc250r swap. There is are only small differences in any of the year 500s, and many parts swap between all years, from 85-01.
The jugs are not larger on the outside in any significant way. I need to eat dinner but I will be back and continue shortly. The main change that occured in 87 was the change to a longer connecting rod and thus 5mm of material was added to the top of the cases and minor casting changes where made to increase strength, no mount changes were made in the castings and the newer cylinders will swap to older cases with a spacer plate and very minor machining. The changes in the cylinders were all in the liners and the internal space to accommodate a thicker liner.

I will post some pics and more info after dinner.

[yaegerb]

Sorry about the small pics. But im using my phone.

That bike is sick....:drool:

[circafwsk8r86]

as far as oem frame the rear crossmember has to be notched or something done to it and the engine mount on the head of the cr500 engine has to be cut shorter or they will not fit in an untouched oem frame period. i had a brand new oem 85 250r frame untouched and there was no way that engine would fit without cutting either the engine or the frame. FACT. so point proven cave rider has a frame that is build for his setup for parts to fit right. my frame was originally built with a drag pipe so it didn't really matter about exhaust at that time because the pipe came out of the frame. also my lower basket is added after the very last stock skid plate threads.

[Cave Rider]

Quik overview :The engine is 86 , frame is 85. Pipe and clutch cover are 01. Cut out cradle,bolted motor in, then fabricated the remaining portion with tubing.Finished off with solid steel skid plate for extra strength. I did not mean to rustle feathers,and I would gladly answer any questions. But Louis is right,the answers are already here. And most guys WILL help if asked. Nice trike you are building,im sure it will rip for ya !!!

[circafwsk8r86]

when you bolt the 500 in with the rear mount/also swing arm pivot point that never changes.some builders make new down tubes at the y in the front of the frame. all of that work will help in the long run for engine mount and all. my frame has basket added at the very bottom making my down tubes oem most of the way down. thats why my exhaust needed more work. my frame is pretty close to oem but not quite.

[circafwsk8r86]

no prob cave rider i can read you have a good attitude and are very helpful. nice trike. are you set up for flat track>?

[Cave Rider]

Yes it was,it has since been sold.

[circafwsk8r86]

How much did u get out of your 500 cave rider?

[circafwsk8r86]

got the trike together today. got it running took it for a ride. what a wild ride with stock swing arm, right up my alley. theres still snow on the ground and pretty muddy here in michigan. still have to finish the silencer. also the kickstart needs work. currently has spacer and its hard as hell to start. i guess thats a good thing. anyway heres a pic.

[circafwsk8r86]

164741 atc 500r

[Mr350x]

How did you route the radiator hoses? Can you post some close up pics of how you did it? Thats where i am now and i am having some issues

[JasonB]

Nice looking bike man, turned out very clean! I found one I am buying and hope I don't struggle wthe pipe