ATC500R "Build Thread"

[JasonB]

I had some issues yesterday getting it started up with the smart carb. APT sent me two needles; one to use with the cr500 and one for the 310 so I could try the carb on both bikes. I made the mistake of running the bike with the 310 needle at first and it was extremely lean. Swapped needles and the bike idled and ran great after I set it to 50 clicks instead of the recommended 76 clicks. Still dealing with start up issues on the carb, it doesn’t want to start without being hit with additional gas or wd40 to help get enough combustibles into the chamber. I have heard of other cr500’s having issues with start up because of the amount of vacuum they pull at start up. Calling APT for advice and solutions today. Eric is bringing an extra 39pwk carb/cable/thumb throttle to Little Sahara for me. If I have continued issues with the SmartCarb I will be forced to run the PWK, but atleast i have a backup plan

During the 3rd heat cycle yesterday I got it up to operating temp and tested out the Rekluse Z Start Pro. IT’S AWESOME. Set the idle low enough with the carb and click the tranny into any gear. It will just sit there until you give it some gas and it engages just like an auto clutch. And the clutch pull is Freaking awesome! Its non existent now, I mean it feels like im pulling a lever with nothing attached to it. Used to be a chore to pull that clutch after an hour of riding. I’m happy with it. Putted around the street testing it out, im in love with that new part.


EDIT*** ok i just got a call from Corey at APT. Received some very helpful info about starting procedures and how to make the bike and carb live together in harmony. Hoping to have some easier luck starting now

[jays375]

Man cutting it close!Good luck!Looks awesome!

[yaegerb]

I had some issues yesterday getting it started up with the smart carb. APT sent me two needles; one to use with the cr500 and one for the 310 so I could try the carb on both bikes. I made the mistake of running the bike with the 310 needle at first and it was extremely lean. Swapped needles and the bike idled and ran great after I set it to 50 clicks instead of the recommended 76 clicks. Still dealing with start up issues on the carb, it doesn’t want to start without being hit with additional gas or wd40 to help get enough combustibles into the chamber. I have heard of other cr500’s having issues with start up because of the amount of vacuum they pull at start up. Calling APT for advice and solutions today. Eric is bringing an extra 39pwk carb/cable/thumb throttle to Little Sahara for me. If I have continued issues with the SmartCarb I will be forced to run the PWK, but atleast i have a backup plan

During the 3rd heat cycle yesterday I got it up to operating temp and tested out the Rekluse Z Start Pro. IT’S AWESOME. Set the idle low enough with the carb and click the tranny into any gear. It will just sit there until you give it some gas and it engages just like an auto clutch. And the clutch pull is Freaking awesome! Its non existent now, I mean it feels like im pulling a lever with nothing attached to it. Used to be a chore to pull that clutch after an hour of riding. I’m happy with it. Putted around the street testing it out, im in love with that new part.


EDIT*** ok i just got a call from Corey at APT. Received some very helpful info about starting procedures and how to make the bike and carb live together in harmony. Hoping to have some easier luck starting now

Would you mind sharing that info/advice Jason? An APT smartcarb is next on my list of 250R goodies.

[JasonB]

Need to address fork guards and brake line holder.



Brake. Had a local shop zip the shaft welds off the brake lever and basically popped it into the other side and welded it back up. I had to grind a little off the lever so it would clear the peg. Could be angled a little differently but its functional and im happy with it. And the kicker shouldn't hit it anymore either so my goal was met.

[JasonB]

[JasonB]

Would you mind sharing that info/advice Jason? An APT smartcarb is next on my list of 250R goodies.

ya no problem! Corey was saying that the LAST THING you want to do when trying to start it is opening the throttle up. I do it out of habit with my pwk carb, half throttle one kick starts. He said opening the throttle diminishes the signal and will cause starting issues. He suggested when it comes to tuning the carb that I make smal changes of one click at a time, listen for the idle hanging (lean) or blurbuling (rich) after rev's. The screw on the side is for the idle circuit and effects (affects???) the richness/lean-ness of the carb. Basically i just need to play with it, but he said the bulb is a last ditch effort fix and that after the first hour or so of running with the carb that the metering rod and jet (i forget their technical term for it) will break in and the bike will become easier to start. Just going to be a learning process for me, so i will be patient and play with it.

[JasonB]

update on the 500 build. Made the trip to Little Sahara I spent the last 2 months scrambling to achieve. Smart Carb wouldnt run for anything, changed setting on it for richer and leaner within 50 back up to the recommended 76 clicks. Wouldnt start after the first day. The first day i did get it running but it was extremely rich but after adjusting it she wouldnt start again.

Motor has some kind of tranny issue. it will ride around in 1st gear but lock the tranny randomly. It rides fine in the other gears though without issues. Looks like we forgot a thrust washer somewhere in there even though we didnt have a single issue with going through the gears when it was on the bench. so the motor is coming back apart. Im not real thrilled about this project right now so this is probably the last update for a while on this pile

[Louis Mielke]

Care and feeding of a 500 is a torturous endeavor, really only meant for those who hate themselves.

[yaegerb]

well the good news is APT is in Kansas City. I would take the bike up to them (if you have the time) and let them tune it.

[jays375]

That sucks.After all that time and money.Don't let it beat you up.You'll figure it out in time.

[El Camexican]

Chin up buddy! You'll get it right and it will be worth the effort when you do

[Dirtcrasher]

Yes, a WOT run on a 500R must be a ball!!

[JasonB]

thanks for all the responses guys. I was pretty set on taking it back apart and harvesting the good parts for the 310 (inverts/front end , swinger/rear end) , selling the complete motor with rekluse/new everything online, and even already had a buyer for the frame. I think after calming down from the ride last week I have decided to stick with it, at least for just right now until I've actually had the chance to ride this damned thing and form an educated opinion on whether its something i want to keep. Motor has only had heat cycles on it, Rekluse hasnt even been abused yet either. I am shopping the 4-strokes and plan to acquire a 350x for Eric to slap a 400 kit on this summer though. I was just feeling extremely depressed about how all the work and effort I put into this so far had turned out. Going to see about heading to Erics this weekend to rip into the tranny and fix the issue its having. Hopefully have it back together and ride-able next week.

On another note, I think i may be running 18's on this bike from here out. The tranny is geared so tall! I was able to cruise around the lot at little sahara last week the only day this worked in 2nd and 3rd gears and its just TOOOOOOOOOOOOOO fast for me to be comfortable with. I have a 42tooth rear sprocket and a 13tooth front sprocket. I think 18's will slow this down enough for me to be comfortable.

[jeffatc250r]

Geared too tall?!?! Im rolling 13:38 in the WOODS!
You attacked too many things on it at once, its hard when doing multiple things at once as each mod usually never is bolton and done process. Stick with it, my 5-hundo is as reliable as morning wood and gives me a smile ear to ear everytime i ride it. All i do is change the oil, and tighten bolts

[roostin atc]

Geared too tall?!?! Im rolling 13:38 in the WOODS!
You attacked too many things on it at once, its hard when doing multiple things at once as each mod usually never is bolton and done process. Stick with it, my 5-hundo is as reliable as morning wood and gives me a smile ear to ear everytime i ride it. All i do is change the oil, and tighten bolts

I've seen it. But I'm not in the 500 club yet.