ATC500R "Build Thread"

[emmie357]

I see you said you cooked the VHT paint with your heat gun.
I was considering painting some parts with VHT that are too big for my oven. Have you done this before, does it hold up well?

VHT recommends 200 degrees for 20 minutes (for the engine enamel), did you actually hold the heat gun over each part for 20 minutes?

[JasonB]

Lou, the sleeves were in the bottom of the jug so you don't we them in the shots . I didn't even think about washers for those nuts , I knew better but wasn't thinking. And Eric's tri-z has kept the majority of its SS hardware since he hit everything with silicone. That thing makes my hands numb I would say it vibrated worse than my 500 motor prior to the rebuild!

Thanks for the call Eric, pulling all the bolts back out individually for silicone treatment. On my list for today!

The VhT paint was sprayed on and I cooked it for about 20 minutes on each coat hitting it with the 1300 degree setting on my heat gun being mindful of the seals. The entire motor was warm for a good 40 minutes after I moved onto assembly after paint, I think I baked it well enough . Ya I sprayed the completed engine seals and all, output shaft shifter shaft it all got a coating of VHT. I tried not to hit the seals directly, the VHT sprayed on pretty evenly and controlled to my surprise. Not real worried though, if things fail I take it back apart. This is the second top end I have assembled without Eric's or Corey's direct supervision, I think the 310 turned out fine and has taken 50+ hours of abuse to date this should be fine too lol

[JasonB]

I see you said you cooked the VHT paint with your heat gun.
I was considering painting some parts with VHT that are too big for my oven. Have you done this before, does it hold up well?

VHT recommends 200 degrees for 20 minutes (for the engine enamel), did you actually hold the heat gun over each part for 20 minutes?

Forgot to ad, I haven't used VHT before but MRE that did my motor suggested I use it, they use it for their builds and it holds up to gasoline spills etc. Adam glass blasted all my parts including the new right side cover I just bought, paint seems to have taken to the fresh surface well for now.


Thanks for the feedback and compliments guys, if you see anything else I missed feel free to point it out lol, I don't want to have to mess with this thing after it's all done and on it's wheels any more than I have to

[Louis Mielke]

What didn't you like about it???

Freaking fell out and was never tight! Also prefer the oem stuff!

[riverrat]

Might I suggest using a big bore intake?

[JasonB]

Might I suggest using a big bore intake?

hmmmm. hadnt crossed my mind. I didnt change the stroke or really go up in size on the motor, and I will be running a 38mm carb on it as well. I think keeping it with the same intake diameter and exhaust flange diameter that it would maintain the same intake velocity. My builder Adam didnt suggest one so I didnt second guess what i have. He went over any parts I should upgrade/replace/modify for this build and it just didnt come up. I see the CR640cc kits online have a bigger intake manifold they come with but I am sure for a second bore size up from stock that this intake should suffice.

[riverrat]

I don't know if that is a stock 500 intake or if that is different from a 250 one, but when I made my 370 and went up in carb size the stock intake was restrictive.

[JasonB]

Yep its a stock 500 intake. im actually running the stock intake on my 310 as well, wonder if i would benefit from a different one... hmmmm

Rads, groments, and other misc goodies that showed up from Manbearpig


Rads and groments in place.


My mint 86 seat showed up from manbearpig, and I just took a pic of all the seats in my garage because I feel like a hoarder lol


Last night we moved the bike to the garage since it will be too big to get out of my shop soon. Installed the rebuilt/revalved/resprung shock. Starting to look like a real bike


Planning to get the new clutch basket and some other random items from Eric this weekend. Liz from APT said my carb should ship Friday. So if things go well I should be able to fire it up next week. Jason Hall said my inverts should hopefully be nearing completion this Sunday, my clamps are done just waiting on his machine shop guy to finish shortening the forks so he can rebuild them.

[JasonB]

Flexx bars arrived today. And they came with grips and universal bar mounts

[JasonB]

the seller of the Flexx bars (ATVGALAXY on ebay) took 12 days to ship my bars and as a 'thanks for the patience' i got 15 bucks off another item from their store. so why not buy a new MX ONE Industries pair of pants and jersey?! Thanks to an awesome ebay seller


Parts arrived with the outfit this morning from usps/ups. KFX400 master cylinder and lines with lever so now I will have rear brakes. T3 throttle cable that Liz Harvey at SmartCarb suggested i run with the 38mm cast I have coming from them. Also pictured are items from Magnum (eric bought) such as two sets of pipe springs, one of the Uni filters (the other is on back order), clutch perch and lever, gallon of my favorite 2 smoke oil, and a new clutch basket.


fun item i found when i was painting the motor this last weekend; inside the old clutch cover is a handful of info scratched into the cover to date parts replaced etc. They stuck a new clutch basket in this thing in 1989 among other things. From the list of items and the second sleeve in the cylinder im guessing this 88 motor was run hard and enjoyed by someone once upon a time. Lord only knows the kind of abuse its about to see from the current owner

[jays375]

Man your poor credit card bill.HA haaa.Very nice parts selection!

[JasonB]

No credit cards were harmed in the making of this abomination
New shock came fed ex this afternoon. Just a used shock for the 310 to use since I stole the revalved resprung shock for the 500 to run

[ATC-Eric]

Man this bike is going to be SOOOO NICE!!!!!!!!

[JasonB]

Yesterday I was pretty sick so I stayed in from work and got a few bits done. Started with the clutch and basket. The old clutch basket had to have the rivets ground off so I could get the ring gear off and the center gear. I have no clue what the correct terms are for those parts so bear with me. Shot below is after I took a grinder to the rivets and popped the gear off the back of the old basket.


Gear on new basket. Installed the baffles (little black rubber inserts). I had to use my heat gun on the old basket to get it super hot and out the center gear. To get that big gear into the new basket I stuck the gear into the freezer for an hour and heated the new basket up with my heat gun for about 10 minutes and then that gear just slid right in with a few good hits from the . drilled out the holes on the tin cover for the new screws to secure the gear to the baket, Little bit of loctite on the screws and away we go!


This part is something I overlooked. Went to install the Rekluse into the new Pro-X basket and got hung up on this part. its the top hat (throw out bearing part), I didnt realize i needed to upgrade this to the newer style clutch. I have an 88 motor but had to update to 90-2001 basket, 90+ right side crank case, and 90+ clutch cover for the rekluse to fit and function. The 90+ clutch uses a throw out bearing that utilizes a newer top hat with flat bearing and washer instead of the one im holding that utilizes this top hat and a bearing inside. Jumped on partzilla.com after i figured that out yesterday and ordered up the correct throw out bearing and associated washers and new push rod etc.


Not pictured here is the KFX master cylinder. The banjo bolt from the line to the caliper just bolted right on to the master cylinder, no size difference issues. Bolted right up to the frame with some special spacers I had (some shiney nuts I had laying around). The push rod is right where it needs to be for the brake lever and little arm to line up and work perfect. For anyone in need of a new rear master cylinder the KFX and z400 masters work! I bought an 03, only found limited info on here to confirm it worked but went ahead and bought one anyways. fits like a glove.

Parts I have left before I can move forward are the SmartCarb, inverts with shortenned cr125 forks and 450r footpeg adapters from Hall, front wheel from Honnerlaw, and the o ring exhaust manifold from MRE. other than that i have all the parts I need to make this roll on its own!

[JasonB]

Exhaust manifold showed up today.


Waiting on my smartcarb, was scheduled to get it last Friday but it has been postponed. Trying to get an answer from Liz about when it should arrive.

I bought a Quick 2 Mix ratio rite cup and a 5 gallon VP jug with hose lid today. Tonight I was feeling like I needed to buy more stuff so I bought a set of durablue hub spacers for the 310. Never ending spending