SR500 Engine/entire bike overhaul

[foundation982]

I picked up this 78 SR500 from a DTT member yesterday and just thought I'd upload some pics of the engine rebuild

Photo0179.jpg by foundation982, on Flickr

Photo0178.jpeg by foundation982, on Flickr
Here's the engine as is when I got it

Photo0183.jpg by foundation982, on Flickr

Photo0181.jpg by foundation982, on Flickr
Trashed piston, I'm assuming a valve got stuck from not being run for a while.
I've found many pistons but I'm having a hard time finding valves at a reasonable price

 

[foundation982]

Re: SR500 Engine rebuild possible tracker (in the future)

I also was wondering if anyone could identify the model. Obviously its a SR500 but was just wondering which models include disc brakes on both wheels the internet hasn't been much of a help

 

[scm]

Re: SR500 Engine rebuild possible tracker (in the future)

There's only one model at a time.
The code is in the begining of the identification number,
in your case probably 2J2 ... (look on top of the right
half of the crankcase)

Best regards
Sven

 

[foundation982]

Re: SR500 Engine rebuild possible tracker (in the future)


IMG_0594 by foundation982, on Flickr
New valves got a lightly used piston and cylinder off a guy on ebay for $100 out of a xt500 back to stock bore :]


Photo0191_EDIT.jpeg by foundation982, on Flickr
Got my gaskets now assembling


Photo0192_EDIT.jpeg by foundation982, on Flickr
bigass motor

 

[teazer]

Re: SR500 Engine rebuild possible tracker (in the future)

It looks as if the broken piston has a raised crown and the replacement is a flat top. How much does that drop the compression or was the dead piston a high comp?

30 seconds on google images suggests it's an 81.

 

[scm]

Re: SR500 Engine rebuild possible tracker (in the future)

Dead one (probably Pro Tec) was high comp.

Regards
Sven

 

[foundation982]

Re: SR500 Engine rebuild possible tracker (in the future)

Yeah I'm assuming it was a 11.1 and they were trying to get a ton of power out of it and it was bored to the maximum they recommend but on some forums guys were saying if you arent using premium fuel in a 11.1 it'll blow I'm assuming thats what happened

 

[foundation982]

Re: SR500 Engine rebuild possible tracker (in the future)

first coat of paint on the frame I used appliance rustolium paint and it seemed to work great and dry hard

IMG_0597 by foundation982, on Flickr


IMG_0598 by foundation982, on Flickr


IMG_0601 by foundation982, on Flickr


IMG_0602 by foundation982, on Flickr

 

[foundation982]

Re: SR500 Engine rebuild possible tracker (in the future)

Primed the motor with rustoleum engine high heat paint and painted with rustoleum engine paint black turned out great!

IMG_0610 by foundation982, on Flickr


IMG_0613 by foundation982, on Flickr


IMG_0614 by foundation982, on Flickr


IMG_0617 by foundation982, on Flickr


IMG_0616 by foundation982, on Flickr

Dunno what was going on with the camera in that photo its a piece of junk

 

[foundation982]

Re: SR500 Engine rebuild very pic heavy (possible tracker in the future)


IMG_0632 by foundation982, on Flickr


IMG_0631 by foundation982, on Flickr
buffed exhaust discs


IMG_0636 by foundation982, on Flickr

 

[foundation982]

Re: SR500 Engine rebuild very pic heavy (possible tracker in the future)

Got her running my god this bike is fun!

<iframe src="http://player.vimeo.com/video/21354203" width="400" height="300" frameborder="0"></iframe><p>SR500 THUMP from [email]jakechia982@gmail.com[/email] on Vimeo.</p>

 

[warpedworm]

Re: SR500 Engine rebuild very pic heavy (possible tracker in the future)

Hey! I'm glad it went to someone who appreciates it.

You bet it's fun It's so light and has lots of guts, a really fun ride

 

[scioncb450]

Re: SR500 Engine rebuild very pic heavy (possible tracker in the future)

Foundation i noticed in your profile pic you have the restored version of my project!! looks great

 

[foundation982]

Re: SR500 Engine rebuild very pic heavy (possible tracker in the future)

yeah mines a 350 but they are similar


heres the thread to my build

http://www.dotheton.com/forum/index.php?topic=21806.0