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Author Topic: CR500 Kart engine rebuild  (Read 16592 times)

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Offline sandblaster

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CR500 Kart engine rebuild
« on: May 13, 2016, 02:30:02 PM »
I know I know... It's not green and it's not a bike... But still pretty cool...

We received a pair of CR500 engines to rebuild.
One, the customer needs back within a week.
Also, it will not be a total rebuild.... Not ideal but I'm sure we can still put a smile on his face





« Last Edit: May 13, 2016, 02:44:19 PM by sandblaster »
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #1 on: May 13, 2016, 02:31:01 PM »
So, the first thing we did was get out the Hot water pressure washer and get all the dirt and grease off this engine.
I hate cracking open a engine with dirt and grease on it..



Cracked open the stator cover and found a nice little surprise!
Light weight fly wheel... Yes!! and other goodies...



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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #2 on: May 13, 2016, 02:31:46 PM »
Cool head!



Ugh! Not so cool..



Oh no... A crack...

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #3 on: May 13, 2016, 02:32:35 PM »
I see some improvement to be had..



Looks good..



Not so fast...

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #4 on: May 13, 2016, 02:33:13 PM »




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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #5 on: May 13, 2016, 02:33:49 PM »
Cases are back from weld...





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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #6 on: May 13, 2016, 02:34:43 PM »
I must love lapping cases... I have gone through a entire can of Timesaver..





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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #7 on: May 13, 2016, 02:35:27 PM »


This is ugly....



Polished the ID of the exhaust flange..

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #8 on: May 13, 2016, 02:36:06 PM »
Hogging material



First clean up on the cases..



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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #9 on: May 13, 2016, 02:37:13 PM »
The clutch basket is hashed and there is not enough time to get another...



So, out come the files  :-o I know, I know, that's not all that great but it will get him through a few races..



Hogging more material... Jason is a porting machine

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #10 on: May 13, 2016, 02:38:04 PM »
Worked on the basket a bit more today..



I even cleaned up the inner hub a bit..



I've been working on the head but I'm going to see if I can get a new one before Thursday..
It's just too beat up..

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #11 on: May 13, 2016, 02:38:46 PM »
Getting it ready to slap together





More progress..

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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #12 on: May 13, 2016, 02:39:19 PM »




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Re: CR500 Kart engine rebuild
« Reply #13 on: May 13, 2016, 02:39:51 PM »
Race day





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Offline sandblaster

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Re: CR500 Kart engine rebuild
« Reply #14 on: May 13, 2016, 02:40:25 PM »




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