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Swedish CR550 Liger engine build

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Hi. Johnny from Sweden here. A while ago i decided to build myself a strong engine for my Cr500 iceracing project bike. This decision was taken in June this year, and finally parts are starting to drop down in the post office here in Sweden. After some talk with the guy i ordered the parts from we decided to go for their new version on 550cc. I choose this because it doesn't require any mods of the engine cases, and it also gives an engine that revs better and gives less vibrations. Remember that it will be used in a CR500 frame of some kind. Either one of my stock frames or my AF gen1 frame, and it must be controllable and rideable for iceracing. We choosed to build a low comp engine, both for reliability and rideability. The engine will be built with only new parts, except engine cases and gearbox. Hot Rods crank, Wiseco 94mm piston,OEM bearings and seals,cut gearbox dogs. I will use a Lectron 48mm carb for this engine, which will be a tight fit, especially if i use the stock frame. CPI Racing has built a pipe for me. I will also use a Hinson clutch with Barnett carbon clutch and steel plates with heavy duty springs. For those who is intrested i thought i start a build thread. this project will take some time, but i will put up pictures during the build. Here is some pics of the pipe, carb and reeds.

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/CPILiger2_zpseb96a444.jpg

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/LectronmedRPMinsug1_zps1056a35c.jpg

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/ReedsLiger_zps7044bfcd.jpg

Edited by Johnnymannen
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I look forward to this Johnny! Hopefully, you'll run it on the same dyno that you used for your other half liter bike.

Lynn

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Hi. Johnny from Sweden here. A while ago i decided to build myself a strong Engine for my Cr500 iceracing Project. this decision was taken in June this year, and finally parts are starting to drop down in the post office here in Sweden. After some talk with the guy i ordered the parts from we decided to go for their new version on 550cc. i choose this because it doesn't require any mods of the engine cases, and it also gives an engine that revs better and gives less vibrations. Remember that it will be used in a CR500 frame of some kind. Either a modified stock frame or a AF gen1 frame, and it must be controllable and rideable for iceracing. We choosed to build a low comp Engine, both for reliability and rideability. The engine will be built with only new parts, except engine cases and gearbox.Hot Rods crank, wiseco 94mm piston,OEM bearings and seals,cut gearbox dogs. I will use a Lectron 48mm carb for this Engine, which will be a tight fit, especially if i use the stock frame. CPI Racing has built a pipe for me. I will also use a Hinson clutch with Barnett carbon clutch and steel plates with Heavy duty springs. For those who is intrested i thought i start a build thread. this project will take some time, but i will put up pictures during the build. Here is some pics of the pipe, carb and reeds.

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/CPILiger2_zpseb96a444.jpg

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/LectronmedRPMinsug1_zps1056a35c.jpg

 

http://i1204.photobucket.com/albums/bb419/Johnnymannen/ReedsLiger_zps7044bfcd.jpg

Awesome! I look forward to the build! It's far and away as foreign to me to see an iceracing project but I do have some norwegian blood. That's as close as I get to sweden. Thanks ahead of time.

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I look forward to this Johnny! Hopefully, you'll run it on the same dyno that you used for your other half liter bike.

Lynn

 

I look forward to this Johnny! Hopefully, you'll run it on the same dyno that you used for your other half liter bike.

Lynn

Hi Lynn! Well, i will not dyno at the same place as i wasn't satisfyed with what he did, or should i say, not did. But i will of course run it on a dyno that i know is as accurate as possible, and most important, that the guy who runs it really knows what he's doing when it comes to jetting and ignition.

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Awesome! I look forward to the build! It's far and away as foreign to me to see an iceracing project but I do have some norwegian blood. That's as close as I get to sweden. Thanks ahead of time.

Hello! Well, the bike is planned to be street used  in the summer, so it's Supermoto kitted in the summer time :=).

Edited by Johnnymannen

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Nice, can't wait to see the results of the build. Keep the pictures coming of what you're working with.

 

Seasons are just starting to getting close to transitioning here and the MX bikes are going to go away for the winter, and going to be bringing our 500's back for the winter.

 

Really curious to hear how the 48MM lectron works on your 500 though, I ordered a 38MM APT smartcarb for the 250sx which I am going to fit on my 500 on the ice and I'm really excited to see how that works.

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Hi Zappa. Yes, i will post up pics as the build goes, and what i do in preparation on the engine. Quite a lot to do to get everything matched up.

Ok, so you ride CR500 on the ice too :=). I've heard good about the APT mostly, so that should work out fine i guess. It's a very tight fit with the Lectron in the stock frame, if it's possible at all. I did some measuring today, just to see where it would sit, and it's not an easy thing to get it in...

i have a few different intakes to choose from, so we will see if any of them works.

 

Johnny

Edited by Johnnymannen

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Yep, specifically bought my CR500 just for running on the ice. Haven't done much for mods specifically for the ice beyond the tires though. Rodgini on here has put a smartcarb on his 500, so hopefully my install goes as easily as his. The cast Smartcarb is 94mm end to end though, not sure how long the Lectron is. The 38mm is a bit small though for the 500, especially on the ice, but it will have to do for now.

 

Been considering replacing the Gnarly that came with the bike and putting on something that isn't so focused on the low end. Love the look of the CPI pipe you have there... looks awesome.

 

http://www.flickr.com/photos/steve-89/sets/72157632643439057/

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Nice pics, Zappa :=)! I use the 41mm PWK on my previous bike and it has been fine. The CPI will give you a new Engine if you decide to gio with that. Strong as a PC from the bottom, but pulls to 7500 rpm, and is perfect with a good portjob :=). I prefer low comp on the ice btw.

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I finally got the last parts today! Cylinder, head, headstay, gaskets and some other stuff. Dave has been very kind and cleaned up the ports, applied a drain plug as there is none on them stock, Everything looks good, but i need to do minor adjustments on the exhaust flange as it isn't perfectly centered, but that's an easy fix.
I did a quick check, and if i'm lucky i don't need to do any mods to the stock frame at the front, but i need to move the radiators abou 1/2" forward and it should be clearance enough. I will check more this weekend and put the cases together and put them in the frame.
This is how it looks with the RPM intake, headstay and carb on. I maybe need to use another intake though.

http://s1204.photobucket.com/user/Johnnymannen/media/LigerochLectron1_zpsf147be73.jpg.html

 

http://s1204.photobucket.com/user/Johnnymannen/media/Ligerochlectron2_zpsabb87836.jpg.html

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Today i put the cases together, pulled out the cylinder studs, put the engine dummy in the frame and started to look at how the cylinder would fit in there.
This was very positiveas the only thing i needed to do was a minor adjustment to the middle frame rail just above the Y-section. I actually just hammered it slightly, and the cylinder dropped in, almost all the way down. the problem that it didn't drop in all the way is that the sleeve botttoms out in the cases, abou 2 mm before the it hits the adaptor plate. i guess i have to do some machining to the cases there. I maybe need to do a minor mod to where the exhaust flange is connected, just to get the bolts in, but that is no big deal.
The big deal is to get a 48mm Lectron in there. it is impossible. i have done a lot of measuring this evening, and the only way to do it is to put the carb further back so it sits next to the rear shock. This requires a longer inlet tract, or hose, and the connection to the airbox will be very angled. maybe it's easier to just put a fine net over the inlet of the carb, but i don't like that really. i have to think about this.I also have shorter intake rubber, but then the carb hits the frame rail at the top and the throttle wire can't be connected.
her eis some pics.
 

http://s1204.photobucket.com/user/Johnnymannen/media/Adaptorplateonblock_zpsf108d410.jpg.html

 

http://s1204.photobucket.com/user/Johnnymannen/media/Topendinframerightside_zps77381af0.jpg.html

 

http://s1204.photobucket.com/user/Johnnymannen/media/Topendinframeleftsidebehind_zps4409105a.jpg.html

 

http://s1204.photobucket.com/user/Johnnymannen/media/Topendinframe1_zps552e925e.jpg.html

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Got any pictures of the big CR on ice? Or the bike itself? I like seeing how others have set up there bikes for ice.

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you may have better luck with the aluminum frames but even then im not sure. but you wouldnt have the backbone in the way. seems like one off machines always require a bunch of compromises. change one thing and it creates 3 more problems :smirk:.  mine was hitting the bowl on the cases. had to get made a manifold so the carb was higher and cut the airboot.  eventually sorted all the problems and it fits good now but yours looks more difficult than what i had

 

IMG_20131025_220047_zpsdbe6a812.jpg

 

 

IMG_20131025_220208_zps3b952fa1.jpg

Edited by harryhandshake

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Got any pictures of the big CR on ice? Or the bike itself? I like seeing how others have set up there bikes for ice.

If you mean big CR with this bike, no. This bike is a new build, but my other iceracer is on Youtube if you search on JohnnyLehti. There you can find some movies. here is a nice movie my friend made this winter.

http://www.youtube.com/watch?v=Ejv0lRk2VQM

Edited by Johnnymannen

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I have done a lot of measuring and thinking here, and finally i think i have the solution to the carb fitmant issue. This will be perfect when it's done! As you see i can even use the stock airbox, which is very good when i icerace. Too much snowdust is not good as it affects the jetting, and the throttle can freeze open too. No good.. The throttle cable will also fit nice.Shock clearance is also good.What is complicated is the space to the reedcage and inlet boot. But i think i will solve that. I cut the carb 3mm, use a reedcage in alloy that i can weld an alloy inlet on and then use a short rubber boot to connect the carb to. I will maybe cut the cylinder a few millimeteroo at the reedcage to get more space, but i will see if that's necessary.

 

UPPintaketocarbtoairbox3_zps77a49e94.jpg

 

UPPintaketocarbtoairbox2_zps8d4376e3.jpg

Edited by Johnnymannen

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good thinking. also i had to shorten the carb :thumbsup:

 

something to pay attention to, the lectron bell end diameter is slightly smaller then pj or pwk so it probly wont fit as snug in the airboot. thats another issue i run into. you can put a thin sleeve to make it good fit like the stock carb

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Yes, Harry, i have noticed that the air box boot is slightly bigger compared to the Lectron body, but on my bike it seems to work fine. it's just about 2mm difference, so it should be ok with the hoseclamp there :=)

i tried my fueltanks yesterday too, and it is also a very tight fit, but i am lucky here again :=)! i have a factory alloy tank that i intend to use. I have to modify the headstay slightly to make the tank drop in all the way, so i will look more into that, and if i decide to use the stock plastic tank, it also fits with just a millimeter or two of clearance. crazy tight, but good :=)!

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i will do more mods to the carb. I have to do everything i can to make it as small as possible. I will cut the throttle 2mm, the housing 5mm, the front housing 8mm, cut the top cover 2,5mm, remove the locking nut for the cable pipe. All these mods gives me a bit more room to make this possible. Damn, it's not easy!

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If you mean big CR with this bike, no. This bike is a new build, but my other iceracer is on Youtube if you search on JohnnyLehti. There you can find some movies. here is a nice movie my friend made this winter.

http://www.youtube.com/watch?v=Ejv0lRk2VQM

 

Thanks. Checked out the vids, looks like fun. In our area we have similar type tracks for endurance style races and also 1/4 mile oval racing which is what I do.

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