In Memory of Caleb Taiki Thomason
|Welcome to Part three
of Project NSR 500. This is the final part of this series. Engine was
rebuilt, custom pipe fitted, custom wire harness and many more problems
sorted out. How did Project NSR500 turn out? What is it like to ride?
Keep on reading below.
Chris had the CR500 engine out again, he decided it would be a good time
to rebuild the engine to freshen it up and make maximum power.
On the left is the
NSR250 crank and pistons while on the right side is the massive CR500
crank and single piston.
With the engine
apart it was a perfect chance to remove the shift lever shaft. Chris
then had his professional welder friend extend the shaft by 2.75 inches.
This should help a lot with some of the shifting and linkage problems.
The stock CR500
carb was cleaned up and fitted with a UNI Pod filter to keep dirt and
dust out. Click here to see
the carb and filter installed on Project NSR500.
back in Project NSR500 and the pipe fitted again. Next step was the electrical
system. Chris picked up a few parts and also had three extra harnesses
lying around. He ran an ELINE stator to a ELINE regulator, then he ran
the outputs out of the ELINE regulator straight into the old plug that
went to the original regulator. Finally he tapped into the tach wires
and ran those down to the CR500 coil on the frame. With the wiring and
electrical problems solved it was time to move on to fit the bodywork.
This is where Chris was worried a bit.
After trying to
install the bodywork there were some problems with the big pipe. The
first problem was the front of the pipe was hitting the air scoop cowling
under the radiator. Chris simply removed it, not exactly the prettiest
solution but works well.
problem is the width of this pipe, it is big and also required some trimming
of the under fairings as well. A spacer on the right side at the rear
where the pipes exits was added as well and helps to widen things up a
bit. This took care of the bodywork.
is the kickstarter tucked back into position while out of use. Note the
extended kickstarter shaft, this length is crucial. After further testing,
the shaft bent from the extreme load needed to start this beast. Another
support of some kind will be needed externally. More pictures of the custom
kickstarter and shaft when the kickstarter
is tucked in, here is the extended
view and the side view
of it extended.
on the CR500 is a monster, and you need the full motion to start a beast
like this. Chris literally has to stand up and jump with all his weight
on the kickstarter, so it is imperative that you need to leave lots
of room for the kickstarter to have full range of travel...... or else
this happens. More trimming of the bodywork was done (see below)
This is an experimental
shift linkage. It uses the original Coerce backstep linkage flipped
upside down. The linkage must be upside down to retain the 1 down, 5
up shift pattern. The original CR500 shift lever is used because of
it's compatibility with the shift shaft protruding from the engine.
The shaft is much bigger than an NSR250 shift shaft. Then a piece of
angle with different height selections was added to give different leverage
and travel to the touch of the shifting, for experimental purposes.
Too much leverage made the travel longer and too soft, too short was
too hard to shift. A piece of slippery UHMW (Ultra High Molecular Weight)
plastic was added around the shift shaft which keeps the drive chain
from bouncing and hitting the shift shaft.
more trimming of the bodywork was done here.
With the bodywork
out of the way and the massive pipe finished things were looking good.
At least it seemed that way.....
shot of the back shows how high the silencer comes up. There were plans
for an aftermarket GP type silencer, but these plans were later canceled
due to a few other problems......
NSR500 all finished !! It looks great and Chris really did his best. Next
step was to go for another test ride and make some minor adjustments.
test riding Project NSR500, all Chris could say was "Vibration !!
Vibration!! Lots of vibration!!" Chris experimented with all kinds
of rubber grommets to put in place between the mounts and the engine,
but this did not help.
problems were creeping up too with the shifting, the kickstarter and the
bike was having problems with it's charging system. After several days
of Chris riding Project NSR500 he felt the bike was worse than before
and just felt the bike was unrideable and not practical.
quotes from Chris "I got it out for a good ride today and it just
does not seem very rideable. It vibrates extremely, extremely bad, and
it just did not feel right in the turns. Even when going straight, it
will not hold a steady speed, it wants to jerk and kick. It just does
not run like it is supposed to be in there. The vibration is just unreal.
It feels like I am holding the dang engine in my arms when it is running.
Then all of that mass in the crank spinning must be affecting the handling,
because it did not feel like it wanted to lean as easily. I think mostly
the vibration is scaring me more than anything. I just hate to ride it
very fast when it feels like every bolt in it will vibrate out in less
than 2 minutes."
you go, would Chris recommend this conversion? No!! Sure it can get the
front wheel up in third gear, even fourth, but the bike is unrideable.
Future plans for this NSR will see Chris rebuild his stock MC21 engine
and go with that. New bodywork will eventually be ordered and painted
in the same colors plus a few other things that need to be done. The engine,
pipe and the parts are all for sale, but he does not believe anybody would
want them. You can decide for yourself if it is worth it?
thanks to Chris and his Family for their help and cooperation with this
one - getting started
Part two - engine installation and exhaust
Part three - completion