Carnz' 500cc Blaster Project

[Paulie B]

I like your bigger stud upgrade.
Even my lil 406 had chronic head gasket leakage.
I had an oring machined into the head.
Different ways to skin a cat I guess.
I'm also happy to see your getting the crank re-built/balenced.
Money well spent brother keep up the good work I:I

 

[CARNZ]

I like your bigger stud upgrade.
Even my lil 406 had chronic head gasket leakage.
I had an oring machined into the head.
Different ways to skin a cat I guess.
I'm also happy to see your getting the crank re-built/balenced.
Money well spent brother keep up the good work I:I

Thanks I:I

after it's all built and broken in i'm doing another big improvement to it!

I think I will be able to get the max power usable power of it, nothing like a drag port.

You all will be the first to know!

 

[CARNZ]

Looking good dude.

This is off topic. But are you in school engineering? I don't know many people around our age that can draw up a wiring diagram.

nope. I goto school for computer science and criminal justice. Work as a Subaru Master Tech right now. Know my way around wiring diagrams pretty well after working with them on cars for a while now. Did some big custom car wiring and stuff, so a simple ATV electrical system isn't much to handle to me.

Either way, I try to do everything to the best of my abilities and not cheap out.

 

[motoman9911]

Well it's looking good.

 

[CARNZ]

thanks bro 15155151

 

[darederek]

anything coming along on this or is it on halt for the holidays

 

[CARNZ]

Just bought:
-93 WR500 Cylinder
-93 WR500 Head
-93 WR500 Reed Cage and Manifold
-WR500 Boyesen Power Reeds

Ordering in Two Weeks:
*92-93 WR500 LA Sleeve Rebuild Kit
Comes with:
-LA Sleeve
-Top-end Gaskets
-Standard Bore Wiseco Piston and Rings
-Wrist Pin Bearing
*OEM Yamaha YZ490 Connecting Rod Kit
Comes With:
-Connecting Rod
-Crank Pin
-Thrust Washers
-Big-end Bearing
-Small-end Bearing


I will be picking up speed on this come February. My goal is to have the crank sent out to Surf&Turf Racing for Crank Reassembly, Trueing, and Balancing by beginning of Feb.

Once I get my crank back I am going to get this all together and then get it going!

-Mike

 

[motoman9911]

How much hp are you estimating for this?

 

[CARNZ]

a lot lol. honestly, i don't know a good number to guess. but i'll try to get it on a dyno after its broken in and tuned properly.

 

[79xs]

nope. I goto school for computer science and criminal justice. Work as a Subaru Master Tech right now. Know my way around wiring diagrams pretty well after working with them on cars for a while now. Did some big custom car wiring and stuff, so a simple ATV electrical system isn't much to handle to me.

Either way, I try to do everything to the best of my abilities and not cheap out.

Looking great. I thought I would share a cool app I found for drawing wiring diagrams:

ExpressPCB - Free PCB layout software - Low cost circuit boards - Top quality PCB manufacturing

Have a look at that program. It's free and works very very well. I made the diagram for my 550 in it ( http://mirror.servebeer.com/xj/YFZ550R.gif )

 

[CARNZ]

sweet, i'll check that out!

nothing to report as of now, waiting on my most recent purchases to get here.
-mike

EDIT:
wait.....discovered that my swingarm has a crack in it, so I'm going to buy another stocker to send to tater for mods. discovered that my axle had like 1 inch of play side to side, good thing i'm rebuilding the carrier and getting a dominator ii axle!

 

[StrokedTater244]

sweet, i'll check that out!

nothing to report as of now, waiting on my most recent purchases to get here.
-mike

EDIT:
wait.....discovered that my swingarm has a crack in it, so I'm going to buy another stocker to send to tater for mods. discovered that my axle had like 1 inch of play side to side, good thing i'm rebuilding the carrier and getting a dominator ii axle!

after the new one is reworked and gusseted you will never have that problem again I:I

 

[CARNZ]

Got my WR500 Jug/Head today!

Took a bunch of comparison pictures, the WR is better in every-way.

Comparison Pic of WR500 Manifold

and YZ490 Manifold

.

Comparison Pic of YZ490 Cylinder

and WR500 Cylinder

/

Picture of Ancient 1982 YZ490 Cylinder Porting

Picture of Updated 1993 WR500 Cylinder Porting

Comparison Pic of 82 YZ490 Head

and 93 WR500 Head

Comparison Pic of 93 WR500 Reed Valve

and 82 YZ490 Reed Valve

Upgraded Parts FTW.

Going to use the old 490 stuff on the dirtbike now.

-Mike​

 

[Blasterdude27]

Nice!!!!! Hope to see it all together soon.

 

[89blasty]

sweet dude cant wait to see it runnin

 

[Paulie B]

Thanks alot Mike for the comparo pics.
Me bein an oldskool Yamaha buff I've never seen for myself what the difference was between the 2.
Learn somethin new everyday- still lol
Keep on keepin on brother.

 

[specialized7]

This is a neat build, suck that you hade to rebuild the bottom end thou.
iv always been keeping my eye out for a liquid cooled dt to swap in

 

[brandoz28]

does that jug just bolt on?


talk about some serious custom tailoring, the only thing left that's regular yz490 is gonna be the engine cases lol

 

[CARNZ]

EDIT: typed this post on my phone before, so i'm cleaning it up now on the computer.
Yeah, brando, the jug is a straight bolt-on. And I am using a big vareity of parts on this engine, nothing from only one model on here!

Crankshaft: IT465/490 Heavy-Weight
*Dynamic-Balanced and Trued by Surf-N-Turf Racing
*New OEM Yamaha Connecting Rod, Crank Pin, and Thrust Washers

Cylinder: 1993 WR500
*LA Cylinder Sleeve
*Wiseco Piston
*Aggressive Trail Porting

Head: 1993 WR500
*Squish-band Mod

Crank Primary Drive Gear: 1981 IT465

Clutch Assembly: 1981 IT465
*EBC DRC Clutch Kit

Transmission: 1981 IT465 with 1980 YZ465 5th Gear

Crankcases: 80-90 YZ/IT 465/490

Magneto: 1981 YZ465 Magneto with custom-wound Lighting Coils
*Ricky Stator Regulator/Rectifier
*12V Gel-Cell Battery

CDI: 1980 YZ465 CDI[only going to be used for break-in]
*MSD Programmable Single-Cylinder Power Sports CDI [summer-time project]

Coil: Stock Blaster Coil[for now]

Other Engine Details:
*100 %; New OEM Bearing Replacements [every bearing in cases,except Crankshaft]
*SKF High-Precision 17000RPM Rated Roller Bearings [Crankshaft]
*100% New OEM Oil Seals
*Rebuilt Tranny Shafts with new shims and circlips
*Shift-Star Mod

there, cleaner list with more details

-Mike

 

[Paulie B]

Man Mike I hope this quad works out for ya with all the R&D/$$$.
If it don't though put that sucker in a dirtbike frame!
Just so you know the Yamaha Banshee takes the same clutch.
Might be a lil easier to find + more options out there for ya.
You can also mod a Shee pancake bearing to fit.
I have personally welded the ball to my clutch rod so there might be a time when you will need that mod.
I can also hook you up with the part# for a nology coil that will be a nice upgrade in the future.