any how to requests??

[hmmmnz]

obviously i can't do body work how to's as someone changed all min to jawa stuff ???
but any requests for frame or engine stuff let me know, and ill do a how to with pics

[Nozz]

That's kind of you to offer. I am needing to rebuild some forks from my 500. Your step by step might embolden me to take it on alone.

[hmmmnz]

sounds like a plan, i have a blown fork seal anyway and im out of gas on the mz so one of the other bikes has taken up commuter duties hehe ill try and do it this week for ya

[comanche91]

Ever do a 504E Rotax engine big bore kit install hmmmnz? Got a line on one for pretty cheap.

[DAVID THOMPSON]

why bigger mine goes fast enough to scare the crap out of me
dave

[comanche91]

Yeah Dave, mine too. But, why not? I have a spare engine, and if I can stick a big bore kit on it for cheap, maybe it'll scare me more. Got my Jeep Comanche stroked out from 4.0L to 4.6L, and it's perfect.

[hmmmnz]

sorry this is taking so long
my bad, i havn't had a camera, ive wanted to do it and had the time as well, but no cam, but ill pick up the camera tomorrow,

no i havn't done a big bore kit but i have stripped the engine down,
its a fantastic engine to strip, almost as easy as a smokey, by far and away the easyest 4 stroke ive stripped down,
i might do a top end strip down for ya if you need the guidance,

[comanche91]

Thanks hmmmnz. I do have the Rotax manual but it seems like even the simplest procedures call for "special" tools that I don't have.............

[hmmmnz]

specialist tools??
you can strip the whole engine down as far as it'll go with a simple metric socket set,
a set of allen keys, and a couple of crescents,
no special tools are required,

a set of feeler gauges for the valve clearances
spring compressor of you are changing valves
and a flywheel puller, no other tools required... ever

that s why the engine was used by the British military for so many years
even for a ham fisted soldier, jobs are simple and can be fixed on the side of the road when things break
especially not for the top end


thats just.
take off cam cover
take off cam belt
unbolt head

and slide everything free,

you dont even need to unbolt the top cam pulley.
replace cylinder with bored out one, change piston,
and slide everything back in place,

i reckon you could swap the barrel out in less than 2 hours having never done it before,
and i reckon after doing it once you could do it again in under 45mins

[DAVID THOMPSON]

the flat track racers in the usa loved this engine for almost 20 years and i heard that some have even rebuilt there's
to 450 cc to race because the ama made the size change to 450cc to get rid of them
almost any thing you do to it makes it go faster
dave

[hmmmnz]

yeah ive heard of guys running the standard bottom end, with a 590cc top end and different cams getting near 70hp
the engine is a piece of art in its simplicity and tunability (is that even a word )

[nikitino]

What about a how to check valve clearances? I have about 20,000km and not sure it's ever been done.....thanx

[hmmmnz]

ok, ill do one tonight

[GordonS]

I'm almost embarrassed to ask such a basic question, but how do I get to the air filter in a Saxon 500 Tour. I have the manual but it's quite basic and doesn't seem to contain this info. I think I overfilled the engine oil and it clogged the filter. How do I resolve this problem.

Thank you very much iin advance!

[comanche91]

I'm almost embarrassed to ask such a basic question, but how do I get to the air filter in a Saxon 500 Tour. I have the manual but it's quite basic and doesn't seem to contain this info. I think I overfilled the engine oil and it clogged the filter. How do I resolve this problem. Thank you very much iin advance!

Remove the right side cover, then the battery and you will be able to access the air filter.