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Author Topic: LTR500R Hybrid MX Build  (Read 4470 times)

Offline Cartee#2

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LTR500R Hybrid MX Build
« on: May 21, 2013, 12:20:29 pm »
Completely hand fabbed, welded, and built by myself including the engine. Powerplant is 1987 Suzuki LT500R Quadzilla 88mm bore x 86mm stroke hand ported/polished fed by 40mm Lectron dual stack pro carb. Purposely built for motocross only. Nowhere near finished but soon to have it's maiden voyage before being stripped back down for PC if everything goes accordingly.














22 hours on frame hacking, mocking up, and finally welding in mounts and gussetts. Built in 4 days of solid work. Pretty proud of myself honestly. Before you go to bashing me on the welds like others did.... they are rooted and not capped yet. I was running low on gas and had other things that needed welded before I put the finishing cap on all of them.

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Offline Motoman991

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Re: LTR500R MX Build
« Reply #1 on: May 21, 2013, 12:24:14 pm »
Where are the pics?

Offline Cartee#2

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Re: LTR500R MX Build
« Reply #2 on: May 21, 2013, 12:34:28 pm »
Chassis is a 2007 LTR450, lowered subframe, and full long travel suspension Laegar's A-arms with Fox Floats, factory LTR swingarm with Fox Podium single rate remote rezzie and Walsh long travel linkage. This is what I'll be riding at the Loretta Lynn's National this year due to transmission failure on my 09 LTR450.

Offline El Diablo

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Re: LTR500R Hybrid MX Build
« Reply #3 on: May 21, 2013, 12:48:21 pm »
This hybrid will get a lot of attention do to the fact that you are probably one of the 1st to attempt the LTR-500 hybrid. Keep the pics coming & be sure to document everything.

p.s.  - I've thought of doing this same thing for a duner so let me know how she handles
Brian
1988 Suzuki LT-250R (The HPR test mule)
1987 Suzuki LT-500R
1990 Suzuki LT-500R
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Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #4 on: May 21, 2013, 01:02:59 pm »
The first initial mock up went great but the final building is slow going right now mostly due to the fact that I'm laid off work. I'm hoping to hit some humps and jumps on it by the weekend. I'll also have the dry weight listed soon. The hardest thing to do for me was sacrifice that factory shock mount and reinforce it enough to clear the 40mm Lectron carb bell and custom build the exhaust which I'm really honestly not happy with. It's too small for my likings but any bigger and it'll burn the piss out of my leg when I get her into a corner. I'll keep ya'll updated but like I said between job hunting, shade-treeing, and paying bills she's a slow process at this point. Not bad for a 22 year old Redneck, eh? lol and thats not my liquid encouragement in those pics, i stay sober as a burnt stump, but my buddies like to knock em down!

Offline Glamisrider

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Re: LTR500R Hybrid MX Build
« Reply #5 on: May 21, 2013, 01:38:41 pm »
You need a JH hybrid exhaust for that puppy

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #6 on: May 21, 2013, 01:42:33 pm »
Point me in the right direction lol, I was thinking about hauling it to AAEN and see what they could come up with but I'm open for all suggestions! The exhaust I made started out as a 85 Tecate 3 Coffman, factory LT500 neck, with a FMF ATC extention. Hook me up! I don't want my only other option to be an ol FTZ OOF drag pipe for MX lmao.

Offline Dezsled

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Re: LTR500R Hybrid MX Build
« Reply #7 on: May 21, 2013, 01:48:46 pm »
Jerry Hall 623-931-8132

He has THE pipe proven in the dyno testing!
87 HPR LT500
04 Roll LOBO II TRX250R
06 LTR450
87 LT500
85 & 86 LT250
86 & 87 TRX250R
07 & 09 Husqvarna TE450
00 CR125R

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #8 on: May 21, 2013, 04:06:47 pm »
Where's he located? I'm sure i'd have to take the whole quad to him to make the correct fit. Any pics?

Offline Dezsled

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Re: LTR500R Hybrid MX Build
« Reply #9 on: May 21, 2013, 04:31:54 pm »
Pics





87 HPR LT500
04 Roll LOBO II TRX250R
06 LTR450
87 LT500
85 & 86 LT250
86 & 87 TRX250R
07 & 09 Husqvarna TE450
00 CR125R

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #10 on: May 21, 2013, 05:05:00 pm »
That's slickern owl shit right there! I know it's kinda hard to say since your not the man behind the tig rig but reckon bout how long it'd take him to build me one for my quad? Being that it's in an 07 LTR450 frame I'm sure he'd basically have to start from scratch and what's the price range I'm looking at? I'm also in serious need of a good reed cage setup, clutch basket, clutches, water pump bolt(or whole shi-bang), and maybe a good HC head. Engine is set-up at zero deck height now with stock head. Fairly new to the quadzilla engine but i did make my old 86 LT250R run 8.30's in an 8th mile when i was 12-13 years old with several mods to the motor. I just remember it was hell to make the clutch not slip. Any tips for big power on the 87 Zilla would be greatly appreciated. Planning on running the Loretta Lynn national on this bike in August.

Offline Buckeye513

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Re: LTR500R Hybrid MX Build
« Reply #11 on: May 21, 2013, 05:10:03 pm »
Call Jerry he will answer all your questions. Price wise he's expensive but you get what you pay for and Jerry is arguably the best there is when it comes to the LT500. Clutch basket go with a Hinson Jerry has a 9 plate Kevlar clutch that will tolerate up to 70 ft lbs I'm about to order that set up for my zilla. Reed cage V2's are the best if you can find them and a good mx port job will get you squared away. Won't be cheap because unlike the newer bikes or banshees there's not a ton of aftermarket stuff and the stuff that's really good is custom made by guys like Jerry.

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #12 on: May 21, 2013, 05:13:03 pm »
I guess I'll wait a few weeks and call him up, no need in wasting his time when my wallet's suffering from the lay off.

Offline Kyle T

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Re: LTR500R Hybrid MX Build
« Reply #13 on: May 21, 2013, 07:33:44 pm »
Cartee is the second one to attempt an LT500R powered LTR-450 FWIW.

Offline Buckeye513

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Re: LTR500R Hybrid MX Build
« Reply #14 on: May 21, 2013, 07:37:13 pm »
Who was the first? I want a yfz450 chassis lt500/cr500/kx500 hybrid.

Offline Kyle T

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Re: LTR500R Hybrid MX Build
« Reply #15 on: May 21, 2013, 07:47:24 pm »
Here it is. I saved from long ago when I was going to do this. But that's a story no one cares to hear.

"The rear motor/swingarm pivot mount is the same width on the LTR450 as it is on the LT500....the only difference is that the LTR450 swingarm bolt is a larger diameter so the rear mount on the 500 will have to be bored to the same dia as the 450 swingarm bolt. The front sprocket on the 500 seems to line up in the stock position on the swingarm as the 450 sprocket did. The kickstarter looks like to have plenty of clearence to miss the frame. All of the other engine mounts will have to be fabricated. I still have some other clearence issues to check out when I get some of the other parts installed on the frame.
I have a new set of 500 cases that I am going to get the pivot mount bored out and do a complete mock up of the 500 in the 450 frame.
I got the cases back from the machinist the other day and had to find out if I was right about the engine/swingarm mount....slid the swingarm bolt thru the frame/swingarm/engine/swingarm/frame....tightened it up....WOW! Perfect fit! One down, more to go.....
Found out real quick that the rear stock shock will not work....will have to use a aftermarket rear shock setup w/remote rezzie so I have the clearence for the pipe and the carb. The stock rear shock has the "built in" rezzie that interferes where the carb needs to go.
I also mounted the radiator.....plenty of clearence between it and the front of the QZ engine. Thinking about using the 12v fan on it too.
The airbox will have to be custom made. The stock airbox has the inlet hole (carb) and the pipe offset that is formed on the airbox.... both on the wrong side.
http://www.quadracerhq.com/forum/picture.php?albumid=27&pictureid=255
http://www.quadracerhq.com/forum/picture.php?albumid=27&pictureid=277
I had thought about doing the extended LT500 bolt and making bushings to fit in the LTR450 swingarm to fit the LT500 bolt also.....problem is that I would have to make bushings for the LTR450 frame too. It can be done this way if one wants to do it that way."

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #16 on: May 21, 2013, 08:00:08 pm »
I didn't have to mess with swing arm pivot bolt holes on mine. Nice and snug, but yet still pivots freely with zero drag. I also cut the factory LTR450 oil tank tubes completely out of the way to clear an exhaust better and welded in gussets. It's not a hard conversion to do, especially if your not going to motocross it. You could just cut the original top rear shock mount off completely and build it from scratch once everything was mounted, but ride height and handling was key to me for MX. I just cut the right side of the upper shock mount off as close to the mounting tab as possible and did some reconstructive surgery on her. Now I can clear almost any carb no problem and never worry about it breaking either. There's a guy on youtube from france or australie, something like that, who built a YFZ/LT500R hybrid for motocross and has performed really well on it. I'll be running all long travel Fox Float/Laegars setup up front, Stock Swingarm/Walsh Linkage/Fox Podium single rate remote rezzie rear, 40mm Lectron, custom alluminum airbox etc etc etc. More pics to come when I get it rolling(1-3 days).

Offline Q2W

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Re: LTR500R Hybrid MX Build
« Reply #17 on: May 22, 2013, 11:30:24 am »
That thing is gonna be sick!

You might share some of your secrets with the other guy on here that was building one.  Or, better yet, give us a detailed break down (when you're done)  on all the problem areas and how you corrected them and i'll sticky it.  Keep us updated!

Also,  Jerry Hall is an active member on this site.  His user is motorgeek.

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #18 on: May 22, 2013, 12:14:20 pm »
I ported it myself. Not my first rodeo on that scene lol. I have the engine altogeth now with the crappy clutch basket and screwed up water pump, bout to mount it and my suspension, make sure it's firing and crank it a few times before I tear it back down and put all new stuff in it. Also going to experiment with a motoplat mini flywheel set-up and timing plate that picked my old LT250R up 3 tenths in an 8th mile..... it fires so hard that it literally will bring you to your knees if not put you on the ground.(Ol 250 leaned out on alcohol and had to jerk the coil wire off when I was 15 and I've never been electricuted like that by anything in my life) Pics tonight, mind you she's uglier than sin at the moment but that's the least of my owrries. Function>Form.

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #19 on: May 22, 2013, 02:23:44 pm »
I didn't have to mess with swing arm pivot bolt holes on mine. Nice and snug, but yet still pivots freely with zero drag.

I lied to ya'll by accident. I just f--ked up bad. I was using a YFZ450 swingarm bolt during mock up and once I started putting my suspension on it I used a factory LTR450 swing arm bolt and it didn't want to go, so what'd i do? Yep, drove it halfway in before realizing my mistake. Now it's stuck tighter than dick's hat band and I've been cussing up a storm trying to get it out with no luck. I can't believe I just screwed everything up over a dumbass mistake like that.
 NOTE: USE A YFZ450 SWINGARM PIVOT BOLT!

Any ideas on how to get it out without using a dye-tool and slitting the Zilla cases where the bolt goes through? If I have to I will but I know when i weld it back it's going to draw up and be even tighter. Tight's good when it comes to females but not so great when it comes to suspension travel..... I oughta be slapped. I know better.

Offline Q2W

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Re: LTR500R Hybrid MX Build
« Reply #20 on: May 22, 2013, 02:50:02 pm »
The other guy bored the cases so the ltr bolt and bearings would fit.  Won't there be slack if you use the yfz?

Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #21 on: May 22, 2013, 03:06:06 pm »
I used the YFZ swing arm collars too in the mock up. I just didnt realize it til it was too late when I started putting it together. I have to get this LTR bolt out and need some input as it's going nowhere fast and at this point I don't care if it messes the bolt up. I have about 5 more lol. But yes if you use the YFZ bolt and LTR swing arm collars(bushings) there will be a tad amount of play, less than a mm of wiggle. OD is the same on both but the ID is a little smaller on the YFZ collars.

Offline Chuckie25

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Re: LTR500R Hybrid MX Build
« Reply #22 on: May 22, 2013, 03:42:32 pm »
You're gunna have to hit it from the other side with a punch or something man. Maybe heat just the tail of the cases with like a little propane torch to get just the slightest bit of pressure off the bolt
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Offline Cartee#2

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Re: LTR500R Hybrid MX Build
« Reply #23 on: May 22, 2013, 03:45:20 pm »
Little cold air, little hot air, wala magic. Whore's out now and still useable after I ran the thread chaser over it. I thought I had screwed the whole project up with that simple mistake.

Offline Glamisrider

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Re: LTR500R Hybrid MX Build
« Reply #24 on: May 22, 2013, 06:04:47 pm »

 

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