VF500F Engine Swap/Refresh

It's been a while since I've updated this...primarily because I started a new job a few weeks back and there hasn't been much time for fun. That said, I have made some progress:

1. Calipers got some silver caliper paint and new pads, did the upper fairing bracket in black Plasti-Dip. Also re-did the swing arm using a chrome/aluminum high-temp paint used for fences and natural gas tanks...came out awesome.
2. New head bearings and mounted the triples and forks
3. Installed CBR shock and Galfer brake line in the back.
4. Installed seat latches with factory security bolts.
5. Took the rubber off my F2 rims and pulled the bearings. Rear rim is off for powder coat and the front will be getting machined in the near future.

Currently in the mail:

1. Galfer lines for the front (3 line set)
2. New wheel bearings and seals
3. F2 kit from Jamie arrived this week...looking forward to mounting that rear wheel.

Getting the frame on rubber is the next major focus. Once that's done I can start working on the motor...

 

Nice work!

Thank you for posting the photos.

You mention 'factory security bolts' for the seat latches. What are these?

Where are you planning on mounting the mono-shock reservoir?

 

are you planning to also do the F2 wheel up front as well?

 

Is there a way to tell if a 500 needs the valve springs replaced? or is it just pretty much recommended that they are replaced every 20,000? I have an 86 vf500 with 40,000 on it, and I have no idea if any of the previous owners changed them or not.

Thanks!

 

The security bolts are designed to be installed once and only once. The heads break off when you wrench them down...which is awesome...unless you have to remove those latches. Had to grind mine off before I could get the frame coated.

As for the reservoir...haven't decided yet. The hose to the remote on this shock is very long, so I think I'll have some options...

 

Definitely. Would like to chat with you off line about the fork work you had done...

 

There are several threads that discuss this in detail. If you are not 100% sure of the condition of your motor, my advice would be to go and have the entire top end looked over...preferably by someone with some V4 experience.

 

Thank you for the post and for the photos.

The longer hose for the reservoir will definitely give you some options.

I have mine currently 'zip tied' to the seat frame but I am not sure I like this detail – it looks a bit ad hoc. I was thinking about machining a mount for this.

 

yea man pm me with your phone number and i'll call you with the details

 

I was able to get the security bolts off of mine by gripping them with vice grips. i'm pretty sure i can reuse them when i need to put them back on, but if not, where did you get yours?

thanks.

 

Babbitts Sports Center | Arctic Cat OEM Parts | Can-Am (Bombardier) OEM Parts | Honda OEM Parts | Kawasaki OEM Parts | Polaris OEM Parts | Sea-Doo OEM Parts | Ski-Doo OEM Parts | Suzuki OEM Parts | Yamaha OEM Parts

Part 12 under "Seat + Rear Cowl"

Part # 90104-KE8-000

You will need 4. They are $3.31 a piece, but worth it IMO.

 

Galfer braided lines for the front were installed last night and the EBC "wave" rotor showed up in the mail yesterday for the F2 rear. I'll post some pics tonight...wish I had a scale to compare weight. Just need a sprocket set and some new rubber to be 100% on the rear.

 

Thanks a bunch.

 

Something looks familiar


Sounds cool where are the pictures????? Where did you order the brake lines from?

 

I actually picked up my F2 rear from the PC guy today...and I have a few other pics to post. Tonight it's the O's vs the Rays @ Camden Yards, so I wont be able to upload until later.

Thanks for the pics!

 

Holy Carnage Batman!

 

Thank you for the post. These are very clear photos of what can go very wrong when a VF500F engine isn't maintained. Do you know the mileage on this engine or its history?

 

OK, looks like my game will be rained out so here is a few pictures to keep your mouths wet...

Rear F2 fresh from the PC. This was a new shop and I am not entirely pleased...there is a decent amount of orange peal and they didn't mask the rotor seat.




Next are some pics I took a few weeks ago but didnt take the time to post up.

First the Galfer "WAVE" rotor for the rear wheel, please pardon my crappy photo skills



Next is the braided steel clutch line...these are NOS upgrades. Not sure if I will keep them or go with a different setup. They do not have the nice plastic sheath that new Galfer lines do...



Next we have a set of engine guards that I picked up for a song...$35 shipped! Not sure if I like them though and I will have to modify the body work on the bottom to make it all fit...mostly I just bought them because I thought it would be cool to have some more original 500 gear.

 

Thank you for the post.

If I could ask, regarding your CBR600F2 rear wheel conversion - what tire size will you be selecting? Have you dialed in the chain length and front and rear sprockets?

 

MOAR PICTURES!

New Brake Master - This is a new Master cylinder from a GS450. Not sure if it will work, but if not I am only out $45




Next is the Corbin saddle that is in desperate need of a re-cover...



Next is the V&H Full exhaust. This thing has some serious problems. First, it was rusty as hell and getting into all the nooks and crannies with my wire wheel has been tough. Second, the previous owner was using these when his engine blew and the insides are coated with oil. Third, one of the cans had a huge dent in it. Fourth, the glass was completely shot and full of oil as well...so a complete restore job is in order here.




Last set...some random pics...of my basement. I did mention that I am doing this work in my basement workshop, right?