CBR500R Primmed ver.2 - mod to the max - Honda CBR500R Forum : CB500F and CB500X Forums
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post #1 of 72 (permalink) Old 07-02-2016, 10:28 AM Thread Starter
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CBR500R Primmed ver.2 - mod to the max

Some of you might be familiar with my bike going back a few years now. Things have changed a bit since and I reckon time for a new thread.

'My Garage' has some hyperlinks to some of the other mods done.
Before all the nay say'ers get up in arms with the "why bother" posts, I do it cause I love mechanics, to learn, and basically because I find it enjoyable... Plus being single helps to throw coin at things other than T&A. If I had a higher capacity bike, I'd still be doing the same things, so no need for any negativity.

So the latest foray into mods... There's been a few "race engine build" threads started, but to date none completed; here's to changing that.
The most recent add-ons have been the addition of custom ground high-lift cams and the IXIL race spec header, so most definitely has to have dyno tuned after install.
The dyno tuner was very knowledgeable and dealt with a handful of CBR500s in his time, was keen to see what this little bike can actually do with a proper tickle. He did quite a number of runs with different configss to find the best combo, not just for top-end but all round tractability. Because my modifications have been progressed over time, and through the course of changes I'd been doing my own tuning via the DynoJet AutoTune, there is no base run available. The "base-run" line in the dyno image below as the tune as it was at that stage.

The dyno run was done at sea level with ambient temperatures of ~22*C. Just completed major 25K kilometer service (26K on the odo) days before; so new plugs and all new fluids (Honda 10W-30 oil).
Some of the key outcomes of the dyno work:
-1.5-2hp gain having the slip-on baffle installed... a little back pressure can be good.
-'potentially' a couple more hp can be gained with increasing the size of the air filter inlet hole
-Interestingly, most of the fuel map has less fuel input at any given rpm. (Don't get confused thinking stock runs rich, there's more dynamics at play with this)

Base line runs of stock bikes he said, and can also be found comparatively from other sources on the internet, yield averages at the wheel of 42-43hp and 28-29ft-lb torque.

My dyno chart:

To help make things easier though, I've taken 4 different stock dyno results sourced from the internet, plotted them in Excel and then took the average of them and charted alongside the results from my figures, and derived the below comparative results. Note, my engine has Rev X-Tend enabled to 9600rpm, cut-out for stock is 9100.


So how does my bike feel these days?
It's got more pull than a wild Bangkok night!
With 32ft-lb available from 3600rpm rising to a peak of 36ft-lb between 6600-7800rpm, I can pretty much use one gear higher even with a taller 38T sprocket.
In 6th gear doing 70kph at ~4K rpm it will accelerate to 100kph in under 4 Mississippi - yes, that is an accurate measurement :P
The relaxed riding rev range, i.e. grandma riding commuting duties, is between 2500 and 4000rpm; 3rd & 4th gears has plenty of pull even as low as 2000rpm.
And when you feel like getting on it, it's like it has a little power band after 6K, from that to 6600, it jumps 4ft-lb... you do notice it, thinking "oh hello!" 7K, 8K, 9K, oh that grin factor

Now with the baffle in, it's quieter than before, which is nice when you just want to cruise. And with the better fuel map, I'm anticipating a reduction in fuel consumption too, well, so long as I can log a full tank run without getting too excited with the throttle.

Here's what it's looking like these days









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Last edited by tothezenith; 07-02-2016 at 01:30 PM. Reason: grammar
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post #2 of 72 (permalink) Old 07-02-2016, 10:53 AM
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A few accents are bit too much of a bling for me - but that's only me and the most important that you like it this way. In genereal I can only congratulate.
One can see that you really care for this bike.
Thanks for showing the community what can be done with the engine with bolt-on stuff it is a new ference from now on.
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post #3 of 72 (permalink) Old 07-02-2016, 10:56 AM Thread Starter
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@Oyabun the cam specs may be hard to acquire, especially seeing they are installed now. The company didn't have them when I asked. I'd gone to them with the specs from the Daniel Crower website, they said they "wouldn't be able to grind stock ones to those specs, but they'll give 'em a bit more lift and in the grind process will probably get a little more duration too".
I only had a vernier gauge to get my own measurements before I put them in.
Intake heel-to-toe is 0.16mm smaller
Exhaust heel-to-toe is 0.30mm smaller
Based on the change in shims sizes, the tuner reckons the rockers are about a 1.6 ratio; so it's a pretty mild cam. Considering that, I'm quite impressed with the results.

Refer attached the PC-V map from the tuner.
This is for engine with:
Camshafts as noted above
port matched exhaust outlets
mildly ported and polished throttle bodies
IXIL decat race header
Yoshimura R-77 slip-on with baffle installed
PAIR system removed
K&N air filter
PC-V Rev X-Tend enabled to 9600rpm
Tuned at sea level with RON95 fuel.

----for reference---
the DCR cam specs are:
.355" intake /.355" exhaust lift
.165" cam lift intake and exhaust
226 duration intake and exhaust
.012" intake / .014" exhaust clearance
lobe centerline intake 106
lobe centerline exhaust 104
Attached Files
File Type: zip PCVmap160701.zip (1.1 KB, 20 views)

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post #4 of 72 (permalink) Old 07-03-2016, 01:48 AM
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tothezenith,
so you got your stock Honda cams ground to a new profile, that cool. Did you need to get both of them done, or just the intake cam? thanks, Grant.
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post #5 of 72 (permalink) Old 07-03-2016, 03:47 AM
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Quote:
Originally Posted by granteuk View Post
tothezenith,
so you got your stock Honda cams ground to a new profile, that cool. Did you need to get both of them done, or just the intake cam? thanks, Grant.
As I see from the specs bot of the cams have been reground though to a smaller degree than the DCR ones.
I suggest to read your race specifications throughly. Do they allow modification of cams? Head work? Custom ECU?

Last edited by Oyabun; 07-03-2016 at 12:28 PM.
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post #6 of 72 (permalink) Old 07-03-2016, 09:48 AM
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Awesome build.
When they ground the cams, Did they add metal to the lobes, then grind? They would have to be hardened afterwards, correct?
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post #7 of 72 (permalink) Old 07-03-2016, 05:49 PM Thread Starter
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Quote:
Originally Posted by blipco View Post
Awesome build.
When they ground the cams, Did they add metal to the lobes, then grind? They would have to be hardened afterwards, correct?
No they remove metal from the heel and into section of the ramp, the toe stays the same height. The extra lift come from the taller shims.
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post #8 of 72 (permalink) Old 07-03-2016, 05:58 PM Thread Starter
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so after having a good 280km ride yesterday to really get a feel of the results; about 60%city, 30%highway, 10fun, used 9.8L or 3.5L/100km. Will need to get more sample data, but from this run will say there is no loss in economy, if anything slightly better than what I was getting previously, typically 3.6-3.7L/100km.
With the baffle in it is quieter, but to be honest I don't really like the sound; line someone's put a duck's bill on a farting hippo, in the pursuit of best output though, I'll live with it.
That 4sec mississippi count 70-100 must've been in 5th not 6th previously mentioned. Geez it's got low down pull, I'm going to have to get my camera on too do some test runs to be able to get accurate figures. The grin factor us awesome though
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post #9 of 72 (permalink) Old 07-04-2016, 03:15 AM
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Originally Posted by tothezenith View Post
No they remove metal from the heel and into section of the ramp, the toe stays the same height. The extra lift come from the taller shims.
Interesting. Thanks.
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post #10 of 72 (permalink) Old 07-04-2016, 08:29 AM
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I've found a guy in Melbourne who can apparently re-flash the CBR500R ECU with a new programme. charges $470.
I'm waiting to hear from him how many 500s he's done and how many different maps he has to accomodate different mods

http://http://motorcycleworkshop.com.au/flash-tune-ecu/
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