550 to 496 conversion?

Gokai134 · Aug 16, 2011

Hi Guys,

I own a 2008/Fe550 and now it´s time for a major rebuild.

I`m thinking about reducing the displacement to 496ccm (As used by the Factory Riders some years ago)
So here´s my questions:
Is the conversion just an simply "plug and play" with a 501 sleeve (95mm) and 501 piston?
Or is the 501 piston different to the 100 mm (Deck heigt, pocket size, weight?)
Rebalancing of the crank necessary with the 501 piston?
Or does any other piston fot?

Has anybody done this conversion before? (tm-enduro has one ex-works 496 bike, but (as far as I know) bought it already with this displacement)

Thanks for any replies

Peter

What parts are necessary for the conversion?

stefan2230 · Aug 16, 2011

Hi Peter,

in 2007 and 2008 i build two 496 by myself. It was realy easy, you just need a piston-kit, sleeve and a head gasket, connecting link for timing chain, waterpump gasket, clutchcover gasket.
If you use a used engine some of the big O-rings around the sleeve will be a good option. If you just change piston and sleev, the Crankstaft can stay in the left engine case (after fitting the last circlip you still can turn the sleeve 180 around).
No changes on carburator or ignition, maybe another front or rear sprocket (14/48).

stefan

Gokai134 · Aug 16, 2011

Hi Stefan,

thanks for the reply.

This is good news -so it´s basically a "plug and play" rebuild.
Sorry, that I didn´t mention the gasket set, but it´s a complete rebuilt (new mains and & timing chain will be replaced anyway), but thanks for the info, that the sleeve can be placed without removing both cases.

I assume, you´ve been using the Wössner piston "8537D*" - as there´s price difference to OEM is 250% ? :?:
Or did you use any other piston brand?
Did you measure compression or how did you decide to use the stock (1,4mm) headgasket ?

Peter

550 to 496 conversion?

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