panthera CR500 User manual

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
List of Panthera parts you need
1- Panthera starter electric motor
2- CRF450x 110W Stator
3- CRF450x backward adapted flywheel
4- High strength flywheel adapter
5- One way clutch
6- Main starter gear
7- Needle bearing
8- Bolting nut and bearing holder
9- Panthera starter cover and cap
10-Sealed ball bearing
11-Crown starter gear
12-Intermediate gear
13-Sprocket guard and motor mounting
14-Starter relay

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Hardwares
Botton socket head cap screw
Socket head cap screw
Flat socket head cap screw

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Installation
CRF450x Stator
The starter unit will require to run oil in the flywheel compartment. To do so, you will have to block the
CR500 flywheel vent hole. Use silicone or any other sealing compound that has oil sealing capability.
Figure 1 Vent sealing
As you receive your unit, the new CRF450X stator will be already bolted, loctited and troque to its
backplate.
Bolt the new stator unit to the cases with two button heap cap screw. The stator plate as angle goes
from +3 to -3 deg, zero being in the middle position.
Figure 2 Stator installation

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Place the rubber boot into its proper location in the case opening. Place the cable back to ensure they
won’t touch the flywheel. Zip tie the pick up cable and the stator cable together and place them as deep
as possible.
Once the cables and boot at the proper location, fill the opening of the rubber boot with silicone to seal
the boot.
Flywheel
Align the flywheel with the key way and slide it in place. You will have to fight the magnets to place it
straight and all the way down.
Once you will have the flywheel bolted, spin the flywheel (and motor) by hand to make sure you don’t
feel any rubbing between the flywheel and the stator. This can happen if the stator back plate is not
properly sitting, or sometime with after market stators that happen to be thicker.
One way clutch and ring gear
If you have taken off the one way clutch and ring gear from the flywheel, you can easily put it back on by
pushing it on the flywheel with a clockwise rotation.
Bolting the flywheel
Bolt the flywheel in place with the specially designed element. You will simply need a 1/2in extension on
your torque wrench or even use the torque wrench itself. Use the gear holder tool supplied to prevent
the engine from turning.
!! Do not forget the needle bearing before putting the bolting unit !!
!!! The flywheel has to be torque at 70 ft-lb. Not doing so will have the key way sheared by the starter!!!
Figure 3 Flywheel torqueing

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
The flywheel trigger bump will tend to touch the rubber boot. You will have to shave the rubber slightly
with a blade.
Figure 4 Rubber boot shaving
Sprocket guard
The billet sprocket guard supplied with the kit is necessary as it holds the electric motor in place.
Bolt the guard in place with the supplied socket cap screw, or any other M6x1.0 bolts you like.
The sprocket guard is designed to receive up to a 15 teeth sprocket.
Starter cover
To install the cover, remove the two small gears from behind the gears cap. Leaving the gears will make
it hard to put the cover on and align the gear at the same time, you will risk damaging the gears.
Do not forget to put the gasket on the cover.
Align the starter cover so that the flywheel bolting unit slides in the bearing inside the cover. This
bearing ensure that the main ring gear is at the exact right distance to the secondary gear.
Bolt the cover in place with standard honda flywheel cover bolts or any other M6x1.0 bolt you like.
!!! Before putting the gears back in, putt 300ml of gear oil in the cover.
But back the gears in place, top gear first.
Then put back the gear cap in place with its gasket, and torque back all the bolts to 84 in-lb.
Starter motor
Slide the starter motor in gently. Put grease on the o-ring to ensure not damaging it. Putting grease on
the starter shaft will also help for the first dry start. Finding the gear alignment might require to rotate
the motor a couple degrees. Bolt the motor to the sprocket guard.

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
!!! IMPORTANT !!!
First start up should always be done by foot,
with the gears out of the unit. Firing a new
ignition system should always be tried without
e-start first. Wrong wiring can end up with
backfiring and risk damaging the starter gears.
Electrical connection
For wiring, see the wiring diagram at the end of the document.
Connector are supplied for you to match the new stator connectors.
Battery
The recommended battery is a lithium battery of at least 4.5 Ah and 250 cranking amp.
For those who will run the unit in very cold environment, a lead battery with a 250 cranking amp
capacity will work.
Starter relay
The starter relay included in the kit can be place anywhere on the bike. It is best to place it near the
battery and make the power cable from the battery to the relay to the electric motor the shortest
possible the limit the resistance.

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Wiring diagram

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Security concerns
Engine assembly must always be accomplished by a qualified mechanic.
Use the proper tools for every operation and always wear the proper personal protective equipment
(glass, gloves, etc.)
The parts sold by Panthera Motorsports are often machined parts and are at risk of having sharp edges.
Always handle with care.

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Returns and Exchanges
General:
All returns must be postmarked no later than 10 days from the original customer shipment date.
Returns and exchanges must be in new condition and must include all instructions and original packing
material. Customer pays all return shipping charges. Include a copy of your packing list and authorization
number with all returns.
Original shipping and handling charges are not refundable. Returns must be preauthorized by us and are
subject to a 20% re-stocking fee. These amounts will be deducted from the original amount billed and
the remaining balance will be credited to the original credit card or paypall account.
Incorrect Item:
If you received an incorrect item, we must be notified within 10 days of receipt of the shipment so that
no extra charges will be incurred. We will replace incorrect items and pay the additional shipping
charge. No returns of items will be accepted beyond 21 days of the original shipment date.
Return Shipping Instructions:
Return via prepaid mail only. Insure shipment for full value of purchase. Use original packaging. We are
not responsible for packages lost during return shipping.
Return/Exchange Instructions:
Enclose a copy of your packing list along with detailed return/exchange instructions.
All returns require prior authorization by e-mailing us at [e-mail] . All
return shipping charges will be the responsibility of the customer. No returns on items under $30.00 will
be approved. Items must be returned within 90 days of the original order date in the original packaging
with the labels intact.

PANTHERA MOTORSPORTS
PANTHERA CR500 E-START Installation guide
Warranty Items:
All merchandise manufactured by Panthera Motorsports has a warranty against manufacturing defects
for a period of one (1) year from the date of original shipping. Warranty is limited to the repair or
replacement of defective products. There is no warranty for normal wear and tear, any type of crash.
Panthera Motorsports reserves the right to repair, replace or issue a Panthera credit for defective
product at its discretion. Credits are valid for a period of one (1) year from issuance. No credit will be
issued for labor or other costs incurred beyond the value of the original product. Product returned as a
warranty after having been used, if found to be defective, is not valued at the full purchase price. A
depreciated value will be estimated for used product. Warranty excludes product that has been
modified or where the product was improperly installed, abnormally used or misused. This limited
warranty is in lieu of all other guarantees or warranties implied or expressed. This includes, without
limitation, any warranties or merchantability and fitment for a particular purpose. We make no warranty
as to products distributed by Panthera Motorsports, expressed or implied. We will, however, pass on all
warranties made by the manufacturer, who has sole responsibility for performing such warranties. A
return authorization number must be issued by Panthera Motorsports before product is returned.
Returns must be sent back to Panthera Motorsports freight prepaid. Proof of purchase, such as a copy of
the original invoice, must accompany all warranty claims. Warranties will be honored to the direct
purchaser only.