BannedCR500Riders.com

You're going to run into the same problem I had trying to fit my '88 engine into an '05CRF250R frame--the carburetor won't clear the shock spring due to the reed cage casting on the cylinder being 7mm longer on the pre '89 cylinders. You may want to consider selling/swapping your '87 engine for an ...

The only issue I had putting an '85 engine in my '88 frame was having to slightly elongate the holes in the head stay. The '88 model PC pipe fits. I didn't have any problem using the '88 carburetor boot on the older engine.

Cool--looks like the 300 pound beast is hooking up!

Honestly, I don't know if I need to go ahead and try to run it, knowing the tank isn't pressurized. It will hold water indefinitely, but I know it's going to be bounced around on this bike, and I don't want to be the dude at the track that set's his homemade bike on fire in the middle of a race.

I ...

Maddog--One of the hoons here had given me a set of bushings that work.

Gregrobo--The bike had been changed over to the '06 dual exhaust setup, and yes, it was the first thing that sold.

This project has been on the shelf more than it should. I've got my tank looking good, but the plastic welds ...

I started a new thread on this in case there was any interest in duplicating it or doing it with a real hot air plastic welding rig.

My attempted solution for the gas tank mod on a '05 CR250R conversion has been to cut the bottom of the tank off and weld a new plastic bottom on. I bought a piece of ...

Here's some pics I promised. This is the first time I've welded plastic. I used a propane torch, which is not the optimal tool, but it can be done. My welds aren't as pretty as I would like, but the tank holds water. I will pressure test it before filling it with fuel.
To be brief, I tried and ...

Arkansas tags on the truck and car....I should know these people.

Sorry about the delay. I'm not done yet. We're racing this weekend so it'll be the first of the week before I can put some pics up. I've welded the new bottom of the tank on and it is structurally sound. I have yet to fabricate a "catch-pool" resevoir for the spigot so that the bike will not starve ...

Paul and Mrs. Stoffers,

I've been off the forum for a couple of days and just saw this. Sorry for your loss! Enjoy the memories you have. It's a blessing to have had a Dad that is involved in his son's life.

I've verified that the tank is HDPE. It's 1/4" thick. I purchased a 12x12x1/4" piece of black HDPE from Grainger for $10 that will give me enough to put a new bottom on the tank, and also fabricate the airbox-boot piece. I'm practising my plastic welding right now on scrap, but also asking around ...

I'm not savvy on airplanes--but a bbc isn't common in small planes, is it? Sure sounded good!

That's a good idea and I think I know where I can score an old tank.

But I still need to know what kind of plastic they are for the welding process. Anyone?

I think it may be High Density Polyethylene (HDPE), but need confirmation.

1. What kind of plastic are newer Honda tanks made of?
2. Where can I find some of it?

My attempt at modding my Gen4 tank with a heat gun didn't go so well. I tore a hole in the plastic next to the fuel spigot. I don't think I was going to like the results even if I hadn't had problems, because it ...

This is not my kid--looks like his dad let the kid wake up to RedBull this morning. Gotta love it!

http://youtu.be/hC0rWwlxeks

I like it at the end when the kid pulls off the old style open face helmet with the mouth guard. Takes me back!

Thanks,
We haven't done much else with the gokart--got too wrapped up with the bikes. The kart will bust the tires loose with my boy in it, but not so much with me. The little Honda clone engine really makes good power with the mods--I wish I knew where I could buy a cam for it.

http://youtu.be/ZARlEcbICXk

Spun a few laps in the heat yesterday. My son has trouble figuring out where to stand and get good shots--we've got too many trees on the private track. But the bike sounds good coming up the hill in the first second of the video, and also in the last second when I hit ...

UPDATE:
Got the EBC Dirt Racer kit in today, soaked the cork fiber plates for 2 hours, then installed it all. WOW--what a difference!

I had no idea how much performance I had been losing with the old plates--even at low rpms. Bike is faster than I realized :D . I will have to get used to how hard ...

He got caught sleeping on the line on that last run!

Didn't take him long to get there.

I just ordered an EBC drc complete kit for this bike. I didn't find a Tusk kit anywhere for the older style clutch. Could only find EBC, Barnett, and a couple of brands I didn't recognize. As said before, will plan on putting the Barnett carbon fiber in the AF because I expect it to be raced hard ...

Most every clutch lever I've ever wiggled when checkin' out bikes had near zero freeplay.

Zero freeplay kills clutches

Hadn't thought of that Bob, and yes, I'm guilty.

And thanks everyone for the input. I may put a Tusk kit in this bike, and spend the money on the carbon fiber kit on the AF ...

If you can, upgrade to a modern basket- 85 clutch sucks. That stupid little BB in there doesn't work worth a damn.

Probably not gonna happen on this bike--at least for a while. I'm putting the good money in parts for the af conversion. This bike is just the play-bike, test mule. I might even sell ...