Gen 5 CR500AFX build started on 01.12.2012

IMG00205-20130416-2034 by fmikhele, on Flickr

Here is the E-line and rectifier, been reading through the forms and cant find any wiring diagrams. Going to keep it simple, no battery, possibly a switch for the high/low beam? (not sure if its worth it)... Any advice, diagrams or a link to someones post regarding this would be greatly appreciated.

IMG00201-20130416-2021 by fmikhele, on Flickr

IMG00202-20130416-2021 by fmikhele, on Flickr

IMG00203-20130416-2022 by fmikhele, on Flickr

josh · Post by **josh** » April 17th, 2013, 9:33 pm

i was going to go this route

http://www.supermotojunkie.com/showthre ... c-Reg-take

fmikhele · Post by **fmikhele** » April 23rd, 2013, 1:06 pm

Thanks for the reply. I found this from trail-tech and liked it because its adjustable. I am going to try it out...

Regulator by fmikhele, on Flickr

Going to wire it as the E-line manual says...

E-line by fmikhele, on Flickr

fmikhele · Post by **fmikhele** » April 24th, 2013, 6:02 pm

Waiting on a few parts...

DSC01018 by fmikhele, on Flickr

DSC01019 by fmikhele, on Flickr

Where is everyone doing there custom AF decals?

fmikhele · Post by **fmikhele** » April 26th, 2013, 2:47 am

She's a runner!

Fired right up, decompression head works good. Little trickle of coolant coming from the waterpump between one of the gaskets and the separator plate. I installed a new separator plate during the rebuild and I think I should have put just the plate in there first and tighten down the waterpump cover to "take the shape" of the sealing surface and then re-assemble with the gaskets...

Also a little bit seepage at the cylinder head near two of the stud bolts in the cross bike direction (side to side) Had to do new studs with the new cylinder so its the first time the cylinders had a head torqued on it... I've heat cycled the bike a few times hoping it seals up!?!

Kuma · Post by **Kuma** » April 26th, 2013, 12:11 pm

Looks great, are you going to put blinkers on and make it street legal? How is that dry clutch working

fmikhele · Post by **fmikhele** » April 26th, 2013, 1:10 pm

Thanks man

To be honest kind of had an oops with the wife

So the bike may be forsale soon enough... It would be pretty sweet to make it road legal thou! The dry clutch works great if you dont get it dirty

fmikhele · Post by **fmikhele** » April 27th, 2013, 6:48 pm

All together... Still have to do the wiring for the lighting and a few other odds and ends

DSC01020 by fmikhele, on Flickr

DSC01021 by fmikhele, on Flickr

CR500AFX · Post by **CR500AFX** » June 18th, 2013, 5:36 am

Looks good, nice work

Post by **AlisoBob** » June 18th, 2013, 6:37 am

Sweet!

Gravel Scratcher · Post by **Gravel Scratcher** » June 18th, 2013, 3:45 pm

Very tidy, selling it after all the work would really suck

fmikhele · Post by **fmikhele** » June 18th, 2013, 4:05 pm

Yes, it is currently forsale! It does suck, but I can always make another

fmikhele · Post by **fmikhele** » May 27th, 2014, 3:44 am

Sold for $6000

JohnnyAirtime · Post by **JohnnyAirtime** » January 4th, 2015, 10:14 pm

fmikhele wrote:Purchased another airbox adapter plate from DZ and made some hinges

DSC01000 by fmikhele, on Flickr

Sorry to hear you sold this gem... but am thankful you documented the work as you did. As I'm about to embark on the same journey.

... have to ask; Why not use the original adapter plate and the OEM plastic hinges that you were first trying out? Did it not work as planned?

Also, any reason you chose this kit... and not CP500's kit? I'm going to buy a kit, but want to make sure it's as close to accurate as possible.

Thanks!

fmikhele · Post by **fmikhele** » January 12th, 2015, 8:12 pm

Sorry to hear you sold this gem... but am thankful you documented the work as you did. As I'm about to embark on the same journey.

... have to ask; Why not use the original adapter plate and the OEM plastic hinges that you were first trying out? Did it not work as planned?

Both methods worked, but in the end I felt like the second design was more of an OEM look.

Also, any reason you chose this kit... and not CP500's kit? I'm going to buy a kit, but want to make sure it's as close to accurate as possible.

Thanks!

This build was using CP500 parts if you look at the build pics...

Good luck with your build

JohnnyAirtime · Post by **JohnnyAirtime** » January 20th, 2015, 8:54 am

Awesome... thank you for the replies!!

I bought the CP500 kit, and am acquiring parts now. Have almost all I need, and am like a kid in a candy store. Trying to be patient!!

The newer air box mod with the mini alum hinges. How did you secure them? They don't look welded to the plate. Epoxy maybe?

Again... thanks, your thread is helping me immensely!!!

fmikhele · Post by **fmikhele** » January 28th, 2015, 4:40 am

Patience young grasshopper!

I believe in this photo the hinges were tack welded (on the back side) and I welded them in after and powder coated the finished plate.

No problem, glad to help

BannedCR500Riders.com

Gen 5 CR500AFX build started on 01.12.2012