Newby looking for parts CRF 250 05 conversion

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 2:56 am

Looking for a US dealer that can help me with a decent order of parts for my 500 - looking for PC pipe and silencer (pref the AF one), silencer to match, some Boyesen engine cases, air boot required for this conversion, left hand crank case, and a few other bits I ve probably forgotten!! Also looking for any advice anyone can give on this conversion - Im in the early stages, notched the lower frame rail to make room for the clutch case to swing the motor down as much as poss, cut out the Y and grinding out the old material from that. Few Q's: what size swingarm bush do i need? from what year? what air boot? Thanks in advance, great site! Im in the UK by the way

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 9:56 am

sorry to be dumb, but i wanna post some pics up of my conversion so far. How do i do that?[/img]

dannygraves · Post by **dannygraves** » July 22nd, 2008, 10:04 am

we have had about 4-5 gen-4 crf250 conversion, everything you need to know is already on the site.
use a cr125 bushing on the right to center the motor. use a gen-1 cr250, or a cr500 airboot.
to post pics highlight the link to the pics and click the "img" button

atank · Post by **atank** » July 22nd, 2008, 10:48 am

Checkout the stickys, and chachi243's 05 build its sweet like honey

eyesky2002 · Post by **eyesky2002** » July 22nd, 2008, 11:16 am

Post pics like this below, but first you must upload them to get the URL. I use photobucket.com to host my pics.

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 12:34 pm

thanks guys. Just a link to my album - hope it works. I found an 02 CR250 air boot and just sat it on, not tried the 500 one yet. 250 one isn t far away though. No welding done yet, just the cuts. Does everyone have issues with the shock spring & crank case clearance? Saw in one thread someone took a grinder to the cases at the back. Was hoping not to do that but cant see any other way round it. Any suppliers wanna cut me a deal on the items i need? thanks

dannygraves · Post by **dannygraves** » July 22nd, 2008, 12:36 pm

that was only because Bob needs the big spring to handle the weight. I weigh 190 and the stock springs on my '04 are perfect for me and don't require trimming the cases.

eyesky2002 · Post by **eyesky2002** » July 22nd, 2008, 12:37 pm

Looks good!!

Post by **AlisoBob** » July 22nd, 2008, 12:42 pm

dannygraves wrote:that was only because Bob needs the big spring to handle the weight. I weigh 190 and the stock springs on my '04 are perfect for me and don't require trimming the cases.

Not 100% true, the "X" model has different linkage that puts the shock closer too.

Clearencing the cases is a 3 minute job, counting the time it takes to pick your beer back up.

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 12:42 pm

Its going slowly and Im no fabricator - trust me!! Have heart set on a Bailey rep so we ll see how it goes. Has anyone come up with a 'kit' for these - motor mounts and double sided head stay? Must be double sided though? thanks

dannygraves · Post by **dannygraves** » July 22nd, 2008, 12:46 pm

front mounts, yes, shanman makes them. headstay...no, the only way that would work is if the kits also contained lower mounts and everyone did their motor angle the same. I cranked mine as far forward as possible and it seems to have worked out.
I used the stock headstay and modified it to work.

Post by **AlisoBob** » July 22nd, 2008, 12:47 pm

http://www.bannedcr500riders.com/board/ ... &start=145

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 12:49 pm

OK sorry, I ve read so many threads, i dont know whos modifications are whose anymore! I like the motor rotated as much as poss. Need to notch out a little more on mine yet i think. The crf250 head mounts dont look too far off angle wise so ill have a go at chopping them up. Cos thats where my skills end!

dannygraves · Post by **dannygraves** » July 22nd, 2008, 12:51 pm

I did mine in a similar way. sorry, don't have pics... my 3YO keeps taking the digi can and snapping pics of the dogs and his starwars action figures and burns through the batteries

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 12:51 pm

AlisoBob wrote:http://www.bannedcr500riders.com/board/ ... &start=145

And then just weld them 2 pieces together? No recommendations on suppliers yet? thanks

eyesky2002 · Post by **eyesky2002** » July 22nd, 2008, 12:53 pm

jpddb100 wrote: Cos thats where my skills end!

Don't cut yourself short, a lot of us with minimal skills and tools have and are currently building our own!!!

jpddb100 · Post by **jpddb100** » July 22nd, 2008, 12:57 pm

me included! Pretty scary taking a grinder to a perfectly good Honda frame, but im getting kicks out of it already. Not ridden a 500 for 8 years - bring it on!

dannygraves · Post by **dannygraves** » July 22nd, 2008, 1:07 pm

its been a while since I updated my build, check it out
http://www.bannedcr500riders.com/board/ ... 52&start=0

dannygraves · Post by **dannygraves** » July 22nd, 2008, 1:08 pm

shit, I welded my own frame and had zero aluminum welding experience.

teemtrubble · Post by **teemtrubble** » July 22nd, 2008, 3:09 pm

Do not use a "Grinder" ever! Only use a saw, file, rotary file. Do not deburr your aluminum parts ever with abrasives if your going to weld them it contaminates the material.

Post by **AlisoBob** » July 22nd, 2008, 5:08 pm

Yuuuuuuuuuuup......

JBaze · Post by **JBaze** » July 22nd, 2008, 6:23 pm

Listen to those guys about the grinder!!! Thats what I did, then got to spend a couple hours "cleaning" with hand files.

jpddb100 · Post by **jpddb100** » July 23rd, 2008, 2:58 am

By a grinder, I meant a grinder with thin metal cutting blade. Not sure if that counts or not. Getting the material from the Y milled out today so will post more pics later

Post by **AlisoBob** » July 23rd, 2008, 6:25 am

If it has physical "Teeth", its o.k.

If it is "Abrasive".....its not.

nmdesertrider · Post by **nmdesertrider** » July 23rd, 2008, 6:29 am

I have heard this one way too many times.
Does the abrasive contaminate the weld? Sure along with a dozen other things.
Does it make the weld weaker in the cr500 application? I think the jury is out on that.

BannedCR500Riders.com

Newby looking for parts CRF 250 05 conversion

Newby looking for parts CRF 250 05 conversion