soooo, what year frame takes the least fabwork?

[LAYNFRM]

i'm really wanting to build a street driven CR500AF supermotard, and have wanted to for a long time now. i have a 06 CRF450X supermotard (already plated), and a 00 CR250 (would have to get the title, major PITA). would either of those bikes be an easy conversion, or would it be less expensive/easier to build a different year model? i don't know the years of each Gen frame, so that would help too. whatever year i end up doing, it will definitely be getting a larger tank for those 150-200 mile days. will the aftermarket tanks fit with the different motor? how much work is it to get an exhaust, or make one fit. what about the air boot/box? run a pod filter instead?

i was told my 00 cr250 is a Gen2 frame. could the suspension off my CR250 fit on a gen1 frame? i know generally some random things are interchangable between different frames to keep production costs down. if needbe, i guess i could sell the CR250 to get a different rolling chassis.

i've looked on here for most of these questions, but some of it is hard to decifer for someone who has never fabbed anything like this, and of course some are a little biased to what they have done. a friend who has done similar things will be helping do all this.

[Roostius_Maximus]

sounding like the 02 250's (gen3) are the easiest with no tank or airbox mods, and shared lower mounts

[LAYNFRM]

so on the 02, you have to modify the Y on the frame, the front motor mounts, headstay, exhaust, and possibly the radiators?

what else is required when converting the 06?

[JBaze]

From what I have learned from these guys here is that the Gen 1 is the easiest build. Pretty much amounting to moving the front engine mounts. I could be misinformed though. Mine is a Gen 2 an 01 250, and I had to move the Y section and lengthen the frame a little to accept the 500 motor. No airbox mods or fuel tank mods either.

[south central hoon]

if you have the parts in hand, you can take a running gen1 250 and make a gen 1 500 in 7-10 hours labor.

[Exnav]

if you have the parts in hand, you can take a running gen1 250 and make a gen 1 500 in 7-10 hours labor.

true dat

[lewisclan]

if you have the parts in hand, you can take a running gen1 250 and make a gen 1 500 in 7-10 hours labor.

yep and that includes re building the motor re-springing the fronts & rear

[Balaclava]

if you have the parts in hand, you can take a running gen1 250 and make a gen 1 500 in 7-10 hours labor.

I'm at about 12 hours total of actual fab work on my Gen 3...I don't really have much left to fab but my rads, and silencer mounts. I figure a total of 15-20 hours for the gen3...which is by far the cleanest looking and most likely the best platform for a 500 engine. Gen1 is deffinately the easiest but who wants easy anyways, it's more enjoyable when you have to work things out.

[Exnav]

See any of the Gen 1 builds that are stickied. I had more time cleaning everything than doing the swap. Beyond simple.

[Spooled-up]

I found this in my reading on this site:

GEN 1- '97-'99 CR250
'98-'99 CR125

GEN 2- '00-'01 CR250 and 125

GEN 3- '02-'07 CR250 and 125
'02-'04 CRF450 (although had handling problems the 250 didn't)

GEN 4- '04-'08 CRF250R (and the X model, when it started)
'05-'08 CRF450R( and X)

[AlisoBob]

See any of the Gen 1 builds that are stickied. I had more time cleaning everything than doing the swap. Beyond simple.

Yup......

[hoofarted]

Gen2 and Gen3 are about the same in terms of conversion. Biggest advantage is the lack of a need to mod the tank. You can just pop on a desert tank. Plus handling on the Gen2/3 is better than a Gen1. Gen2/3 also vibe less due to less rigid frames. See my Gen2 build here:

http://www.bannedcr500riders.com/board/ ... php?t=3653

My build and JBaze's builds are virtually the same. G/L with whatever you decide to do.

[LAYNFRM]

sadly, i think i'm gonna look into doing the gen4 build since i can get more money for my 450 motor. i don't know what the 00 CR250 motor is worth, but if i can get a title for it, that's my other option. i appreciate all the replies.