JR's Gen 3
JR's Gen 3
Well, i finally got up the courage to hack up my 250, beer helps. Bought it in April for the sole purpose of converting. Bike is an 02. Got an 85 engine thats going in it, fresh top end by Millar Engines (and a decomp too!) bottom is tight, gonna run it for now.
Wheel bearings in lovely shape
It ran awesome so i decided to ride it for a bit while my engine was being rebuilt. Proceeded to crash the shit out of it and wreck myself for a couple weeks, (been a couple years i was due).
rode it for the last time last weekend in the mountains, then started pulling crap apart
Wheel bearings in lovely shape
It ran awesome so i decided to ride it for a bit while my engine was being rebuilt. Proceeded to crash the shit out of it and wreck myself for a couple weeks, (been a couple years i was due).
rode it for the last time last weekend in the mountains, then started pulling crap apart
Last edited by JR650 on June 7th, 2009, 10:25 pm, edited 2 times in total.
00 XR650R street legal SM
02 250/500
02 250/500
turns out hydro jacks dont work upside down, had to go get the 45K tool out of the truck
y needs room
so, not sure if this has been done before, but it works awesome, one its nigyvered up
and some really smashed up hands, try getting the drill stopped before your hand smacks the frame, well excercised fuck word
y needs room
so, not sure if this has been done before, but it works awesome, one its nigyvered up
and some really smashed up hands, try getting the drill stopped before your hand smacks the frame, well excercised fuck word
00 XR650R street legal SM
02 250/500
02 250/500
the chunk
a nice arch, very close to factory radius (3.25" holesaw)
followed the exhaust angle as good as i could
building motor mounts, freehand with a drill, beltgrinder and bandsaw, started as 1.25 solid round 6061. I need a mill
light is bad, but the hole is in the same spot
thats where she sits tonight, mocked up but i didnt get a shot of it, dont know how im going to do the coolant hose to 85 style jug around pc pipe thing yet.
a nice arch, very close to factory radius (3.25" holesaw)
followed the exhaust angle as good as i could
building motor mounts, freehand with a drill, beltgrinder and bandsaw, started as 1.25 solid round 6061. I need a mill
light is bad, but the hole is in the same spot
thats where she sits tonight, mocked up but i didnt get a shot of it, dont know how im going to do the coolant hose to 85 style jug around pc pipe thing yet.
00 XR650R street legal SM
02 250/500
02 250/500
I love the lateral thinking that people show, a block & holesaw - absofuckinglutely brilliant !
And the "well exercised fuck word" - yup, works better than meds. at times
I've probably got it wrong with this (took out a low hanging tree with my head yesterday, feeling spaced out), have you given thought to clearance if you have to put a long rod & spacer under the cylinder @ some time?
Great idea
And the "well exercised fuck word" - yup, works better than meds. at times
I've probably got it wrong with this (took out a low hanging tree with my head yesterday, feeling spaced out), have you given thought to clearance if you have to put a long rod & spacer under the cylinder @ some time?
Great idea
Last edited by bearorso on June 8th, 2009, 7:05 am, edited 1 time in total.
- Roostius_Maximus
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I like it
http://www.youtube.com/user/500bigbore
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- Roostius_Maximus
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Make LOTS of spring clearence room
http://www.youtube.com/user/500bigbore
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
now comes the fun part(s)
kicker is going to have to be indexed (using 250 kicker for now)
Is anybody using a short rod with old style jug in a gen 3?? because i dont know how the hell im going to get the line from the pump to the jug in here
going to pull the motor and do some clearancing right away here, i have room to bolt it in right now, but not once its welded shut i dont think
kicker is going to have to be indexed (using 250 kicker for now)
Is anybody using a short rod with old style jug in a gen 3?? because i dont know how the hell im going to get the line from the pump to the jug in here
going to pull the motor and do some clearancing right away here, i have room to bolt it in right now, but not once its welded shut i dont think
00 XR650R street legal SM
02 250/500
02 250/500
Couple other quick questions, what clutch cable works on these things?? newer 500?? and also throttle as it looks like it has a different end than the 250 did. the carb (PJ) has a 168 main in it, are these just normal keihin hex jets?? ive got from 170-185 for the 650 if they are the same, im not starting that lean. Any help is appreciated, thanks, JR
00 XR650R street legal SM
02 250/500
02 250/500
- Roostius_Maximus
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i like that kicker. My bro and Nick wanted to try my bike, i said sure, with the 250 kicker neither could start it without the decompressor.
http://www.youtube.com/user/500bigbore
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
Turns out an m10x165 bolt is really hard to come by. grade 8 3/8x7 sae is 10thou bigger diameter than the factory front bolt so im using it until the right one shows up, less slop anyways. dropped the rad off to get modded, ordered an 01cr5 clutch cable at the dealership, hope it works.
00 XR650R street legal SM
02 250/500
02 250/500
Awesome!
The spacing between the pipe and cylinder doesn't look much different than on my gen 1.
I have the pipe rotated out so as to give as much spacing as possible, and I cut the hose on an angle to that it points towards the front of the bike and spliced in a copper 90 to clear the pipe. I also beat on the pipe a lbit with a rubber hammer, but very little.
The spacing between the pipe and cylinder doesn't look much different than on my gen 1.
I have the pipe rotated out so as to give as much spacing as possible, and I cut the hose on an angle to that it points towards the front of the bike and spliced in a copper 90 to clear the pipe. I also beat on the pipe a lbit with a rubber hammer, but very little.
Yah, I'm from Saskatchetoon!
MRE 02 250/500 conversion, pulse injector, twirp porting, coolhead, MRE ignition, blah blah blah blah... www.millarengines.com
MRE 02 250/500 conversion, pulse injector, twirp porting, coolhead, MRE ignition, blah blah blah blah... www.millarengines.com
- Roostius_Maximus
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i used a jug that had dual drain plugs, so i cut the pipe side part down as much as possible and put a button head plug in there so the fatty pipe cleared and installed easier
http://www.youtube.com/user/500bigbore
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
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- dannygraves
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Ill check that hose out, thanks. had to work today so didnt get much done, picked up the rad, good to go there. going to tear it apart and get it all prepped for weld tonight, A good buddy welds aluminum for a living, so he is going to burn it all together for me tomorrow night, hope to hear it run this weekend.
00 XR650R street legal SM
02 250/500
02 250/500
Shes all welded up. I told buddy make it strong pretty comes second, well, its strong. ended up having to mig it, the filler for the y after I finished clearancing was a real funny shape and tough to fit close enough to make a nice tig weld, might redo a bit for asthetics this winter, for now its gonna get ridden. ill get pics tomorrow, doesnt look bad just not perfect row of dimes. Getting closer have some reassembly action tomorrow night.
00 XR650R street legal SM
02 250/500
02 250/500
- dannygraves
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got home from work, put some of the huge pile of parts together, repacked all the bearings that i could, you know exciting stuff
weld pics, I had the motor in before I remembered
so, got it to being a roller and remembered i havent clearanced the cases yet, but the motor is in at least, forks on, seals still blown, put one rad on, still need to bend the crossover on the left side. is everybody just using heater hose for the upper lines??
weld pics, I had the motor in before I remembered
so, got it to being a roller and remembered i havent clearanced the cases yet, but the motor is in at least, forks on, seals still blown, put one rad on, still need to bend the crossover on the left side. is everybody just using heater hose for the upper lines??
00 XR650R street legal SM
02 250/500
02 250/500
- Roostius_Maximus
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i didnt clearence the cases on my 250 chassis, had a pile of room then, and hasnt contacted yet
http://www.youtube.com/user/500bigbore
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
My CR500 Tech Reference... http://sdrv.ms/1a0CIiz
MRE Components... http://sdrv.ms/1bs2zhd
Really simple....JR650 wrote:.... i havent clearanced the cases yet, but the motor is in at least...
Get a angle grinder, like this...
The diameter on the wheel needs to aproximate the diameter of the spring.
Hold the grinder spindle at the same angle as centerline of the installed rear shock.
Slowly plunge the edge of the grinding wheel into the case, while moving it up and down along the imaginary "centerline" of the shock....
It should result in this...
- dannygraves
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- Joined: June 1st, 2007, 2:03 pm
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Interent took a shit yesterday am, so im short a sparkplug that i couldnt find a number for. got the cases clearanced, pipe is on checked the torque on pretty much every bolt, clutch cable is on. For the record, the 01cr5 cable fits perfect, except its bigger diameter than the 250 adjuster, no big deal tio fix., clutch is lighter than i expected, springs going maybe? barring some natural disaster, it should run today *knock on wood*.
00 XR650R street legal SM
02 250/500
02 250/500