Jay Lewis's Gen 1 A/F Conversion

lewisclan · Post by **lewisclan** » October 5th, 2007, 6:50 pm

its all about the love brother

Post by **AlisoBob** » October 7th, 2007, 10:13 pm

lewisclan wrote:its all about the love brother

lewisclan · Post by **lewisclan** » October 7th, 2007, 11:10 pm

I love you bro and you know it. I will post up the photos I had to re take ended up dleating 195 photos off our camera so all I have now are the finished photos I know what a screw up........
I still need to figure out the brake resiovor mount & I need to run a die over the crank mag threads befor I can run it

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I added an extra reed block spacer to help the short air boot problem but as you can see I still need a biger spacer

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here is a shot of the bitchen welding Bob guy did totaly awesome

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I fricken lost all the assembly photos ... sorry guys

sabreguy · Post by **sabreguy** » October 8th, 2007, 7:37 am

That is sweet looking J!
That baby looks like it was born with that engine.
Well done fellas!!

lewisclan · Post by **lewisclan** » October 8th, 2007, 8:49 am

A Friend just gave me the part number for the brake res. mount #50409-KZ4-J00. You guys will need this bracket if the AF roller don’t come with one.
You will also need a head coolant Y or SPLITTER see the photos above.

I also think if maybe had a bigger spacer from the cyl carb mount to take up a little more room as you can see the boots are a little short.

One more thing you need to assemble the top end before you dump it into the frame. had to pull the motor to re-do the shifting syncro thing then I put it back in with the wheel mounted in the swing arm what a pain , then tried to put the cyl on No fricken go. So I had to pull the motor again and built it on the bench and installed it complete.

I guess it took me about 11 hours from start to finish but I was trying to fit different aftermarket parts on and such and had to assemble the complete frame / plastics & rebuild the top of the motor.

You could probably put one together in a few hours if it wasn’t completely taken apart.

If/ when I do another one I am sure ill shave a few hours off the build

I still need to install the hand guards & E-line coil. & the steering dampener

lewisclan · Post by **lewisclan** » October 8th, 2007, 9:11 am

I just think I found the brake res mount. man sometimes I am a dumbass
97AF Mike was that the plastic thing ziptied to the gas tank mount?

nope that wasent it Ill order one today

dannygraves · Post by **dannygraves** » October 8th, 2007, 9:46 am

lewisclan wrote:I love you bro and you know it. I will post up the photos I had to re take ended up dleating 195 photos off our camera so all I have now are the finished photos I know what a screw up........
I still need to figure out the brake resiovor mount & I need to run a die over the crank mag threads befor I can run it

[/img]

I added an extra reed block spacer to help the short air boot problem but as you can see I still need a biger spacer

[/img] here is a shot of the bitchen welding Bob guy did totaly awesome

[/img]

I fricken lost all the assembly photos ... sorry guys

NICE!

HrcRacing · Post by **HrcRacing** » October 8th, 2007, 12:19 pm

Looks great. Sweet welds for sure!

Algava · Post by **Algava** » October 8th, 2007, 4:07 pm

Looks good.I don't remember using any spacers on the intake but my bike was a 97'.I just grinded off some of the intake boot and the bolt.
Bob, I need my subframe welded for this weekend.
Any chance I can get one of your welders to help me out?

Al

97af · Post by **97af** » October 8th, 2007, 5:55 pm

lewisclan wrote:I just think I found the brake res mount. man sometimes I am a dumbass
97AF Mike was that the plastic thing ziptied to the gas tank mount?

nope that wasent it Ill order one today

Jay,
I looked in my misc box of parts.No upper mounts.Call your shop back and cancel the order.That res mount is part of the upper head stay mount and will do you no good with the 500 engine in there.
I'll keep checking but I'm 99% positive they were in one of the parts boxes.
I used a 2" long x .25" piece of aluminum for the res hanger.

iggys-amsoil · Post by **iggys-amsoil** » October 8th, 2007, 6:12 pm

Nice lookin Mosheen man!

Keep an eye on the spokes for those new rims, they will loosen up.

lewisclan · Post by **lewisclan** » October 8th, 2007, 8:25 pm

I got the guards on & the throttal tube today Now all i need is to run a die over the crank threads and a kill switch

I want to thank Alisobob #1 for helping me.
Shannon for letting the instructions out ,
Toymaker from the other site for making the custon stuff.
97AF for selling me an awsone roller.
Maddog for letting me get the steally roller
Rabbit for his help.
Thanks guys

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lewisclan · Post by **lewisclan** » October 8th, 2007, 8:30 pm

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Ported&Polished · Post by **Ported&Polished** » October 8th, 2007, 9:06 pm

lewisclan wrote:I also think if maybe had a bigger spacer from the cyl carb mount to take up a little more room as you can see the boots are a little short.

Try a rad valve in there. I think it will give you just enough extra length. And you could always use a standard piece of tubing, just a touch longer, in place of the rad valve one.

Post by **AlisoBob** » October 11th, 2007, 10:21 am

Great job Jay!

As with all finished bikes, I'm making this one a "Sticky"!!!

lewisclan · Post by **lewisclan** » October 11th, 2007, 5:07 pm

Here is the cost breakdown for the 99AFC
99 Roller & shipping $1500
95 Roller Inc new bearings & top end $1500
Handle bars, guards, grips, ant vibe inc. $330
Kick stand & shipping $165
E-Line lighting coil $255
Custom made billet parts $330
Custom cables $100
PWK Air striker-38 $165
Air cleaner $30
Kill switch $10
Exhaust stay clamps $45
New spark plugs $30
Re spring forks & shock $220
Set of sand tiers $70
Set of Bridgestone ultra heavy duty tubes $45
Billet whip & flag quick disconnect $50
Baja soltek headlight $255
Mechanic for the bottom end & respiring $180

Total $5280.00
Not bad for a totally tricked out 99AFC with head light & and extra set of wheels & tires
For a little over $3,000 you guys can build the same bike less all the aftermarket crap, and if ya build a later modle bike like Bob you can regain some of your $$ by selling the left over stuff on e-bay .....
what are you wainting for?

M.F.D.B. · Post by **M.F.D.B.** » October 19th, 2007, 9:13 am

Jay for A 500 presidentay!!

How many is it now?? 73??

Any time you wanna adopt me just say the word!!

lewisclan · Post by **lewisclan** » October 24th, 2007, 10:33 am

Road the bike in the sand and it was great I loved it until I got a rear flat then that was the end for that bike for the weekend

M.F.D.B. · Post by **M.F.D.B.** » October 24th, 2007, 11:20 am

lewisclan wrote:Road the bike in the sand and it was great I loved it until I got a rear flat then that was the end for that bike for the weekend

A flat ruined your brand new bike riding weekend??

Whats wrong, forgot to bring the kids??

lewisclan · Post by **lewisclan** » October 24th, 2007, 11:57 am

no they where on it I just road it for so long flat it runed the tire it had wire sticking through the tire and I did not have any extra rubber to replace it ........ I just grabed another bike.

dannygraves · Post by **dannygraves** » October 24th, 2007, 12:58 pm

lewisclan wrote: I just grabed another bike.

must be nice...

lewisclan · Post by **lewisclan** » October 24th, 2007, 1:00 pm

it is

Post by **AlisoBob** » October 24th, 2007, 1:25 pm

lewisclan wrote:it is

Jays staging area...

lewisclan · Post by **lewisclan** » October 24th, 2007, 2:19 pm

I can see my bike

M.F.D.B. · Post by **M.F.D.B.** » October 24th, 2007, 2:24 pm

BannedCR500Riders.com

Jay Lewis's Gen 1 A/F Conversion