Gen 3 swap, 2002 cr250 swap.... Pic Heavy
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Gen 3 swap, 2002 cr250 swap.... Pic Heavy
UPDATE>>> All done, Took 12 days from Buying 250 to finished..
Ok, Going to do it.. Bought a low hrs 2002 cr250r(keep it green stickered here in ca) today and am using my 96 500 motor and such(roller for sale).. Plan to copy a build I saw on cr500riders. more than likely here too since it looks so clean. I will try to take lots of pics
Algava's Build
http://cr500riders.com/cgi/yabb/YaBB.pl ... 12913934/0
http://www.bannedcr500riders.com/board/ ... php?t=4874
Here are the Doners
Ok, Going to do it.. Bought a low hrs 2002 cr250r(keep it green stickered here in ca) today and am using my 96 500 motor and such(roller for sale).. Plan to copy a build I saw on cr500riders. more than likely here too since it looks so clean. I will try to take lots of pics
Algava's Build
http://cr500riders.com/cgi/yabb/YaBB.pl ... 12913934/0
http://www.bannedcr500riders.com/board/ ... php?t=4874
Here are the Doners
Last edited by Hillbilly500 on March 14th, 2010, 3:18 pm, edited 3 times in total.
- caseyracing222
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- asteroid500
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
is this the one your referring too?
http://www.bannedcr500riders.com/board/ ... 89&start=0
Kinda hesitant to to bend aluminum vs a quality Tig weld, Every time I have tried bending aluminum it gets fatigued.. hmm Well at least you have me thinking now, thanks for the input
http://www.bannedcr500riders.com/board/ ... 89&start=0
Kinda hesitant to to bend aluminum vs a quality Tig weld, Every time I have tried bending aluminum it gets fatigued.. hmm Well at least you have me thinking now, thanks for the input
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thanks for the info Bob.. Good talking to you
After talking to Bob it really looks like it is hit or miss depending on each frame if it is a good way to go.. I will mock up the motor in the next week and see what looks best.. But not scared of a properly welded splice in the frame. Keep you guys posted
After talking to Bob it really looks like it is hit or miss depending on each frame if it is a good way to go.. I will mock up the motor in the next week and see what looks best.. But not scared of a properly welded splice in the frame. Keep you guys posted
Last edited by Hillbilly500 on March 1st, 2010, 7:12 am, edited 1 time in total.
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Yea, Spent good part of the weekend doing just that.. some nice stuff out there. I still think I am going to do it just like the original idea.. I don't see it being weak at all. More than likely going to start cutting this evening or tomorrow
Got alot of good info from Bob too so feel pretty confident on this swap.. Hopefully have some updates by tuesday night
Got alot of good info from Bob too so feel pretty confident on this swap.. Hopefully have some updates by tuesday night
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
Got started today on the frame mod, I have to admit the first cut was a tough one Any ways it is going really well, I used my porta band and sawzall. And to clean up things a file was a big help. Below are the steps I took today
First cut, Kinda nice took the weld flush off with the frame
Second I cut the lower radiator mounts off to make it easier to cut welds flush with frame, this ends up being awesome since when I weld the mounts back on i will kick the radiators out on the bottom slightly to make more room for the Y moving up
ground off rivot for wiring harness, dont know if I will need it again
Second frame weld cut
First cut, Kinda nice took the weld flush off with the frame
Second I cut the lower radiator mounts off to make it easier to cut welds flush with frame, this ends up being awesome since when I weld the mounts back on i will kick the radiators out on the bottom slightly to make more room for the Y moving up
ground off rivot for wiring harness, dont know if I will need it again
Second frame weld cut
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- Posts: 110
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
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- Posts: 110
- Joined: January 8th, 2010, 11:35 pm
- Location: Berry Creek, Ca.
good tip, I will do just that, Hey you want to lone or rent me a jig for a week or so? I know you have one.. I would buy one but he told me he is out of the country for a couple weeksAlisoBob wrote:You can take a large cotter pin, a piece of emery cloth... and make a small "flapper wheel" to clean out any boogers on the inside of the weld area when your done with the modifications...Hillbilly500 wrote:I am going to cut a pie shape piece out to bring the tubes in some to clear the cylinder
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Hi, looks great, you sure aren't waisting any time on this build.
The Y was pushed up just enough to clear the pipe (remember you need enough to hook up the exaust springs and the manifold bolts) but make sure the radiator bottom have enough clearance.
5/8's sounds about right but it's not critical.
Keep up the good work.
I have about 80-100 hrs on this bike.
30-40 of them are at Motocross tracks and the rest is desert riding.
My bike is not exactly a museum piece, it's dirty and the pipe all banged up.I have lost a few bolts here and there but no stractural damage yet.
I and MIKEZEROFEAR built another one he recently sold for $4500, and are doing a gen4 as we speak(I'm making the frame inserts, engine mounts and headstay).
I also have copied the build from other people, and I 'm pretty sure there must be quite a few gen3 built this way.
If the welds are done properly the Y will hold ...it's the stock one.
The Y was pushed up just enough to clear the pipe (remember you need enough to hook up the exaust springs and the manifold bolts) but make sure the radiator bottom have enough clearance.
5/8's sounds about right but it's not critical.
Keep up the good work.
I have about 80-100 hrs on this bike.
30-40 of them are at Motocross tracks and the rest is desert riding.
My bike is not exactly a museum piece, it's dirty and the pipe all banged up.I have lost a few bolts here and there but no stractural damage yet.
I and MIKEZEROFEAR built another one he recently sold for $4500, and are doing a gen4 as we speak(I'm making the frame inserts, engine mounts and headstay).
I also have copied the build from other people, and I 'm pretty sure there must be quite a few gen3 built this way.
If the welds are done properly the Y will hold ...it's the stock one.