Posted: January 29th, 2008, 9:12 am
Basically, I just heated the bottom of the tank with a heat gun. My son and I used wooden hammer handles to push it in once heated and cooled it with a blow gun. I'll take a pic of it next time I have it off. For now, you can save some of the earlier photos I posted of the clearance, and blow them up. The Acerbis tank went from 2.9 to 2.7 gallons.
I'm not known to waste time, so the build lasted 27 days. I fabricated everything except the airbox and silencer before the frame was welded. After welding, I installed stainless thread inserts in all the new brackets. The silencer was done like Bob's.
The airbox is the stock one for the bike. I installed a 2000 cr250r air boot, which has the same mounting pattern as a cr500, but has a step in it for the spring. Honda part # 17253-KZ3-J20. I used a piece of .050 in aluminum to install the boot onto the front of the box with plenty of RTV sealant. The rest of the parts came from a cr500 airbox.
I haven't had her in the woods yet, but she felt good in the yard. I hope to ride it this weekend.
I'm not known to waste time, so the build lasted 27 days. I fabricated everything except the airbox and silencer before the frame was welded. After welding, I installed stainless thread inserts in all the new brackets. The silencer was done like Bob's.
The airbox is the stock one for the bike. I installed a 2000 cr250r air boot, which has the same mounting pattern as a cr500, but has a step in it for the spring. Honda part # 17253-KZ3-J20. I used a piece of .050 in aluminum to install the boot onto the front of the box with plenty of RTV sealant. The rest of the parts came from a cr500 airbox.
I haven't had her in the woods yet, but she felt good in the yard. I hope to ride it this weekend.
