BannedCR500Riders.com

Here is my take on the 450 headstay. Bar clamps are from 2002 RM250, bar is from a old MSR dominator handle bar which is 6061. Blocks are 1"x13/4 6061. Being able to use these made me glad I can't ever seem to throw shit away. Before you tell me my weld looks like shit, I already know it. Got a buddy in the weld shop that is doing my welding. I'm trying to learn and did this myself.
It's very solid but I do have some solid 7/8 bar and might remake another and let him weld that one.

I love it.... A little hillbilly..... But I love it!

thats pretty cool

Okay, I got a good bit more done. I'm getting close enough where I'm itching to ride the damn thing. I didn't take pictures but, I used one of Mik329s engine jigs to hold everything in place when transporting and welding of the mounts. Thanks Mik!

This is looking in from the shock. You can see my reinforcement at the back of Y and coil mounts.


This is the bottom of the lower mounts.


I got interupted while posting. Here's some more.
I had to clearance the weld a little for the bolt head on the left front mount.


These are my bolt on right front mount. I don't think there would be any way to do a in frame top end without it. It also makes roving and installing the motor a breeze. The 450 head mounts had a couple of 1" or so spacers. I milled one of those down for this.





I ran out of time again. I'll post some more of cooling system tomorrow.

cool!

but... um... your Y from the rear looks like it got raped in the rear...

Nice idea for the head stay, good use of parts in the garage, thats how its ment to be. Good lad.

X2 Danny

Here is how I did the radiators. The stock 500 hoses from the head to rads work perfect with no mods. On the bottom, ever part used is from the 450 except for the 1/2" copper elbow. I searched a couple of hardware stores and auto supplies looking for some fittings to make it a little cleaner but had no luck.
This is my crossover location between coil and my violated Y.



The crossover hose is the 450 one that already has a protection ring on it.
It is bent just about right and I just had to cut it off a little on the right side. I didn't cut any yet in these pics. It is hard to see but, the black plastic Y also from 450 is stuck on the crossover hose.



Before I forget, I had to space the lower left rad mount to get it off the frame.


Left after turning spigut up a little.


Right side has alot going on in a small space. One of the 450 hoses has a bend on each end. I cut both ends near the radius. One end to plastic Y the other to copper elbow. It looks like a mess but, I can take the left and right rad clamps and at the water pump and remove the complete assm.
Hose to waterpump is also 450 item.

Well, I've got more done and getting so close I can feel it. Not going to be pictured yet but, I have a new pair of perillis(sp) mounted on the wheels and my suspension should be back today or tomorrow. Just getting both ends serviced and brought to new condition. I used to do my own seals and stuff but I've found by the time you by oil, seals and bushings, not to mention tools and mess, it is almost as cheap to let a pro do it. Heres the website. he does great work at very reasonable prices.
http://cyclesuspension.com
Heres the air box. Much the same as has already been done before. Uses .125 aluminum plate, 98-99 cr250 rubber boot and the original 500s inner and outer rings and filter and cage. Clamp the boot to carb, install subframe with airbox/plate and mark location for boot, remove and cut.





The cdi is mounted using 450 location and rubber holder. The only wire that needed extra length was one from cdi to coil. Rather than cut the oem 500 wire, the 450 kill switch has matching male and female connecters. I used those to make the longer wire to coil. All the wire plugs are behind the rubber boot at the top of radiator. The boot is just an extra large piece of heat shrink made for large cables. I just heated one end to reduce just close enough to be able to slide it back when I need to get to the connections. The wires are all wrapped in some cheap plastic spiral wrap I found at walmart.

Pipe mounts are on subframe. I do have to trim fender and side plate slightly for the front silencer mount.





Not the best picture yet. The fmf fatty had lost its luster from age and repair. That isn't black paint. I blasted it and that is teflon coating same as no stick skillets have. I did that a few years ago on another pipe and it held up suprisingly well.

nice to see it cuming along ke336 thery nice hope you get it done soon mate and injoy it

Thanks, I'm thinking in a week or less it should be alive. All depending on my last parts to get here. I would sure like to have everything by friday and give her a test this weekend but I'm not holding my breath. I forgot to mention earlier that I have the ironman sprockets and chain coming.
And an FYI for those that don't know(I didn't) MSR packages the ironman and sells it under their brand so If you have a source for some discounted MSR stuff you can save a fair amount over buying from dirt tricks.

do you have a pic of the cr500 filter in the box.how does it fit,is it tight going in and how tight is it in the air box?

zorak-2 wrote:do you have a pic of the cr500 filter in the box.how does it fit,is it tight going in and how tight is it in the air box?

No I don't, but will try and get one up in the next few days. There is plenty of room inside the box. The filter does fit a little lower and very slightly to the left of center but , taking filter in and out is no problem at all. I haven't even compared 450 vs 500 filters but I think the 500 is smaller and more round in shape.
As I'm typing this my suspension guy calls. Shock is done and in good shape. I'm going to pick it up this evening so I can atleast get the ass end of bike together. The reason he called was to tell me about a problem on one of the forks. Apparently someone screwed up the rebound adjustment screw or hole that it goes in. They niggyvered a regular screw with an o-ring on it to just plug it up. It will be a couple more days now on parts.

KE 336 wrote:.... Rather than cut the oem 500 wire, the 450 kill switch has matching male and female connecters. I used those to make the longer wire to coil.

KE 336 wrote:

zorak-2 wrote:do you have a pic of the cr500 filter in the box.how does it fit,is it tight going in and how tight is it in the air box?

I haven't even compared 450 vs 500 filters but I think the 500 is smaller and more round in shape.

Zorak, I looked last night and yes, 500 filter is smaller. Not so much top to bottom but probably 1 1/2" less left to right.

Santa paid me a visit today!

Merry Christmas.

I picked up my forks last night. Those were the last piece of the puzzle to complete. Going to test ride this weekend. I'll try and post pics and ride report on Monday. Hope everyone has a happy and safe 4th of July!

You absoultly made the correct sprocket choice.

Here it is all done for now. Thinking about all white plastic in the future but this is it for a little while. This thing has put me in the dog house more than a few times already as my honey do list has been put on the back burner. I'm going to have to get caught up on that now.
Pictures are kind of shitty for some reason but here they are.

first time out of garage




First outing July 3





I'm very impressed with its first ride. Zero rattles or any stange sounds.
Rides and feels like a good solid 250 except motor is like no other 250.
I've ridden a buddies KTM 300. That bike now seems weak after riding this. I'm thinking there is no issues with cooling as temps were around 100deg. and it hasn't lost a drop of coolant.