BannedCR500Riders.com

Finally finished my CR500 hybrid. Everybody already knows what went
into the engine build. Works Showas, frame mods by everybody's
favorite "AF" fabricator , "dogger" original hubs laced to Excel rims.
Lots of weight saving parts and fasteners. This one is pure MX

dogger

wow, looks great!









chain is too tight

Sexy bike! Hope mine looks as good in a few weeks.

Where did you get the PC "Works" pipe?

Your lawn looks like mine did this morning

HAHAHAHAHAHA!
Crabgrass! And lots of it!
I knew you had a fault somewhere!

Hey man, didn't say a word about all the bits.
Titanium? Ya know?
That's a beautiful motorcycle.

Is that a 21", or 20" front rim?

Is the back of the case radiused for shock spring? Does it not rub?

Very clean!! Looks good!

Nice

Very nice.

Thanks guys! I really appreciate it.

Where did you get the PC "Works" pipe?

Service Honda

Your lawn looks like mine did this morning ...Crabgrass! And lots of it!

Yeh, my yard looks like crap. Like much of the rest of the country, TN
is sitting under this heat dome. I'd rather work on my bikes in the air
conditioned shop than mow the grass in this heat and humidity.

Is the back of the case radiused for shock spring? Does it not rub?

No it's not, and yes it does. There has got to be another way to fix that
issue than grinding Aluminum and gasket off the back of the case. I have
a little more time to figure something out because I'm waiting on the
exhaust flange to pipe gasket and can't start it up anyway.

Is that a 21", or 20" front rim?

21" with a Dunlop 80/100-21 756 RR tire. Out back is a 19X2.15 with a
Dunlop 110/90-19 756 RR. I also have a 19X2.50 with a 120/80X19
when conditions dictate it.

chain is too tight

That's a problem. I am running a 14-47 combo and that causes the chain
length to be too short or too long. Before I took a link out, the adjusters
were full out and I still had way too much play. After removing the link,
the adjusters are all the way in and I have 25mm (minimum required),
play. I could work around this with a one tooth larger or smaller rear
sprocket, but I need to ride the bike first to see which way to go.

dogger

Dogger do you work for service honda? It looks like the frame says SH on the picture of the shifter side of the engine.

Those covers look like the ones i got from the old dart (England) machined billet.
It is a replica and says HONDA RACING.

So where are the pics of it on the ground? Are you going to share a little bit more about the build? What did you learn about the geometry of the motor to frame......

It looks like the frame says SH on the picture of the shifter side of the engine

that is definately a service honda, looked at mine closely and all the frame mods are the same

nice clean bike, as far as saving weight youd be much better off getting a frame and having it built with tubing instead of billit, that would save more weight than all your titanium, and probably be cheaper too

any chance you can weight it, full of fuel? just want to have something to compare to
im at 246lbs with all the woods gear


some more ideas if you are really serious about saving weight
regular 1 1/8th bars are probably lighter
toss front disc guard for easy weight loss
plastic ignition cover is easy weight loss, ill trade you
never put it on the scale but tubliss might be lighter, if not it will have less gyros cause the weight isnt going as fast
light flywheel might be worth looking into if your into that kind of thing
aluminum exh flange
aluminum sleeve
toss fuel valve
toss hpsd, i dont really like it makes the bike "feel" quite a bit heavier, even tho it probably weighs less than 1lb
make thin 2 sided headstay, service honda 1 sided billit one is pretty big

Are you going to share a little bit more about the build?

I'll be more than happy to share, I thought this post had already faded
away. Since I didn't do any cutting or welding myself, I suppose the
term "assembled" would be more accurate.

This bike is essentially a 2008 Service Honda with the following changes:
My engine (already detailed here)
Vortex programmable, multi map ignition controller
Pro Circuit works suspension and steering damper
Excel rims I laced to OE hubs I polished and powder coated
Dunlop RR tires
Fluidyne custom radiators
Twin Air Power Flow filter system with billet flange and cage
Titanium nuts, bolts, axles, swingarm pivot, linkage bolts, foot
pegs, shock spring, fork springs, brake pistons
Renthal Ultralite sprockets, TwinWall bars, grips
Works Connection Pro perch, rotating bar mount, skid plate
Motion Pro T2 cables
DID ERT2 chain
Custom graphics by MX Graphix

My goal was to put together a bike that would be similar to what
Team Honda would field if there was still an open class.

Problems encountered: Shock spring to engine case clearance,
shock spring to carb bell clearance, front fender to pipe clearance.

I solved the spring/case clearance issue by swapping out the ti
spring (unfortunately) with a steel spring. The bell/spring problem
was solved by removing the 10mm spacer between the VForce 3
and the cylinder. And the fender/pipe problem was solved by
trimming and reshaping 1/2 inch from the fender.

The weight loss program countered the weight gains from the billet
cradle and works suspension. The smaller flywheel helps give a
nice light feel and the bike changes direction like a 250. The EG
ported "mo better" powerband was also a good choice for MX, and
with the 14/47 gearing, I can ride most of the track in two gears if
I want.

Future additions include a CRF Stuff HGA replica 280mm front rotor
with a matching rear, DID Dirtstar rims and two piece head stays
with a provision to mount my carb cannister vent.

dogger

Nice bike dogger. What are the graphics you are using? Like the yellow with yellow backgrounds. Is the mo betta porting the kind for mx? I am looking into it now.

Thanks. The graphics are customs by Graphic MX. I originally wanted
to mimic the early 90s Team Honda look of White on Red, but the Black
tank and seat cover made me rethink that and go with the 96 Yellow
on Red Team combo instead.

The porting goes a long way to make the abundant power more useable.
I can definetly recommend it over anything that boost the power and
hit, especially for MX. It will stretch your arms, it just doesn't dislocate
anything.

dogger

Give 14/51 or 14/50 a whirl if you want that motor to rock like it should. With the proper gearing you can run 2 gears, 3 and 4, not 2 and 3. I'd dump that PC pipe and find a fatty and be much happier. PC's are yawners.

Have you put in any time tuning the A kit for the 500? I'm hoping to get together with factory connection this fall and get my A kitted gen 4 dialed in now that the nationals are winding down. They should be at the local tracks testing the new bikes. Pretty cool having them there doing R + D

280mm disc is very helpful for sure.

I absolutely love a rekluse pro on mine. Got the tip from AJ actually. Makes cornering MUCH easier and scary fast.

What's the rate on that TI rear spring? I've got no problem grinding the back of my motor.

nice scoot.

Beautiful! It's a shame not to use the Ti shock spring. I would definitely relieve the engine cases as long as it wasn't too much. Especially with all the other Ti on the bike.

How much needs to come off?

FZ1426 wrote: How much needs to come off?

This much.

Its a 2 minute job with a 4" angle grinder.

When you do it right, it looks just like a late model 250 case.

I wish it was that easy.

The 5.6 kg/mm steel coil spring is 89mm in diameter. The 5.5 kg/mm
ti coil spring is 99mm in diameter. I would need to take 6mm out of
the case for around 1mm of clearance - not really adequate. Here is
a picture of the case. As you can see, there is only about 5mm of
Aluminum before you get into the swingarm pivot bolt cavity. I
would prefer not to have a gasket width gap in the case to allow the
elements access to that pivot bolt.

I'm sure I could seal that gap up with some RTV next time I have
the cases apart for maintenance. Maybe then if I haven't come up
with another solution.

dogger

Are you sure you are using the right spring?
I had a 5.7 on an 08 crf450 and it was not that much bigger in diameter than the stock spring. I might still have it lying around. I will check the size

he's got an A kit shock on there, they are bigger, the Ti bigger again than steel.

I measured a new case tonight, .400 from the outside to the bushing.

seanmx57 wrote:he's got an A kit shock on there, they are bigger,

Who makes this bigger shock?