My Gen 5 --- shitload of pics

Building Tips, Suspension Set Ups, Conversion Parts .... Build to your Heart's Content!
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killtman
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My Gen 5 --- shitload of pics

Post by killtman »

Hi Guys!!! It's been a long time since my last post... however, the Gen5 conversion is on its way and I'm now almost finished (But I'm not sure if it will be really finished one day... anyway)

First of all, I know that some will complain about the weldings of my Y section.
So let's be clear : I don't fucking care!!!!!

This guy did previous conversion for me and it never broke, cracked or whatever.
I discussed with him about it and albeit it's not good looking as the previous one, it will be as strong.

Jef Van Hasselt from VH pipes whom is in the MX world and welding world for 35 years told me the same when he had a look at the weldings.

So argue about it if you want, it will just make me smile :D

Anyway... here we go!

This is the proud donor. Just another stupid ugly four stroke 2009 450 CRf.
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You know the story --> Started to tear it down and I sent the frame together with the radiators and swing arm for the conversion.

The frame came back and here it how it looks.
The cradle tubes are not bend but cnc machined.
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The head mounts
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An aluminium mount is weld under in front of the tank to get the CDI
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The radiators water ports are modified and spacers are cnc machined to get the rads away from the Y (in fact it was only useful on the right but to look symetrical, both sides are done)
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A plate is machine to close the tank bottom. I putted a genuine CRf O ring to seal it. I Just need the genuine CRf pre2009 fuel tap and an inline petcock.
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killtman
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Post by killtman »

So that's it for the frame.

The guy did also the air box and air boot conversion with a CR 250 air boot.
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killtman
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Post by killtman »

Here is the engine...
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Spacers are machined to center the engine. I putted them in place when I opened the engine.
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Once opened, the transmission sprockets were slightly damaged and I wanted to changed them. Finally, I decided to wait and put it back together with the same transmission. All bearings were right. We just rectified the crank to almost zero tolerance.

New carbon reeds, complete clutch plates and heavy duty springs and that's all.
Last edited by killtman on June 13th, 2012, 11:06 am, edited 1 time in total.
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killtman
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Post by killtman »

So far, I was a bit short on the budget and I left the project as it is for months.
As we say in french "You can't make a rock bleeding"... so I waited for my wallet to fill up again.

Later, a few cosmetics with a full custom grafics kit
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I ordered a full Cycra powerflow kit... but Cycra mispacked it and it was delivered with a OEM type fronf fender instead of the vented one. :(
Sending the kit back for exchange costed me the price of a new fender, so I decided to keep it so. However, I have the powerflow shrouds and rear fender (with air intake under the seat like previous YZ's)

This is how it looked... but something is still missing. I still wonder what :lol:
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Rhino89523
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Post by Rhino89523 »

I'm not an AF guy but just curious why you wanted to do it in billit instead of tubing, seems like it would make it very ridged and prone to cracking. Also the connection at the down tube seems kind of interesting and the weak link. I will just go ahead and say now that I don't know shit and just ask questions to learn so don't take offense I am just asking.
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killtman
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Post by killtman »

I slipped the engine in... Damn, it's tight! I slipped it into the mounts like a huge dick in a 16 yo virgin :lol:
Everything fits perfectly, it's awesome.

The conversion included the mounts to fit the CR5 silencer but I refused.

As on my Gen4, I went to VH pipes to have Jef Van Hasselt making me a custom pipe to fit the new frame.

First undress the bimbo.
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Then see how the silencer fits
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The pipes pieces are waiting to be welded at the right angle
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Because the frame geometry is totally different, the front wheel goes against the pipe at full fork compression.
Van Hasselt had to shorten several times the first part to avoid the wheel to touch it. Finally he got it.
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A fixing mount was welded on the subframe to fix the silencer on a second fixing point. No picture of it. But I can make a few more pics if some of you are interested.
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AlisoBob
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Post by AlisoBob »

Good job, report back on how it all holds together and how it handles compared to your other rides...


Theres always more than one way to skin a cat though.... this seems to me the easiest and cleanest way to do it...

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Britintheuk's bike...

OEM cradle with a billet "Y" , indexed at both ends.
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AlisoBob
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Post by AlisoBob »

I'd like to see the finished pipe.... Custom pipes are too cool, but I crash way to often to own one..

:cry:
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killtman
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Post by killtman »

Rhino89523 wrote:I'm not an AF guy but just curious why you wanted to do it in billit instead of tubing, seems like it would make it very ridged and prone to cracking. Also the connection at the down tube seems kind of interesting and the weak link. I will just go ahead and say now that I don't know shit and just ask questions to learn so don't take offense I am just asking.
Hey Rhino, no worry, you don't offense me with your comments :wink:

Unfortunately, I'm totally unable to answer as I'm not welder or engineer or anything like that...
The guy did it like that for some reasons but I don't know why. On my Gen4 it was billet too and it was really awesome. No vibrations, nothing wrong.

Sorry, I can't help you much more
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killtman
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Post by killtman »

AlisoBob wrote:Theres always more than one way to skin a cat though.... this seems to me the easiest and cleanest way to do it...

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Britintheuk's bike...

OEM cradle with a billet "Y" , indexed at both ends.
I wish I had the same Y. However I have to rely on other's help so I can't choose.

But the most important is the reliability. I will keep you posted for sure about that.
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killtman
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Post by killtman »

Well, although the bike is not yet totally finished, it looks like this right now

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AlisoBob
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Post by AlisoBob »

Nice job... That silencer is HUGE!

:shock:

Let us know how the first ride goes...
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killtman
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Post by killtman »

I don't know about you but I really like it! :D


The fork guard will be on it this week-end and I should normally ride it by the end of the month if everything goes right.

But, because of the heavy duty clutch springs, I have to order a Magura hydraulic clutch. The clutch lever pull is zway too hard.

Also, Boyesen magnesium finish ignition and clutch cover because these ones are so ugly that I won't be able to live with this on my bike.

Then, I'll wait for my wallet to re-fill a bit because next buy is this...
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and this...
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and finally this
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Of course I'm not talking about the new bolts and all that kind of stuff... I guess that this Gen5 will look very nice in a few weeks.

Don't you think? :wink:
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killtman
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Post by killtman »

AlisoBob wrote:Nice job... That silencer is HUGE!
:D We're talking about a CR5, remember? :wink: It's the same lenght as a genuine angled one (or just a bit longer, I don't remember what he said when he built my Gen4 silencer)

But if you look at the bike, the silencer is only visible on the last few cm, I really like it.

Also, a longer silencer smoothes the power, and as I'm a true beginner it helps me not to get hurt :lol:
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warrnum
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Post by warrnum »

Its coming up very nice kiltman, am sure looking forward to seeing how it runs for you and more importantly the reliability. Great work, you sure know what you want in and on your bike. Tear it up mate, good luck.
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Rhino89523
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Post by Rhino89523 »

It looks sweet dude!!!!!!!
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kevin_s
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Post by kevin_s »

Rhino89523 wrote:It looks sweet dude!!!!!!!
x491,looks killer from here dude.
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Rhino89523
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Post by Rhino89523 »

I like the pipe too, trippy bulge where the chamber starts getting big...wonder what effect it has on power delivery, can't wait for the ride report!!
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AlisoBob
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Post by AlisoBob »

killtman wrote:
But if you look at the bike, the silencer is only visible on the last few cm, I really like it.
X 491
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Gmbond
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Post by Gmbond »

Pipe and silencer look awesome, how does that help the noise level?
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Post by hoofarted »

I would love those graphics for a Gen2! Only if.....:(
The CR500 is an acquired taste. If you don't like it, acquire some taste...

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killtman
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Post by killtman »

hoofarted wrote:I would love those graphics for a Gen2! Only if.....:(
Only If what? If I can help, let me know. Do you want me to ask if they have the pattern for a Gen 2?

Go to cirwline and see what they do. It's fully tunable.

MP me if you want :wink:
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killtman
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Post by killtman »

Latest news!!!! Latest news!!!!

Almost exactly 2 years after I crashed and had a Z shape leg (to be exact, 2 years and 8 days), my Gen 5 is running!

Yeah baby!

You know the story. I did crash and had a fully blown knee, all four ligaments were torn and I needed tzwo surgery. One to rebuild the lateral ligaments with my own quadriceps tendons and another one two months later with an allograft of dead people's crossed ligaments.

The first two days after the crash, the doctors were thinking about cuting the leg above the knee. Finally a famous specialist in Belgium trid to save my knee... and he did!

Here is how it looked after the first surgery. :?

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But anyway, I'm fine now and although my knee is no more as flexible as before, I am really fine with it.

So I sold my Gen4 but as soon as I did recover, the Gen5 was quickly home.

And now I just received the last parts needed to make it firing and running.

I have to say tht I did struggle for about 15 minutes kicking, but suddenly... BRAAAPPPPPP!!!!!!! :lol:

Guys, You just can't imagine how happy I was!!! I wasn't that happy when I lost my virginity :lol:

Anyway... it's now complete (although not finished, I still need to order a lot of parts, but yeah... I need some money)

Not a lot of changes, but the fork guards, radiators hoses, chain... it looks like a bike.

I'll go for a ride this week end. Be ready to read the debriefing :wink:

Enough said, here are the pics.

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killtman
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Post by killtman »

Gmbond wrote:Pipe and silencer look awesome, how does that help the noise level?
Sounds very good... sounds deep and powerful but at low noise level. I love it.
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ridin4fun
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Post by ridin4fun »

Man, she's a beauty! Just curious, will a standard CR500 pipe of any variety bolt up with less extensive mods?
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