BannedCR500Riders.com

Hey all,

Figured I should post up the build pics for those who are interested, I have been reading up big for the last year on both forums and the knowledge available has been invaluable and gave me confidence in doing my own. I live in Australia so importing one becomes pretty expensive.

For this conversion I picked up a rolling CRF250R 2007 chassis and I am using my 94' CR500 motor. I ordered Jercs conversion kit which is not only cost effective but accurate for fittment, easy to do, and the instructions and support from him is good

The hardest thing for me was the actual cutting the frame up, it just didnt feel right but it had to be done and the results have changed my thoughts on that, now pass me that saw !!


pics or it didnt happen right.


Old V new.




This jig is a must for saving time. now who did i get that from I wonder?






CR125 spacers


bit of a clean up, motor in.




Headstay brackets lined up nicely.


Radiator outlet ready to weld




ready for my welder to finish the brackets.


MRE decomp head.


Hinson basket and oem fibres. Magura hyd clutch.


Parts on order:
OEM reeds
CR250 airboot and cage
CR250 brake pedal
CR5 kicker
head stem bearings.
new plastics
Clarke 3G tank
CRF'X' model tank petcock.
bolts/screws, collets, rubbers for tank etc.

Once all this is done it is the shakedown ride.
Next on the list will be:
Suspension reset for my style and weight.
Sticker kit yet to be designed

Later on will be a full engine rebuild.
Dig ign
Lighting stator/kit
D inj if or when it is proven and available.
Maybe a GMX tank (bling)

Recommend that a good experienced alloy TIG welder is sourced

Biggest issue is the unpredictable shipping time for parts.

Would I do another one, yes

Parts on order:
OEM reeds
CR250 airboot and cage
CR250 brake pedal
CR5 kicker
head stem bearings.
new plastics
Clarke 3G tank
CRF'X' model tank petcock.
bolts/screws, collets, rubbers for tank etc.

CR250 kicker shares the same spline as the CR500 and fits the frame better!

I will see if i can change the order.

Thanks.

Np. I am running the 2000-2001 GEN 2 kicker. I like the GEN 3 (2002 and up) kicker alot more but find the bushings in it wear out quickly and it rattles like crazy. Also believe with the gen 3 kicker if you run a FMF pipe it will interfere with the kicker about mid-way down the shaft (Atleast it did for me). You can try to avoid this by "clocking" the spline on the the kicker mechanism or just run a PC pipe which should have a bit more clearance.

Where are you guys getting those nice looking engine jigs? Man, would that make it easier....
Kibler

I am almost certain I got it from Jercs on here, it was some time ago.

Scotty wrote:I am almost certain I got it from Jercs on here, it was some time ago.

Looks like one of my jigs.....

kevin_s wrote: Looks like one of my jigs.....

Quite possible, I cant remember whos it was but it sure saves time

Who has one I can borrow or rent or something.....?
Kibler

CR250 kicker shares the same spline as the CR500 and fits the frame better![/quote]

and breaks easier busted 2 brand new 250 kickers within a month of fitting them us the cr500 kicker its designed to start a cr500

Sweet!!!!!!!

I need to prune those bushes in the background.






Its running after a few electical issues. My fault

How do you get youtube to work?

Heading out thursday for the shakedown, all goes well the Husky will stay in the trailer for the long weekend, had a few issues and moments of how the hell can I make this work, having a beer and thinking about it worked many times. Beer is good

I will miss the lounge chair seat ride of the steel frame.
Looking at the old frame then I look at this, those who have done it know

Oppertunity arose to take it to a friends property yesterday, not many good photos as it was raining too much to have my good DSLR out.





I tell you what it is definately like a scalpel as others have mentioned, it felt light and turns brilliantly, ran 14/45 gearing and it was much more manageable in the tight single trails out of the turns, it has to be one of the best bikes I have riden. Didnt notice any vibrations but I will find out on the longer trails.

Not one issue with the build results, the motor ran sweet with new reeds and Roosti's decomp head and could ride a gear higher even in the tight stuff. it was jumped a few times, we hit the stutters fairly quick and generally tested over 3+ hours.

Front tyre just barely touches the pipe under full fork compression. Should be fine.


Waiting on some stickers and a few tasty bits to finish it off, what a ride from the building phase to the testing and having no issues, if it wasnt for this website and all the freely available info i would never have attempted my own build.

Cheers all


If your thinking about converting do it, so much better than the steel frame version.

Stickered up oem look with kind of a retro throwback
White barkbusters
Rad overflow bottle in airbox
Stegpegz
New front pads
14/45 gearing





parts to come:
red rad hoses
Boyesen black engine covers
Scotts steering damper kit
Fast flex bars
CRF450X brake pedal (might fit better)
pivot pegz
Full suspension rebuild and geometry setup (this week.)


Went away for a 4 day weekend out in the sand in the Mallee country with the club for FULL on testing and multiple rider workout.

sweet !

Can you shoot up a pic of the rad overflow in the airbow please? Nice sled!

Slabman wrote:Can you shoot up a pic of the rad overflow in the airbow please? Nice sled!

thanks.


This is the kit i used.
Zip tied inside the airbox as there is little space anywhere else for it.. It works.



Photos later when i get access to the bike.