BannedCR500Riders.com

Im starting to building my cr500 A/F and needed to know some info on the chassis type. Im using a Crf450 2002. Is that model frame a Gen3? Are the crf450 2002 to 2004 have the same cosmetics? Also has anyone done this conversion to the same model as mine? Thanks

Yes 02' is a gen 3... believe from 02'-07' is the same for cosmetic's, but do your research! Take some time and read though the sticky's at the top of the forms as they often have all the general things your looking for such as;

http://www.bannedcr500riders.com/board ... php?t=1840

Hey cheers mate. Yeah i will have a read in that section. Thanks

And if you have some time to kill there is always this guy:

http://www.youtube.com/watch?v=1HJz5WZldH4

Its a gen 3 CR250 frame but a lot of the work is the same and he is pretty entertaining...

Thanks mate. Yeah i have been watching his build part by part over the last few weeks. Its good to see what others do. Im a boikermaker/ fabricator at one of the sugar mills so i have almost everything i need to complete my build as in tig welding machines, guillo, drill presses, centre lathes, milling machines, etc. And lots of time. Im looking forward to it.

Update on the progress of my gen 3 cr500 a/f. I got the 5'' grinder out other day and started to cut out cradle frame from the Top of the Y frame to the foot peg, I am going to replacing the hole cradle frame with 25mm alum square section radius edge because this way will be much stronger and look heaps cleaner . The cradle rails need 3 presses each to fit up which isn't hard now that I have a bending die machined up to form the rails. Reusing the standard Y frame is a bit more work but not impossible. My engine jig and 4 billet engine mounts turned up during the week, and my 97 model cr500 engine should be here in 3 weeks, so things are starting to get a move on. I will post photo's up soon. Rob

I have pressed up a test piece of the cradle rail today, looks really good. I cant wait to get the real ones formed, fitter and welded into place. Order my new FMF gold series gnarly & powercore2 Wednesday. has anyone used a K&N filter and sock setup on CR/CRF, thoughts on the product? thanks. Rob

We need pictures Rob,good to see you're making progress.

We used K&N's on our 08 CRF's. A sock cover may help, we had very fine dust in the airboot and they are still on the shelf in the garage.

If you are looking for opinions on K&Ns, Don't do it! they may breath better than a well oiled 2 stage Uni but they will also pass more than air through.
personally I like the sticky filter oil, FFT is my choice, BelRay also works.
I don't care for the uni oil, it's probably really good for oiling and use it at the track same day but for me it's too thin and will drain out of your filter if left too long.
Good luck with your build!

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Here are some pictures of my build. The rail in these pictures is a sample of what I need. I have been playing around with different angles, radius bends and shapes of the rail to make it look nice. The Y frame still has to be lifted around 15mm to fit into position. I cant do too much more until my engine and new FMF pipe arrives from the states.

[/img]This my Cr500 A/F donor bike..........died as a 4stroke, Reborn as a 2banger.

[/img]My Cr500 97 Engine and parts turned up from the states today, very happy with it. Now its bolted into the frame ready for cradle to be made. I have got 3 weeks off work next week to finish frame mods, so there will be more updates and pictures.

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Afew more photos of the rails, Y frame and Exhaust flange clearance.

This is my first Alum Tig weld in about a year, Keen to weld up my frame after that result [/img]
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My new custom headstay for my gen3, now to design the CDI and Coil mounts which sit on the box section.
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Got my cradle rails pressed up and fitter to the frame today, so tomorrow I am going to weld it out. I will post some more photos after I weld and clean the frame.