BannedCR500Riders.com

Ive got a very tidy cr250 with no engine that was going to be used for my conversion but dont have know how to do myself or find someone local.So at this stage just want put the front end on the 99 cr500 steel frame looking for someone thats done it cheers

I'm pretty sure it will fit. I've got two 2001 CR500s; one I bought new off of the showroom floor and a used one. I was told the forks on the used bike were from a 2003 CR250. The one I bought new was run over by another bike (long story), severely denting the upper fork tube right where the seal goes causing it to leak. While waiting on the seals and bushings to come in, I took the forks off of the used bike and they fit perfectly into the triple clamps of the stock bike. The only thing different was the front axle. I had to use the axle from the used bike to get the front wheel spaced properly - the stock CR500 axle wouldn't work. I also used the front wheel from the used bike; didn't check to see if there was any difference there.

jbird_710 wrote:I'm pretty sure it will fit. I've got two 2001 CR500s; one I bought new off of the showroom floor and a used one. I was told the forks on the used bike were from a 2003 CR250. The one I bought new was run over by another bike (long story), severely denting the upper fork tube right where the seal goes causing it to leak. While waiting on the seals and bushings to come in, I took the forks off of the used bike and they fit perfectly into the triple clamps of the stock bike. The only thing different was the front axle. I had to use the axle from the used bike to get the front wheel spaced properly - the stock CR500 axle wouldn't work. I also used the front wheel from the used bike; didn't check to see if there was any difference there.

ok thx for your reply so you didnt need to use the triple clamp either cool so basically I can just use everyyhing bar the triple clamp forks, axle and wheel etc sweet

The only thing that may be an issue is the caliper mount. In my case, they were the same, but I don't know if the previous owner changed the one on the CR 250 fork.

jbird_710 wrote:The only thing that may be an issue is the caliper mount. In my case, they were the same, but I don't know if the previous owner changed the one on the CR 250 fork.

ok if I use the cr250 complete front end bar clamps shpuldnt be a problem right

Yes, the forks slid right into the stock CR500 triple clamps, I torqued them to whatever the manual said, and have 3 rides on them without issues. Definitely noticed a difference (better) with the twin chamber forks. Might be my stock forks need a little tuning.

jbird_710 wrote:Yes, the forks slid right into the stock CR500 triple clamps, I torqued them to whatever the manual said, and have 3 rides on them without issues. Definitely noticed a difference (better) with the twin chamber forks. Might be my stock forks need a little tuning.

And that's the monkeys with hatchets way of doing it........just sayin

Say what you will; it works fine.

bigpower wrote:

jbird_710 wrote:Yes, the forks slid right into the stock CR500 triple clamps, I torqued them to whatever the manual said, and have 3 rides on them without issues. Definitely noticed a difference (better) with the twin chamber forks. Might be my stock forks need a little tuning.

And that's the monkeys with hatchets way of doing it........just sayin

The 96+ CR5 should be the same diameter fork tube as the CR250 twin chamber forks so it's a bolt up and go mod. No prying the triple clamps open to make them fit or using beer cans for "shims" like some people will do. The trouble is you also need the wheel with spacers, axle, and caliper carrier to make it all work.

cowboyona426 wrote: The 96+ CR5 should be the same diameter fork tube as the CR250 twin chamber forks so it's a bolt up and go mod. No prying the triple clamps open to make them fit or using beer cans for "shims" like some people will do. The trouble is you also need the wheel with spacers, axle, and caliper carrier to make it all work.

Exactly. I did use the wheel, axle, spacers, and caliper mount from the other bike. Really don't want to put it back, but I'm trying to keep one as close to stock as possible.

jbird_710 wrote:Say what you will; it works fine.

Honestly, you're shortchanging yourself by not using the newer clamps. Sure, the twin chamber dampening is much better, but using the beefier clamps improves the handling tenfold.

This should tell you the story, heres a set of clamps from a later model CRF and a '01 CR5 together


Big difference, eh

Here they are, bottom view.



The CR clamps are pretty damn whimpy, and give a hell of a lot more flex than the newer style, proper clamps.
I rode my 01 all last yr, and I can certainly say it was a much better handling machine than before. one thing I did notice right away in the early test phase, it was as stable as a CBR RR at very high speeds. Steering dampener, HA, why would someone waste the $$. My tight twisty single tracking, this thing will hold the line like its on rails.
It only involves pressing out and swapping the stems, and a small adjustment to the steering stops on the frame......do yourself a favor, get the correct clamps.
The only thing that makes the whole package even better is getting the 50mm Showa shock in there....I was told it wouldn't fit, or work, ya, I proved that to be bullshit, too.....................

bigpower wrote:

jbird_710 wrote:Say what you will; it works fine.

Honestly, you're shortchanging yourself by not using the newer clamps. Sure, the twin chamber dampening is much better, but using the beefier clamps improves the handling tenfold.

This should tell you the story, heres a set of clamps from a later model CRF and a '01 CR5 together


Big difference, eh

Here they are, bottom view.



The CR clamps are pretty damn whimpy, and give a hell of a lot more flex than the newer style, proper clamps.
I rode my 01 all last yr, and I can certainly say it was a much better handling machine than before. one thing I did notice right away in the early test phase, it was as stable as a CBR RR at very high speeds. Steering dampener, HA, why would someone waste the $$. My tight twisty single tracking, this thing will hold the line like its on rails.
It only involves pressing out and swapping the stems, and a small adjustment to the steering stops on the frame......do yourself a favor, get the correct clamps.
The only thing that makes the whole package even better is getting the 50mm Showa shock in there....I was told it wouldn't fit, or work, ya, I proved that to be bullshit, too.....................

What all was required to get the shock to work? I have 08 CRF-R suspension components and triples at my disposal. I know for sure the clevis on the 08 shock needs to be shortened up a bit, did you have to make any other mods to get it to fit?

Honestly, a tig welder, a drill press and some Kawasaki parts.........