BannedCR500Riders.com

Looking for a US dealer that can help me with a decent order of parts for my 500 - looking for PC pipe and silencer (pref the AF one), silencer to match, some Boyesen engine cases, air boot required for this conversion, left hand crank case, and a few other bits I ve probably forgotten!! Also looking for any advice anyone can give on this conversion - Im in the early stages, notched the lower frame rail to make room for the clutch case to swing the motor down as much as poss, cut out the Y and grinding out the old material from that. Few Q's: what size swingarm bush do i need? from what year? what air boot? Thanks in advance, great site! Im in the UK by the way

sorry to be dumb, but i wanna post some pics up of my conversion so far. How do i do that?[/img]

we have had about 4-5 gen-4 crf250 conversion, everything you need to know is already on the site.
use a cr125 bushing on the right to center the motor. use a gen-1 cr250, or a cr500 airboot.
to post pics highlight the link to the pics and click the "img" button

Checkout the stickys, and chachi243's 05 build its sweet like honey

Post pics like this below, but first you must upload them to get the URL. I use photobucket.com to host my pics.

thanks guys. Just a link to my album - hope it works. I found an 02 CR250 air boot and just sat it on, not tried the 500 one yet. 250 one isn t far away though. No welding done yet, just the cuts. Does everyone have issues with the shock spring & crank case clearance? Saw in one thread someone took a grinder to the cases at the back. Was hoping not to do that but cant see any other way round it. Any suppliers wanna cut me a deal on the items i need? thanks

that was only because Bob needs the big spring to handle the weight. I weigh 190 and the stock springs on my '04 are perfect for me and don't require trimming the cases.

Looks good!!

dannygraves wrote:that was only because Bob needs the big spring to handle the weight. I weigh 190 and the stock springs on my '04 are perfect for me and don't require trimming the cases.

Not 100% true, the "X" model has different linkage that puts the shock closer too.

Clearencing the cases is a 3 minute job, counting the time it takes to pick your beer back up.

Its going slowly and Im no fabricator - trust me!! Have heart set on a Bailey rep so we ll see how it goes. Has anyone come up with a 'kit' for these - motor mounts and double sided head stay? Must be double sided though? thanks

front mounts, yes, shanman makes them. headstay...no, the only way that would work is if the kits also contained lower mounts and everyone did their motor angle the same. I cranked mine as far forward as possible and it seems to have worked out.
I used the stock headstay and modified it to work.

http://www.bannedcr500riders.com/board/ ... &start=145

OK sorry, I ve read so many threads, i dont know whos modifications are whose anymore! I like the motor rotated as much as poss. Need to notch out a little more on mine yet i think. The crf250 head mounts dont look too far off angle wise so ill have a go at chopping them up. Cos thats where my skills end!

I did mine in a similar way. sorry, don't have pics... my 3YO keeps taking the digi can and snapping pics of the dogs and his starwars action figures and burns through the batteries

AlisoBob wrote:http://www.bannedcr500riders.com/board/ ... &start=145

And then just weld them 2 pieces together? No recommendations on suppliers yet? thanks

jpddb100 wrote: Cos thats where my skills end!

Don't cut yourself short, a lot of us with minimal skills and tools have and are currently building our own!!!

me included! Pretty scary taking a grinder to a perfectly good Honda frame, but im getting kicks out of it already. Not ridden a 500 for 8 years - bring it on!

its been a while since I updated my build, check it out
http://www.bannedcr500riders.com/board/ ... 52&start=0

shit, I welded my own frame and had zero aluminum welding experience.

Do not use a "Grinder" ever! Only use a saw, file, rotary file. Do not deburr your aluminum parts ever with abrasives if your going to weld them it contaminates the material.

Yuuuuuuuuuuup......

Listen to those guys about the grinder!!! Thats what I did, then got to spend a couple hours "cleaning" with hand files.

By a grinder, I meant a grinder with thin metal cutting blade. Not sure if that counts or not. Getting the material from the Y milled out today so will post more pics later

If it has physical "Teeth", its o.k.

If it is "Abrasive".....its not.

I have heard this one way too many times.
Does the abrasive contaminate the weld? Sure along with a dozen other things.
Does it make the weld weaker in the cr500 application? I think the jury is out on that.