BannedCR500Riders.com

First off hello from London (UK). I've been hanging around this site for ages and I'd just like to say a big thank you especially to admin, for all of the information on here.

Here's my current obsession:



Motor was in bits too. Still covered in mud!



Yes, the crank was scrap, got a new one now.



It had ripped the sprocket off the output shaft!

What was a handsome looking machine...



...but it's going into this:



I should post this now and put more pics into another post. In the next installment, I'll cut off the brackets, fabricate some front mounts and strip a couple of CR motors...

Screwdriver.

Screwdriver wrote: It had ripped the sprocket off the output shaft!

About the only time the countershaft snapps, is when the chain is way too tight, and someone bottoms out on a junp.

The chain goes insane tight, and something has to give...

Keep us posted on the conversion!

goodluck mang and if you look around there are plenty of finished builds to look at for reference.

I did one on the cheap as well.
http://www.bannedcr500riders.com/board/ ... php?t=4573

I am super happy with mine.

dude, mine was about as cheap as they get $200 chassis, free conversion kit, etc. I was seriously like less than $1000 into the entire project
gen-1s can come out nice for not much money.

Got myself a cheap chassis off eBay and set about the front brackets.





I spent some time taking them off cleanly so that I could reuse them on another frame. It's a long story but I bought a so called conversion (the "250" above has a badly fitted 500 engine) but the frame has been trashed.



Goes in ok but a bit tight on the bottom mounts. Eased the bottom bolt in with a precision mallet.



Now I am not a machinist but I copied the mounting drawings (many thanks again!) and knocked them up on a milling machine at my University.



Tidied them up a bit with emery paper and they fit a treat.





So here we are today.



I can't weld so I took it to a local specialist. I made a big mistake though; with the engine in place ready for the brackets to be tacked, I clamped the right hand mounting down. This meant that when I pulled the bolt out, the position "sprung" slightly, leading to a slight inaccuracy. I later discovered the bolt I used to line everything up was slightly bent.

It still goes together but its very tight. I guess I can either ream out the mountings slightly or perhaps try to bend the frame a bit. Any suggestions? We're only talking about a mm or so.

Screwd.

Hi mate!!i was born in Hammersmith

Tell us how much it cost you when you'll finished your conversion

maybe it could be a sticky...

"How to do the cheapest conversion"

Hi xtremeslide, I'm just down the road from Hammersmith in Ealing. Long way from Andalucia (wherever that is!).

The cheapness comes from biding my time. I got the steelie in bits from a mate of mine almost two years ago. It cost £270 and came with a box of spares, including a new output shaft. In the meantime I have a few other bikes dotted about; I've built/restored a couple of RD350s (YPVS and LC), an RD250LC, a KTM LC4 amongst others - all of which I picked up cheaply. I currently have a YPVS/Mito thing onn the go, a knackered old XT500 and my main event - an RG500 engine in an MV Agusta chassis.





I work on these bikes in parallel, when I get stuck for an expensive part on one, I move onto another bike until something comes up. While I was considering the steelie rebuild, a CR500AF came up for £1000. Sounded alright on the phone but being 500 miles away, we agreed a price and I had it shipped here unseen (from Scotland). It was a bit of a disappointment. The "conversion" involved cutting away the bottom engine mount and drilling through the front mounts to fit the CR motor.This makes the motor too high, the exhaust simply won't fit, the cylinder head lifts the tank by an inch and the carb is miles from the airbox. Still its about the right money; an engine will set you back £5-600 and a chassis about the same. I'm afraid it's not a great example of how to do things on the cheap, not until I flog off any unwanted bits.

So I waited for a while and bought a bare frame for £75, that's the one in the pictures with the new brackets. Since then and as we speak, I am being offered a complete CR250 '97 rolling chassis for £300 odd quid. I am turning it down because next time I want to do a CRF (and the van has lost its clutch).

When it comes to the conversion process I am relying heavily on the information from this site. I thought it only polite to post here because this site hosts the drawings I am working from. I am a (very mature!) student and have access to enough machinery to have a crack at just about anything. It's a steep learning curve though and I am not doing alloy welding until I can afford a decent AC TiG. Currently I am learning DC TiG which I will need to complete the RG500 exhausts. I have to do it myself because to have a custom set made up would cost in excess of two grand! So I bought some part complete's off eBay which I should be able to modify without ruining them more than absolutely necessary...

That's how I do things on the cheap. Oh and I built that shed at the bottom of the garden to do it all in (on the cheap )

Screwd.

I like that mv augusta ....


How much you paid for the MV chassis?





P.s:I live about 1.200 miles by car from hammersmith,i only was there 2 years

xtremeslide wrote:I like that mv augusta ....

How much you paid for the MV chassis?

P.s:I live about 1.200 miles by car from hammersmith,i only was there 2 years

The MV was so cheap I really can't say, much less than I paid for a badly made CR AF conversion. I only went to buy the forks for the planned RGV/RG500 conversion but the guy had the whole bike (minus engine) lying in his garden! It also comes with a fantastic registration number (important in the UK). Paid top dollar for the RG500 engine though when I had it rebuilt on new cranks

Screwd.

I love the way those RGs sound. Nothing like the sound of a square-4.

Cool toys man.

The MV was so cheap I really can't say, much less than I paid for a badly made CR AF conversion. I only went to buy the forks for the planned RGV/RG500 conversion but the guy had the whole bike (minus engine) lying in his garden! It also comes with a fantastic registration number (important in the UK). Paid top dollar for the RG500 engine though when I had it rebuilt on new cranks

Screwd.[/quote]

Let me know if you find another "cheap" MV chassis

Fancy selling the CR5 steel rolling chassis?

Neilios wrote:Fancy selling the CR5 steel rolling chassis?

sorry I don't sell the chassis,i you're asking me

Neilios wrote:Fancy selling the CR5 steel rolling chassis?

Hmm. Well I'll let you know first if it ever is. Basically the steel frame has a road registration - albeit on a Q plate. Until I get one bike or other running (I also have to put a filthy diesel XT500 back together first) I won't know how easy/difficult it might be to road register the 500AF.

On the other hand, you could always try and make me an offer I can't refuse...

Meantime, I made some alloy brackets (thanks again for the drawings!):



Had them welded in place:





And here's the result as we speak. A bare frame ready to have the motor installed but with no time currently to do it:



I still have a bunch of searches running in the background and have been offered a 1999 AF roller for £325 (!) and found a complete steelie CR500 runner for under £500. Unfortunately the clutch on my trusty van has expired so I can't mop these up. Probably just as well I suppose - so much to do and so little time...

Screwd.