BannedCR500Riders.com

im really just thinking about it as of right now, getting an idea of what is gunna take to build an AF

i would like to ship someone a cr250 frame and have them do the cutting and welding for me. then i can just drop the motor in and bolt all the parts together in my garage with basic tools. sounds alittle too easy though

if you can do this let me know, and also how much $$$ would you charge. PM if you like

thanks

How about you get a kit and buy a gen 1 bike. It's a easy swap that only needs minor welding of a few mounts. For kit info, see the other post in this section with like 5 or 6 pages.

i should buy one of those kits probably, but im not able to weld aluminum and dont really want to do all the mock up to get it perfect

maybe i can send a frame to the guy making the kits and he can do it for me so i all i got to do is bolt the motor in

hamilcrf@cr500parts.com


Send Kenny your request.

Service Honda is doing the conversion now, using the frame you supply.

mxracr121 wrote:Service Honda is doing the conversion now, using the frame you supply.

britincali wrote:

mxracr121 wrote:Service Honda is doing the conversion now, using the frame you supply.

That's a pretty good size bird turd right there. How about this one.

Tough crowd.

Mad Dog wrote:Honest crowd.

I fixed it for ya.....

John wrote:i should buy one of those kits probably, but im not able to weld aluminum and dont really want to do all the mock up to get it perfect

maybe i can send a frame to the guy making the kits and he can do it for me so i all i got to do is bolt the motor in

Well then sure send it to someone. I don't plan to do the welding either, but mock up seems rediculasly easy. The motor is held in place near the perfect position by the rear swingarm bolt and mount, then you put the weld on mounts on the engine, which will put them exactely where they need to be welded, tack them to the frame, pull the motor, weld them up solid, and your done.

What?

Ported&Polished wrote: The motor is held in place near the perfect position by the rear swingarm bolt and mount

ahh i didnt think of swingarm bolt, the motor would be aligned perfectly and i would just have to tilt it correctly. maybe i could make pencil parks on the frame where the mounts need to be welded and then take it to a shop. maybe i will do it myself

what else do i need to do to make the conversion besides the exhaust mount relocation? how would i get the airbox to fit with the carb?

im sure where the airbox mounts on a cr250 wont line up with the carb boot from the cr500 motor

John wrote:im sure where the airbox mounts on a cr250 wont line up with the carb boot from the cr500 motor

You may have to get either a hair dryer or a heat gun and heat the boot up to make it fit.

John wrote: just have to tilt it correctly. maybe i could make pencil parks on the frame where the mounts need to be welded and then take it to a shop. maybe i will do it myself

I realize my explanation post was a bit confusing, I was drinking margaritas when I posted. Anyway, "tilt it correctly" seems like a non issue as well. Reason being, if you take the mounts and bolt them onto the motor, the motor will be resting in the frame, and the mounts will be exactely where they need to be welded. Does that make sense? Then, tack them down with a weld, or possible mark their location with a pencil. Then remove the motor, and have the mounts hard welded to the frame. I never did this either, but I have fabricated alot of stuff and it seems pretty simple to me.

I'm going to add to my original post and will have a complete start to finish build thread.
The lower mount and swaingarm bolt don't need to be modified. you just cut, then grind off the front mounts, then put your motor in, put the mounts in place, put the bolt through, then take it to the welder. Its a lot easier to get the motor in and out without the topend on and the welder will thank you. I took my frame to a reputable fabricator in town and he tacked the mounts, the pulled the motor and finished the welds.
He is the expensive guy and it cost me $60
(I also had a broken exhaust mount fixed and he couldn't decide weather to charge me $40 or $60, so I just handed him $60)
The build really isn't that hard and we are all here to help.
the airboot is really close, just use some elbow grease and "make it fit" and it fits fine. The toughest part is the exhaust, but you can order a replacement gen-1 pipe from SH that bolts right on.
Look at the shanman gen-1 pdf at the begining of the big thread and you will see.
If you want a kit, let me know. They might go fast when they are ready (approx 1 week)
Thanks
Danny

that would be awsome if you had a step by step overview with pictures, it sounds like i could do this myself. i just wish i was setup to weld aluminum. i think i will want a kit, but dont want to tell you for sure yet. maybe after you add to your origional post so ill know for sure.

thanks so much for the help, its awsome that your making that post with instructions

here is Shanmans step by step, very detailed.
http://bannedcr500riders.com/library/CR ... n-RevC.pdf