BannedCR500Riders.com

Well, i finally got up the courage to hack up my 250, beer helps. Bought it in April for the sole purpose of converting. Bike is an 02. Got an 85 engine thats going in it, fresh top end by Millar Engines (and a decomp too!) bottom is tight, gonna run it for now.


Wheel bearings in lovely shape




It ran awesome so i decided to ride it for a bit while my engine was being rebuilt. Proceeded to crash the shit out of it and wreck myself for a couple weeks, (been a couple years i was due).

rode it for the last time last weekend in the mountains, then started pulling crap apart

mounts off


not going to fit yet

shock doesnt clear on mine (02) i have a kyb and showa, both the same clearance, this is the kyb


making some room

turns out hydro jacks dont work upside down, had to go get the 45K tool out of the truck


y needs room





so, not sure if this has been done before, but it works awesome, one its nigyvered up



and some really smashed up hands, try getting the drill stopped before your hand smacks the frame, well excercised fuck word

the chunk


a nice arch, very close to factory radius (3.25" holesaw)


followed the exhaust angle as good as i could


building motor mounts, freehand with a drill, beltgrinder and bandsaw, started as 1.25 solid round 6061. I need a mill

light is bad, but the hole is in the same spot

thats where she sits tonight, mocked up but i didnt get a shot of it, dont know how im going to do the coolant hose to 85 style jug around pc pipe thing yet.

JR650 wrote:


...... works awesome, one its nigyvered up


..... try getting the drill stopped before your hand smacks the frame, well excercised fuck word

Your build friggin' rulz!!!

I love the lateral thinking that people show, a block & holesaw - absofuckinglutely brilliant !

And the "well exercised fuck word" - yup, works better than meds. at times

I've probably got it wrong with this (took out a low hanging tree with my head yesterday, feeling spaced out), have you given thought to clearance if you have to put a long rod & spacer under the cylinder @ some time?

Great idea

I like it

As far as the long rod goes, ya im gonna cut the inside a bit at the corners by the flange to make sure i have the height. Hoping to keep it perfectly round on the outside if possible, it just looks nice and clean.

Make LOTS of spring clearence room

now comes the fun part(s)
kicker is going to have to be indexed (using 250 kicker for now)


Is anybody using a short rod with old style jug in a gen 3?? because i dont know how the hell im going to get the line from the pump to the jug in here


going to pull the motor and do some clearancing right away here, i have room to bolt it in right now, but not once its welded shut i dont think

Couple other quick questions, what clutch cable works on these things?? newer 500?? and also throttle as it looks like it has a different end than the 250 did. the carb (PJ) has a 168 main in it, are these just normal keihin hex jets?? ive got from 170-185 for the 650 if they are the same, im not starting that lean. Any help is appreciated, thanks, JR

i like that kicker. My bro and Nick wanted to try my bike, i said sure, with the 250 kicker neither could start it without the decompressor.

Turns out an m10x165 bolt is really hard to come by. grade 8 3/8x7 sae is 10thou bigger diameter than the factory front bolt so im using it until the right one shows up, less slop anyways. dropped the rad off to get modded, ordered an 01cr5 clutch cable at the dealership, hope it works.

Awesome!

The spacing between the pipe and cylinder doesn't look much different than on my gen 1.

I have the pipe rotated out so as to give as much spacing as possible, and I cut the hose on an angle to that it points towards the front of the bike and spliced in a copper 90 to clear the pipe. I also beat on the pipe a lbit with a rubber hammer, but very little.

i used a jug that had dual drain plugs, so i cut the pipe side part down as much as possible and put a button head plug in there so the fatty pipe cleared and installed easier

go look at my gen-1 build for the water hose, I included the hose part #

Ill check that hose out, thanks. had to work today so didnt get much done, picked up the rad, good to go there. going to tear it apart and get it all prepped for weld tonight, A good buddy welds aluminum for a living, so he is going to burn it all together for me tomorrow night, hope to hear it run this weekend.

Shes all welded up. I told buddy make it strong pretty comes second, well, its strong. ended up having to mig it, the filler for the y after I finished clearancing was a real funny shape and tough to fit close enough to make a nice tig weld, might redo a bit for asthetics this winter, for now its gonna get ridden. ill get pics tomorrow, doesnt look bad just not perfect row of dimes. Getting closer have some reassembly action tomorrow night.

nothing wrog w/ MIGing it, I MIGed my whole gen-4 conversion and it stayed together

got home from work, put some of the huge pile of parts together, repacked all the bearings that i could, you know exciting stuff



weld pics, I had the motor in before I remembered



so, got it to being a roller and remembered i havent clearanced the cases yet, but the motor is in at least, forks on, seals still blown, put one rad on, still need to bend the crossover on the left side. is everybody just using heater hose for the upper lines??

i didnt clearence the cases on my 250 chassis, had a pile of room then, and hasnt contacted yet

JR650 wrote:.... i havent clearanced the cases yet, but the motor is in at least...

Really simple....

Get a angle grinder, like this...




The diameter on the wheel needs to aproximate the diameter of the spring.

Hold the grinder spindle at the same angle as centerline of the installed rear shock.

Slowly plunge the edge of the grinding wheel into the case, while moving it up and down along the imaginary "centerline" of the shock....

It should result in this...

I used the stock 250 hoses, had to trim like an inch off the right side one. came out tits.

Interent took a shit yesterday am, so im short a sparkplug that i couldnt find a number for. got the cases clearanced, pipe is on checked the torque on pretty much every bolt, clutch cable is on. For the record, the 01cr5 cable fits perfect, except its bigger diameter than the 250 adjuster, no big deal tio fix., clutch is lighter than i expected, springs going maybe? barring some natural disaster, it should run today *knock on wood*.