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I am thinking about building a Gen 2 or Gen 3 AF. Do you have to modify the tank and have issues with plug clearance in either of these generations? Also do you have to modify the pipe (other than the mount) with either of these generations?

I did not have to modify my tank on the 2 or 3 I built. I went the easy way on both and bought an FMF pipe from SH. I would build a Gen 3 if I were you.

thers alot more gen3 parts available, just ask seanmx57 about trying to find good gen2 stuff

i'd buy the standard pipe if its less, then make a key shaped piece and use a body pannel clip to thread into...

you can use it on a steelie or af, theres no goofy welding to the pipe that takes the finish off, and the stock little banjo piece is the right length

Mik329 wrote:I did not have to modify my tank on the 2 or 3 I built. I went the easy way on both and bought an FMF pipe from SH. I would build a Gen 3 if I were you.

I emailed SH one time about buying a pipe and they told me they only sold to SH bike owners - strange.

Roostius_Maximus wrote:thers alot more gen3 parts available, just ask seanmx57 about trying to find good gen2 stuff

i'd buy the standard pipe if its less, then make a key shaped piece and use a body pannel clip to thread into...

you can use it on a steelie or af, theres no goofy welding to the pipe that takes the finish off, and the stock little banjo piece is the right length

This is much easier than the mod I had to do with the pipe on the Gen 1. I have a Gen 1 frame and other parts but the plug clearance issue is what I want to avoid - I found it a real problem changing plugs in my Gen 1 - thank god the CR500 hardly ever fouls them. Of course the Gen 3 is a much newer bike as well so I think I will go for it. Does anyone know anyone who sells the modified "Y"s for the Gen 3 conversions - I would love to have one of the Team Trouble Ys.

CR500PHIL wrote:I am thinking about building a Gen 2 or Gen 3 AF. Do you have to modify the tank and have issues with plug clearance in either of these generations? Also do you have to modify the pipe (other than the mount) with either of these generations?

No tank mods. No plug clearance issues. Rear pipe mounts needs modification. Very similar to Gen3 but I had a Gen2 so thats what I built. Parts are still around, btw..

Honda manufactured the Gen 2, for what.....45 minutes???

Thats ALOT in tooling costs, for minimal return.

I say Gen 3, all the way.

I can give you measurements for the stuff the way some guys do it.
I cut dumbo ears in the Y + pressed the frame. clean and guys arent sure from the outside of the bike on how it was done.

I'm doing a gen1 what's the go with the pipe mod?Thought it was a matter of relocating the pipe mount.

boris wrote:I'm doing a gen1 what's the go with the pipe mod?Thought it was a matter of relocating the pipe mount.

Yes you need to relocate the rear mount and fabricate a bracket for it and the silencer. The problem is I had with my Gen 1 was the plug clearance - I worked it but it was a real pain when trying to change plugs - even with shorty plugs - especially when 10 miles away from everything. I basically had to remove the seat, number plates, shrouds, and tank to change a plug.

gen-1 is the worst for pipe fitment and tank clearance. gen-2 and 3 250 are the only way to go IMO. the have to make spacers for the swingarm bolt on a gen-2, on a get-3 you just have the buy the 59mm cr125 swingarm bushing. no tank clearance issues on either. some rad clearance issues on the gen-2. You don't NEED the rear pipe mount, infact all of my conversions didn't have one and I never had an issue. the silencer mounting is the worst part about a gen-3.

hoofarted and I did our gen-2 and 3 the same way, cut in the bottom of the bend in the craddle and cut the top of the Y and tapped the y up while extending the front out. leaving and inch gap and filling it with dowels, then welding it in and smoothing it out works perfect and its impossible to tell its not OEM. I personally prefer the gen-3 250 to all others.
also the rad modding on the gen-3 is just adding a 3/4" spout out the bottom and covering the existing one. Gen-3 also gives you a kick ass coil mounting spot where the powervalve servo sits.

dannygraves wrote:gen-1 is the worst for pipe fitment and tank clearance. gen-2 and 3 250 are the only way to go IMO. the have to make spacers for the swingarm bolt on a gen-2, on a get-3 you just have the buy the 59mm cr125 swingarm bushing. no tank clearance issues on either. some rad clearance issues on the gen-2. You don't NEED the rear pipe mount, infact all of my conversions didn't have one and I never had an issue. the silencer mounting is the worst part about a gen-3.

hoofarted and I did our gen-2 and 3 the same way, cut in the bottom of the bend in the craddle and cut the top of the Y and tapped the y up while extending the front out. leaving and inch gap and filling it with dowels, then welding it in and smoothing it out works perfect and its impossible to tell its not OEM. I personally prefer the gen-3 250 to all others.
also the rad modding on the gen-3 is just adding a 3/4" spout out the bottom and covering the existing one. Gen-3 also gives you a kick ass coil mounting spot where the powervalve servo sits.

Thanks - I am pretty much convinced it will be Gen 3. I have some Gen 1 parts left over but I really want to go newer with no plug issues. I may be able to use the tree - not sure. Of course with the prices of the engines lately I am not 100% sure I be able to build it. There are engines over 20 years old on eBay selling for well over $1000.00 and a late 90s + engine is going for about $2000.00 +. This is insane to say the least - especially considered that I can buy a mint 2001 KX500 with all the aftermarket parts for about $1800.00 locally.

you are much better off buying a complete bike... it will come with a pipe and silencer, a rad spout you can use and othe misc. stuff, then you can sell off whats left over to recoup some funds. I bought my '89 complete bike for $400 because it wasn't running. the clutch was fubar and the cdi was missing. I opened it up and it was the cleanest motor I had ever seen inside and was on the stock bore. try hunting craigslist, you should have some luck there. I've been seeing complete '80s bikes going for like $500-$1000 A friend of mine got a perfect running an very clean '92 for $850... they are out there, just keep your eyes open.

Man I was selling a complete 89 500 motor with carb, electronics, silencer and didnt get $500 for it after shipping and paypal fees, it was a good deal for sure and I'll probably regret it in the future.