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Old 03-28-2013, 09:14 AM   #106
jar944 OP
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To make this bike even more unique i'm attempting to add a core exp clutch. Rekluse does not sell a core exp for the 500, and it may not work due to the low rpm TQ. The only one off part will be the clutch cover. It will require machining up a deeper clutch cover to clear the thicker clutch assembly.

as for the parts:

rekluse RMS-7711 kit with out the deep clutch cover (would not fit)

with the addition of

442-112 PRESSURE PLATE SPRING - EXP (heaviest available)
RMS-268 WEDGE KIT - EXP 2.0 Heavy (heaviest available)

and for the basket
Barnett basket 321-35-01004

Hopefully it will lock up early enough as is and I will not need to add tungsten to the wedges. If it does not my first plan is to replace all the 36 of the 3/16 steel bearings with tungsten carbide.

Failing that I'll be drilling the wedges for more tungsten alloy.

wedges:


core exp
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Old 03-30-2013, 08:23 PM   #107
The Letter J
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Quote:
Originally Posted by jar944 View Post
The only one off part will be the clutch cover. It will require machining up a deeper clutch cover to clear the thicker clutch assembly.
How much deeper does it need to be? A spacer sounds like a much easier (although not as cool) approach than a completely new cover. If it is real close, you can stack a couple gaskets. I've had to do that on the ignition side before when fitting different flywheels... like these http://www.steahlyoffroad.com/flywhe...er-spacer.html
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Old 03-30-2013, 08:31 PM   #108
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Originally Posted by The Letter J View Post
How much deeper does it need to be? A spacer sounds like a much easier (although not as cool) approach than a completely new cover. If it is real close, you can stack a couple gaskets. I've had to do that on the ignition side before when fitting different flywheels... like these http://www.steahlyoffroad.com/flywhe...er-spacer.html
It needs to be .320" deeper.

I thought about a spacer, and might go that way for testing.
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Old 05-19-2013, 12:21 PM   #109
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Jared-what did you have to do make the rear brake lever fit?

The CR5 motor in my ktm 450 conversion sits a bit further out than the stock motor, I had a stock lever from an EXC, but it looks like some serious bending would be required to make it fit.

Thanks!
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Old 06-07-2013, 04:53 AM   #110
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Originally Posted by Research Rat View Post
Jared-what did you have to do make the rear brake lever fit?

The CR5 motor in my ktm 450 conversion sits a bit further out than the stock motor, I had a stock lever from an EXC, but it looks like some serious bending would be required to make it fit.

Thanks!
I bent it out about 1/8". Some seem to fit w/o any bending.
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Old 06-20-2013, 12:57 PM   #111
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I bent it out about 1/8". Some seem to fit w/o any bending.
I need to bend it out more. Its rubbing a hole in the cover now.
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Old 07-08-2013, 08:59 PM   #112
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08 xcr-w 450

I have a 2008 xcr-w 450 which I am assuming shares the same cradle. After finding this build I decided to build my own ktm500. I had a few questions for you what airboot did you use for your build as in model of bikes airboot was it a 2008 ktm 300 airboot and did you use the stock cr carburetor. and did you use stock swingarm spacers or did you have them made for you on a lathe. your build is awesome by the way you have some serious bike building talent.
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Old 07-09-2013, 05:49 AM   #113
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Quote:
Originally Posted by x17shane View Post
I have a 2008 xcr-w 450 which I am assuming shares the same cradle. After finding this build I decided to build my own ktm500. I had a few questions for you what airboot did you use for your build as in model of bikes airboot was it a 2008 ktm 300 airboot and did you use the stock cr carburetor. and did you use stock swingarm spacers or did you have them made for you on a lathe. your build is awesome by the way you have some serious bike building talent.
The XC4 engine bikes have a different cradle (longer frt to Rear) than the RF4
Any 2t boot (08-10) 125-300
You can use the stock carb, I'm running a 39mm PWK
I made custom spacers (should be in a post)
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Old 07-09-2013, 01:39 PM   #114
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so the only real difference is that the engine mounts will be placed in a different spot. correct?
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Old 07-09-2013, 01:40 PM   #115
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thankyou for your help hopefully my finished product will come out close to yours
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Old 07-09-2013, 05:26 PM   #116
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so the only real difference is that the engine mounts will be placed in a different spot. correct?
For the most part yes.
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Old 08-24-2013, 06:51 AM   #117
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thanks for sharing

I have three ktms, 2 300,s 07 and 08, also a 2008 450 xcf....
I recently aquired a cherry, and i mean a cherry cr500 that has low hours and needs nothing. At first i was thinking of doing a hybrid BUT I spoke with a friend that raced cr500,s for 15 years and his opinion was not to tear up the cr because they are hard to find in that kind of condition yet hybrids and parts bikes are easily located..... SO i have decided to use the cr for lite duty as is ??
BUT if i blow up one of the ktms,s i may change my mind...question is the xcf the best canidate ??? or one of the 300,s ?
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Old 08-25-2013, 01:15 PM   #118
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Originally Posted by booniebasher View Post
I have three ktms, 2 300,s 07 and 08, also a 2008 450 xcf....
I recently aquired a cherry, and i mean a cherry cr500 that has low hours and needs nothing. At first i was thinking of doing a hybrid BUT I spoke with a friend that raced cr500,s for 15 years and his opinion was not to tear up the cr because they are hard to find in that kind of condition yet hybrids and parts bikes are easily located..... SO i have decided to use the cr for lite duty as is ??
BUT if i blow up one of the ktms,s i may change my mind...question is the xcf the best canidate ??? or one of the 300,s ?
I'd say stock cr5s are common compared to AF or KTM conversions.

You need the xcf frame, 300 carb boot, rads and coil. The rest is the same between them.
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Old 08-26-2013, 11:34 AM   #119
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Jar944, nice work !!

May I ask what the length of that swing arm is from pivot point to far adjustment slot is.

Thanks in advance

-Buddy
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Old 01-15-2014, 07:50 PM   #120
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I finally finished some extra heavy wedges for my rekluse.







Clamping force: New wedges vs rekluse heavy wedges


I still need to machine a new clutch cover for it all to actually work.
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