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Old 12-23-2013, 05:17 PM   #16
BigDave75
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Old 12-24-2013, 07:32 AM   #17
bobfab
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Looks like a fun project, i saw the chassis for sale thread and was wondering !!
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Old 01-08-2014, 08:54 PM   #18
J Banning OP
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Well, it's been a little while so I've got a bunch of updates...

After about a month of private messages, reading threads and collecting photos I finally started the fab and welding of the frame. Boy, did I underestimated how long it would take! Between cutting out the factory "Y" and mounts, grinding the frame and "Y" smooth, sourcing, measuring and cutting billet pieces for the frame and head stay and then welding everything together I figure that's a solid 24 hours labor. That doesn't count the cutting and welding of the radiator fittings, so that might be close to another 10 hours. This is my first conversion, so I could do it again in maybe 2/3 the time but I'm just saying the first time around took a lot longer than I was expecting.

Grinding the frame smooth where the old motor mounts were...



Trimming more off the "Y" and then we used a mill to remove more material from the inside so it would slide onto the downtube better...



I got two pieces of billet aluminum. One was used to fill the gap in the two lower frame rails. The ends of that were milled to fit down inside the factory hollow tubes...



Once they were tack welded in place we fitted the new motor mounts...



We then finish welded the motor mounts and the rest of the frame. I will eventually grind most of the welds smooth and get the frame powder coated...






The other piece of billet aluminum was cut and then drilled to use as a headstay mount. At this time we also welded the coil mount...









After the welding was done we tore into the motor. Aside from having a big ass crack in the stock piston and a blown crank seal, everything, including the bore looked really good (it is still the stock bore). Just to be safe I replaced the stock crank and main bearings with new OEM Honda parts and the OEM piston was replaced with a new Wiseco.





I haven't put the motor together yet. Still waiting on crank seals, new clutch, water pump rebuild kit and for me to get around to porting the cylinder before machine work to it.

Finally, I was able to get that spare 17x5" rear wheel and 160/60/17 rear tire mounted up and fitted on the bike. I've got plenty of tire clearance between the tire and frame and as long as I can adjust the spokes enough to offset the rim another 3-4mm I think I'll have minimal chain rub on the tire.


The picture doesn't show it, but this new tire/rim combo just looks so much better than the little 17x4.25 and 150/60 tire I had before. Hopefully it will help on the track too.



That's all for now!

-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 01-08-2014, 09:01 PM   #19
J Banning OP
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Quote:
Originally Posted by Fener6 View Post
Sweet. Will you be taking that to NJMP?

Edit: Ahh Banning, just realized the name. I've heard the name somewhere b4, can't put my finger on it. You know jshep or pete? Pete stopped doing track, but jshep is going at it hard this past year.
Yes, as long as it'll run over 110 mph I'll have it at NJ Motorsports Park. Not sure I know those guys though. Hit me up on Facebook. Always looking for new people to ride with!
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 01-30-2014, 07:53 AM   #20
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Looking good!
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Old 01-30-2014, 12:27 PM   #21
dhallilama
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i love and hate threads like this...

awesome build and looks like it'd be a blast! love that.

i've a garage full of project and finished bikes, but come to think of it i don't have an open class 2 stroke in a modern chassis among them. hate that.
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Old 01-31-2014, 05:35 PM   #22
Krasniewski
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This is awesome - I was just itching for a CR500 build.

Are you bumping up the stator coil to run lights and the like, or is this a track-only build?

Great work so far! Keep it goin.
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Old 02-08-2014, 07:28 PM   #23
Foot dragger
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Quote:
Originally Posted by J Banning View Post
Yes, as long as it'll run over 110 mph I'll have it at NJ Motorsports Park. Not sure I know those guys though. Hit me up on Facebook. Always looking for new people to ride with!
You were saying you wanted a 120mph super-moto bike,is it easier to make a CR500 go 120 as opposed to a pumped CRF450F? 450 revs higher as is? I know the go cart guys used to run big HP CR500's but they were usually a real short hour engine.
Simpler to work on 2 strokes though for sure.
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Old 07-17-2014, 12:03 PM   #24
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Wow, here’s my long overdue update. Sorry about that!

The bike is now running and I’ve got about 700 miles on it. Here’s what happened from January till now…

The engine:
I did a conservative port job on the cylinder based on some recommendations I got from guys who road race and ice race their CR500s (190 exhaust duration and 125 on the transfer ports).

My trusty porting tools -- the blue ¼” collet Makita for pretty much everything and the ⅛” collet Dremel with 90 degree adapter for the transfer ports.


I enlarged and raised the boost ports in the intake


For the exhaust port I smoothed, polished and matched it to the flange.


I raised the transfer ports 1.2 mm and the exhaust port was raised 3mm and widened 3mm on each side.


I opened up the transfers where they meet the case and knife edged them some.


I then used a ball hone, some motor oil and a cordless drill to hone the cylinder. It’s times like these that being a bachelor is a good thing :)


Some new parts I ordered for the bike finally arrived just in time for the engine assembly -- Boyesen engine covers, a Pro Design Cool Head, Keihin PWK 41 mm carburetor, and a set of sprockets from Sprocket Specialists (15 & 16 tooth front and a custom ordered 38 rear).



I then cleared my kitchen table, grabbed my service manual and a couple beers and went to work assembling it all.


That’s all for now.
Coming in the next update… airbox modifications and the engine install.

-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 07-17-2014, 12:30 PM   #25
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Next steps: installing the engine, the air box and radiators

Installing the engine
Not much to say here. It went in fairly easy. Here’s some photos of the head stay and coil mount.



I did have to bend the stock rear brake pedal to fit around the engine case. That was easy. I just marked lines for each bend and went slowly, one at a time until I had the clearance I wanted.


Modifying the air box
I used an air boot and filter flange from a 1999 CR250.


I then had to cut the inside of the CRF450 air box to clear the flange and then drill and bolt the adapter plate to the box and flange.


This took much longer than I expected. I’d estimate a good 3 hours to measure everything a couple times before cutting.


Once I knew I had it right and did a test fit I then took it apart and used black RTV sealant between the plate and box.

Radiators
I had to modify both the lower fittings on each CRF450 radiator. The one on the left had to be cut and rotated up and the one on the right had to be cut off completely, the hole opened up and a new fitting welded on at a downward angle. I then drilled a hole in it and welded on a spare fitting I had for the crossover hose to the other radiator.


Here you can see the angled fittings for the crossover hose


Here you can see the angled fitting pointing to the water pump.


At first I used a straight piece of hose but as you can see it had a slight kink in it. Once I got the bike running and warmed up it got far worse, but I was able to go to the auto parts store and get a formed hose that had a slight bend at the end. It worked perfect.

-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 07-17-2014, 05:04 PM   #26
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More fab work and then a running bike!

OK, so now we’re into the March timeframe. I have the engine together and in the chassis. The air box mods are done and it’s mounted too. Now I only have to heat up and shape the bottom of the gas tank to clear the spark plug and then hook up the carb and exhaust.

Forming the gas tank
I used my heat gun to heat up the bottom of the tank (empty and dry first). I kept it at the distance seen in the picture and used slow circle motions to evenly heat the area I wanted to deform. Then, with a heavy leather work glove on I pushed it in and held it there for a minute or two while it cooled.



Carb and exhaust
Although I had a new carb (PWK 41mm) I still hadn’t gotten the exhaust system I wanted to go with it (CPI race pipe) so to get the bike running I put the Pro Circuit pipe, silencer and stock honda Keihin carb on.



To save time and reduce headaches I left the gas tank off and instead hooked up my Motion Pro fuel can to the carb and rolled the motorcycle lift outside to attempt the bike’s first startup.

Video: https://www.youtube.com/watch?v=8Tl1On3bBXM

And with that I now have a complete, running CR500 supermoto!!!
This is what it looked like
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 07-17-2014, 05:24 PM   #27
dlrides
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Great work !

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Old 07-17-2014, 05:40 PM   #28
J Banning OP
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First ride and new exhaust

I started the bike up and let it get up to temp and then cool down. I then did a gentle ride around my neighborhood on it then let it cool. I then went out and went through each gear, not beating on it, but letting it get on the pipe. The bike ran great. It had awesome power, even with the stock carb. T

A few issues I noticed:
1) The Pro Circuit pipe touched the water pump hoses. I had to wrap them in heat tape.
2) The 15/38 gearing is really tall though. Makes it a pain in the ass to leave stops and intersections. Once you’re going though it’s no problem. The bike will cruise at 70 with ease.

New exhaust
My CPI race pipe finally showed up. I wanted the chrome plated version but for some reason they charged me for the bare steel version and that’s what I got. Whatever, I think it looks awesome. The custom Dyno Port silencer didn’t show up though so I ordered an off the shelf FMF silencer instead.



Unfortunately, the CPI pipe needed a little work. One of the welds on the stinger section of the pipe was only half way completed and the exhaust flange up front was too tight so I had to take a 80 grit cartridge roll on my die grinder and open it up some. Once that was done it went on the bike. I was happy to see that there was more clearance between the pipe and the water pump hoses now.



The FMF silencer needed some work too. In order to get it to align with the mounts I had on the subframe I had to cut and weld it. I suppose the Pro Circuit silencer I was running (off the old Service Honda bike) was custom made by Service Honda or there was a slight difference between the CR250 supframe on that bike and my CRF450 subframe. Regardless, I got it fixed. One at a time I made small cuts with a cutoff wheel until I got the bend I wanted. I then welded it up.



Once that was completed I was done. I was also glad to see that there wasn't any clearance issues out back for the 160 rear tire. I can compress the suspension and the pipe won’t hit the silencer.



-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 07-17-2014, 06:00 PM   #29
J Banning OP
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First time at the race track
...and it didn’t go so well.

I was hoping to run the bike at Summit Point Shenandoah the following weekend but was nervous because I had the new pipe and carb on the bike now but no way without breaking a lot of laws to test it on the street to see if the tune was good. What I did then was load the bike up and head to New Jersey Motorsports Park and do a couple slow laps during their lunch break on the big track (Thunderbolt).



The bike sounded different with the new pipe and silencer it was making awesome power. Perhaps too awesome… or perhaps awesomely lean is more like it. I burned a hole right through the top of the piston as I was coming onto the front straight at about 90 mph!!!!



It didn’t seize, it just lost all compression. A post mortem revealed that although the pilot (50) and main jet (192) were fine, the needle (DGH) was way too lean.

I got the bike home and that night had the engine out and tore down (only took an hour to have the cylinder and piston in my hands).

I cleaned everything up and had a fresh piston in the bike and it was running again in 3 days. I took the bike out for a quick road test and everything appeared to be good to go.

Road test video: https://www.youtube.com/watch?v=rzun0c_uotA

I was now ready for the big weekend at Summit Point

Summit Point trackday
Based on the meltdown at NJMP I changed needles and went with a DEG (different length and diameter). The bike stayed together the entire day and I had a great time. I think I did six twenty minute long sessions on the bike.

Here’s a short video from early in the day:
https://www.youtube.com/watch?v=-M_X575CKm4

Need to do a little tweaking to the jetting. Too rich at lower speeds and I think the 192 main is too rich as well, hurting top end power… but it was still fast enough to run dead even with 70hp Aprilia 550SXVs!

-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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Old 07-18-2014, 02:00 PM   #30
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Updates from the Tail of the Dragon

Towards the end of May I spent a week in Western North Carolina and got to ride the CR500 on the Tail of the Dragon.

Here's some Killboy.com photos








And some video:





-B
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Current rides: '04 CR500 AF supermoto, '06 KTM 250 XC-W, '02 XR100 minimoto, '09 GSX-R 600 track, '07 VFR800
Past rides: '77 Goldwing GL1000, '86 Z50R, '86 LT250R, '86 TRX250X, '90 XR600R, '92 KX250, '98 ZX-7R, '99 TM125, '99 CR500AF, '01 GS500E, '04 KTM 525 SMR, '05 KTM 625 SMC
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