CR500 Steel to Alloy frame conversion.

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Mon Apr 29, 2013 5:56 pm

Stickered up. (custom)
White barkbusters
Rad overflow bottle in airbox
Stegpegz
Front pads

For those that are wondering, yes the swingarm sticker is from the 1990's CR500's, it's a bit retro and i wanted a clear background but he didnt have it in stock.

CR500 AFc.jpg
CR500 AFc.jpg (121.01 KiB) Viewed 9626 times



parts to come:
Semco "red" rad hoses
Boyesen black engine covers
Scotts steering damper kit
Fast flex bars
CRF450X brake pedal (might fit better)
pivot pegz
Full suspension rebuild and geometry setup (this week.)


Went away for a 4 day weekend out in the sand in the Mallee country with the club for FULL on testing

It's incredibly light and well balanced, it stops a little too well, turns very well which is expected from this frame, went to 14/45 gearing which makes this very tractable out of the tight sand corners and can ride in 3rd everwhere. it had a few attempts at a big sand dune hill climb (video later I hope) which it did with predictable ease with 2 of our club gun riders making it look easy. 8)
(I didnt make it) :(

We clocked it at 165kmph indicated at 7/8ths throttle once the chase bike caught up and was as fast as he could go, we reckoned maybe 175 was possible which is pretty quick on sandy/hardpack paddock for a dirtbike, they run 40 rears for finke at 180+kmph.

About 8 club members had a blat and the look on their faces afterwards was priceless. Some of these guys ride competitively in SAORC, 24hr reliabilty trials, Hattah and Finke :D

It is an absolute hoot to ride for 20 mins blats hitting the whoops at speed on the back wheel pingin the the tops of them :D it is a bit twitchy at high speed.
I rode for 1.5 hrs through a tight sandy loop through scruby sand hills then a hill climb and return ride, I couldnt even hold a can of beer unless I was using 2 hands afterwards. the strength and endurance needed to hold on to vibrating bars and manhandle it over that time is huge, arm pump central and my arms are killing me still. riding the Husky the next day was a breeze in comparrison and a welcome relief on the 120km ride.

Hence fitting the stegpegz already which are worth every penny, the pivotpegz, flex bars and the scotts will be fitted when they arive, once thats all on and the suspension is rebuilt it will be one hell of a trail weapon. hopefully most of this will be done for the next club ride in less than a fortnights time.

If you think this is a crazy m/f bike... it is :twisted:

So who wants a ride!
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby timmyrocks » Mon Apr 29, 2013 11:18 pm

Wicked jonno!!!!
Ill have a ride :P but ill probably just idle around and shit myself haha
anyone can go fast in a straight line,,,,

Team Crash "09"

TE310 2011 Husqvarna trail bike :)
WR125 2004 Husqvarna :P
User avatar
timmyrocks
KSRC Contributor
KSRC Contributor
 
Posts: 2149
Joined: Wed Jan 16, 2008 3:45 pm
Location: Western Sydney
Bike: Other Kawi
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby the kid » Tue Apr 30, 2013 6:38 am

8)
Ummmm let me see
User avatar
the kid
KSRC Addict
KSRC Addict
 
Posts: 3948
Joined: Thu May 12, 2005 5:10 pm
Location: Bendigo
Bike: Yamaha
State: Victoria

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sun Nov 03, 2013 1:27 pm

ok it's the end of riding season for this bike so the engine will be fully rebuilt and i am contemplating lowering the exhaust port or at least a port job and have been researching a good place to get this done. i have been looking at other carbs like APT smartcarb however i have been following a guy in Canada (FB) who has been experimenting with all kinds of carbs and setups and he reckons the PWK stock carb is the go although mine is an earlier PJ.
i have seen the direct injection setup but the promised conversion kits haven't materialised.


Other stuff that I might do:

larger radiators
CR250R digital ignition.
Stator kit for lighting
manifold pulse injector kit
wide ratio gear set
700 big bore
Motard
build a CRF X ADR compliant frame
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby Gosling1 » Sun Nov 03, 2013 1:44 pm

Jonno wrote:......So who wants a ride!.......


you already know the answer to that question :lol:

sounds like you have go this rig sorted now buddy, would love to take it for a spin..... :kuda:
".....shut the gate on this one Maxie......it's the ducks guts !!............."
User avatar
Gosling1
Team Donut
Team Donut
 
Posts: 13980
Joined: Mon Jun 20, 2005 9:30 pm
Location: Anarchy Road
Bike: Z900
State: ACT

Re: CR500 Steel to Alloy frame conversion.

Postby MAXUMIS » Sun Nov 03, 2013 2:19 pm

Jonno ,raise the barrel and deck the top of it , 20 thou ,It will be a pure beast !! to top it off knock 20 thou off the head for operating compression !!
life starts at 200 kph!
User avatar
MAXUMIS
KSRC Contributor
KSRC Contributor
 
Posts: 1034
Joined: Fri Jul 09, 2010 7:16 pm
Bike: ZX12R
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sat Nov 30, 2013 1:00 pm

MAXUMIS wrote:Jonno ,raise the barrel and deck the top of it , 20 thou ,It will be a pure beast !! to top it off knock 20 thou off the head for operating compression !!


i am actually trying to smooth it out for trail riding


The bike is at Two Stroke Performance for a full rebuild.
It was dyno tested before strip down at a lazy 52 rwhp at 6000rpm.
He reported that it starts easily and it runs fairly aggressively but its also quite rough in its delivery,

It will be interesting to see the improvements.
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby laidback » Sat Nov 30, 2013 3:51 pm

Mad, crazy, insane.... :kuda:
Roady - ZRX1200R
Tracky - ZX9R F1 Team Jerry Atric

I've reached the age where 'happy hour' is a nap.
User avatar
laidback
KSRC Addict
KSRC Addict
 
Posts: 3305
Joined: Mon Mar 02, 2009 4:55 pm
Location: Wagga Wagga, NSW
Bike: ZRX
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Tue Sep 09, 2014 10:37 pm

update.

Achieved most of what we set out to do.

Porting for midrange.
VF3 reed block. reeds
Squish mods on head.
Balanced crank, welded bush/pin.(exy)
New PWK carb, replaces PJ
Woosner piston
Gearbox rebuild
new clutch plates as the others burned out on the dyno.

TwostrokePerformance......Recent CR500 job we did... the pink line is the bike with another tuners high comp head and stock porting, the blue line is after it had been TSP'd with our own low comp head, some very mild porting and a PWK 38mm carb. Both runs used an FMF Gnarly pipe designed for bottom end power. The same setup made 65rwhp with a different top end pipe but had less power through the midrange. This bike starts first kick and idles like a dream, plus now pulls better everywhere and due to the low comp head design is much safer, vibrates way less and is less prone to detonation. To convert these numbers to crank hp add approx 13%... so 62rwhp = roughly 70hp at the crank, and 51rwhp = roughly 58hp which is exactly what Honda claim as the stock power output of this engine.


Image


Hope to pick it up soon, so a road trip to Gippsland is on and a few days riding around Erica is on the cards I would say.

Overall Bike build cost is around 12k, still it is cheaper than a service honda CR500AFC.
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby laidback » Tue Sep 09, 2014 11:09 pm

Way more fun doing it your way mate. :kuda:

How's it go now mate?
Roady - ZRX1200R
Tracky - ZX9R F1 Team Jerry Atric

I've reached the age where 'happy hour' is a nap.
User avatar
laidback
KSRC Addict
KSRC Addict
 
Posts: 3305
Joined: Mon Mar 02, 2009 4:55 pm
Location: Wagga Wagga, NSW
Bike: ZRX
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Tue Sep 09, 2014 11:32 pm

laidback wrote:How's it go now mate?


Tell ya when I go and pick it up ;)
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby Wattie » Wed Sep 10, 2014 8:09 am

Sweet.
Motard that sucker
Wattie #55
ZX10R "The Crim"
ZX10R "Gumby"
Proudly Supported by Allfixed Automotive 9634 1455
sam & srt, survived
RGM, left a message
User avatar
Wattie
Extreme Post Whore :-)
Extreme Post Whore :-)
 
Posts: 10083
Joined: Mon Oct 31, 2005 12:23 pm
Location: Bligh Park
Bike: ZX10R
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby Jonno » Sun Sep 14, 2014 7:12 pm

Wattie wrote:Sweet.
Motard that sucker


Will do :kuda:
User avatar
Jonno
Mobile Chicane
 
Posts: 5675
Joined: Thu Dec 30, 2004 4:10 pm
Location: Brisbane
Bike: Other Kawi
State: Queensland

Re: CR500 Steel to Alloy frame conversion.

Postby RustyAs » Mon Nov 17, 2014 6:57 pm

Jonno wrote:I cant swear in swedish :lol:


Here is a nice little read on the KX500.
http://www.dirtbikemagazine.com/ME2/dir ... 3C382A19F5

Image

"A fuse looking for a light."
"Unrideable."
"Violent."


:kuda:


Jonno

this page has disappeared, I don't suppose you kept a copy of the write up?

Im seriously looking at a KX 500 resto

Cheers

Rusty
If everything is under control.......your going to slow

2012 Husaberg FE570 Dirty
2002 ZZR 1200 Roady
Bandit 1200 (Written off. My fault )
FJ 1100 ( Written off. Not my fault)
2000 ZZR 1100 (Sold)
XR 600 (630 Ballard Kit)
User avatar
RustyAs
KSRC Member
KSRC Member
 
Posts: 364
Joined: Sun Apr 26, 2009 8:09 pm
Location: Hunter Valley
Bike: ZZR1200
State: New South Wales

Re: CR500 Steel to Alloy frame conversion.

Postby Gosling1 » Mon Nov 17, 2014 8:23 pm

RustyAs wrote:......Im seriously looking at a KX 500 resto.......


looking forward to watching that one unfold :kuda:
".....shut the gate on this one Maxie......it's the ducks guts !!............."
User avatar
Gosling1
Team Donut
Team Donut
 
Posts: 13980
Joined: Mon Jun 20, 2005 9:30 pm
Location: Anarchy Road
Bike: Z900
State: ACT

PreviousNext

Return to Dirt Bikes and Motards

Who is online

Users browsing this forum: No registered users and 3 guests

cron