2005 CRF450R conversion finished

Lonewolf039 · Post by **Lonewolf039** » August 13th, 2010, 7:04 pm

Well, I finally got my bike finished today. Went for a rip around the yard and chewed up my lawn, lol. It really feels a lot lighter than my 08 450R, but I don't have the skid plate and hand guards on yet, which my 450 has. I don't have a scale at the moment, but my 450 was 241 pounds with a 1/4 tank of fuel. I'm sure the 500 is less. Anyways, here are a few pics. I welded the frame with my spool gun then got a local welder to TIG the rads and head. Used a 99 CR250 air boot with the 500 filter and cage mounted on a 1/8" aluminum adapter and a CR125 swingarm spacer. Everything went together pretty well, like it was meant to be.

Trial fit after cutting the 450 frame.

The spool gun welds really nice on the thicker stuff, but blows holes real easy in anything thin.

Rads trial fit, replaced all hose with silicone HD hose.

Used the water outlet off the 450 on the 500 head. Opened up the head to match and plugged the other opening. You can see the coil placement and head stay as well.

And here she is all finished and after a quick ride.

More pics here http://gallery.me.com/lonewolf039#10002 ... ack&sel=30

And a great big THANK YOU to everyone here, I got all my ideas from all the other great threads.

scooter5002 · Post by **scooter5002** » August 13th, 2010, 7:25 pm

Nice looking welds on that frame brother. I paid a shop to do mine and they aren't THAT nice! Good job.

blackz34 · Post by **blackz34** » August 16th, 2010, 6:37 pm

I'm curious about what others have to say about this headstay. It seems like there is alot of controversy about what works best.

http://gallery.me.com/lonewolf039/10002 ... 7485820001

KE 336 · Post by **KE 336** » August 17th, 2010, 8:13 am

blackz34 wrote:I'm curious about what others have to say about this headstay. It seems like there is alot of controversy about what works best.

http://gallery.me.com/lonewolf039/10002 ... 7485820001

Might be better to start a new thread on 450 headstays.

As for this one, nice looking bike! Nothing like the feeling riding something you built your self.

kdizzle · Post by **kdizzle** » August 17th, 2010, 9:11 am

blackz34 wrote:I'm curious about what others have to say about this headstay. It seems like there is alot of controversy about what works best.

http://gallery.me.com/lonewolf039/10002 ... 7485820001

I think that headstay design works well. However i had mine made from billet as my original MPS one broke. When i broke i noticed alot more vibes in the chassis, so i know it is doing something.

I would be leary of that cooling design, I believe the stock setup with 2 ports in the head is the most effective for cooling.

nmdesertrider · Post by **nmdesertrider** » August 17th, 2010, 6:15 pm

There's nothing wrong with doing the headstay that way, if you don't mind your bike being screwed up.

100hp honda · Post by **100hp honda** » August 17th, 2010, 8:09 pm

why would it be screwed up ? looks fine to me

eyesky2002 · Post by **eyesky2002** » August 18th, 2010, 1:45 pm

100hp honda wrote:why would it be screwed up ? looks fine to me

Dude that pic has to go.....

eyesky2002 · Post by **eyesky2002** » August 18th, 2010, 1:50 pm

blackz34 wrote:I'm curious about what others have to say about this headstay. It seems like there is alot of controversy about what works best.

http://gallery.me.com/lonewolf039/10002 ... 7485820001

Not sure on the straight head stay, but the round version I did on my 450 conversion is holding up very well. Almost 3 years of my big ass lofting it over big tables, hard step up's and countless diggers.... So far the only thing to crack was my ribs and maybe a few tendons in my knee

Lonewolf039 · Post by **Lonewolf039** » August 23rd, 2010, 10:37 pm

Well, I've run one 5 gallon jug of gas through my bike and am working on the second now, and everything is good so far. Did some tight and twisty singletrack and a bunch of WFO sand trails and am loving the AF. It definetly handles different than when it was a 4 popper. I think most of the difference in handling is the lack of traction to the rear tire compared to the thumper. No problems with heat so far, but the first trip to the dunes will be the true test.

Lonewolf039 · Post by **Lonewolf039** » September 20th, 2010, 6:18 pm

Just got back from a week long camping / dirtbiking trip. Rode the crap out of the 500. Burned two 5 gallon jugs of fuel. Bailed a couple of times on nice sharp BC rocks and dented the crap out of my new PC pipe, also put a small hole in my clutch cover. Bike ran great, although the power is down. It really needs a rebuild now, tons of piston slap. I am going to pop off the pipe and reeds and check it out in the next couple of days. No problems with heat even on the big hills and slow tight booney bashing, but the temperature was pretty cool for September out there. Over all, this is the best bike I have ever owned. I haven't even started the CRF 450 since I got the 500 together.

Rue · Post by **Rue** » September 21st, 2010, 9:05 pm

Great job on your build!!

dubious01 · Post by **dubious01** » September 22nd, 2010, 4:12 pm

Looks good,
We'll have to get a bunch of hoons together for bruel or somethin.
Found about 6 guys with AF's in Alberta now!

Lonewolf039 · Post by **Lonewolf039** » September 23rd, 2010, 8:32 pm

We were actually planning on going to Brule for our camping trip, but the weather sucked so we went to BC instead. We are hoping to hit Brule once more before winter hits, but everybody is getting busy with work now. If you do go, let me know and I will try and get a couple of days off.

Pulled the pipe and reeds, there is lots of blowby on the piston and the intake side has the smile, but no crack yet. I will be riding the rest of the fall then sending the jug to Roosty for a bore and piston.

Rue · Post by **Rue** » September 23rd, 2010, 10:15 pm

Lonewolf039 what was the weight with the 500 in the AF??

Lonewolf039 · Post by **Lonewolf039** » September 24th, 2010, 7:26 pm

Rue wrote:Lonewolf039 what was the weight with the 500 in the AF??

The 450 was 241 pounds with heavy Maxxis tires, HD tubes, hand guards, rad guards and a skid plate. After the conversion, with all the same guards and tires, but no skid plate, the weight dropped to 236 pounds. The steely was 255 all guarded up and with a heavy FMF pipe. It feels a lot lighter than the 4 poke did, I think because the weight is lower. This was all weighed on my crappy digital bathroom scale, so take it with a grain of salt, lol.

The 450

The 500

I don't have a pic of the 500AF weight yet

but here is a couple after a ride

Lonewolf039 · Post by **Lonewolf039** » October 7th, 2010, 4:26 pm

Finally got around to modding the 450 skid plate to clear the pipe and hangers. I stole the step seat and Cycra front number plate off the 08 450 for now. Also cleaned the bike up and took a few pics of how I have it now.

matt_NC · Post by **matt_NC** » October 7th, 2010, 6:56 pm

That's a really nice looking bike.

You did some real nice fab and welding.

I stole your idea for the head outlet

Lonewolf039 · Post by **Lonewolf039** » October 9th, 2010, 5:18 pm

Well, I finally got around to weighting the 500AF, 237 pounds, ready to ride with no fuel. This is with all the guards on, and I still have heavy tires and a heavy steel JT rear sprocket. I am planning on changing to a dirt tricks steel sprocket, as the one on my 450 has held up real good and only weighs a few oz more than an aluminum Renthal. Also I am planning on switching to some lighter tires, but I don't think I am going to drop much weight. The main thing is that it is lighter than the steely and handles a lot better.

gregrobo · Post by **gregrobo** » October 10th, 2010, 4:11 am

nice build why didnt you run the 450 aircleaner?

Lonewolf039 · Post by **Lonewolf039** » October 10th, 2010, 6:40 pm

gregrobo wrote:nice build why didnt you run the 450 aircleaner?

I ride in a lot of sand and wanted the best filter seal I could get. If I used the 450 filter, it would not match up with the 250 boot and I would worry about the seal. Also the 500 filter is slightly smaller and a lot easier to get in and out of the airbox.

gregrobo · Post by **gregrobo** » October 10th, 2010, 7:02 pm

cool its always good to see what other people do to thier projects and how they come out the 500 filter does look neat in there

BannedCR500Riders.com

2005 CRF450R conversion finished

2005 CRF450R conversion finished