Gen 5 CR500AFX build started on 01.12.2012

fmikhele · Post by **fmikhele** » December 15th, 2012, 10:11 am

Thanks DZ. Still have to clean up the plate a little. I test fit the side door and it seemed to work at the time. I've yet to re-install the pins for the door and try it. I will post photos and let you know...

fmikhele · Post by **fmikhele** » January 6th, 2013, 2:31 pm

Here is DZ's air boot adapter with a little tweaking to make the airbox door for the X chassis still functional. Still needs a bit of clean up, but fits nicely:

DSC00981 by fmikhele, on Flickr

DSC00982 by fmikhele, on Flickr

DSC00984 by fmikhele, on Flickr

DSC00985 by fmikhele, on Flickr

DSC00976 by fmikhele, on Flickr

DSC00979 by fmikhele, on Flickr

DSC00978 by fmikhele, on Flickr

DSC00977 by fmikhele, on Flickr

DSC00980 by fmikhele, on Flickr

Post by **AlisoBob** » January 6th, 2013, 5:33 pm

fmikhele · Post by **fmikhele** » January 11th, 2013, 5:06 pm

Birthday present from the wifey

DSC00986 by fmikhele, on Flickr

Post by **AlisoBob** » January 11th, 2013, 5:32 pm

fmikhele · Post by **fmikhele** » January 13th, 2013, 2:04 pm

Snatched this 1992 up on Saturday for $900. Fresh engine with an hour on it.

DSC00988 by fmikhele, on Flickr

DSC00990 by fmikhele, on Flickr

fmikhele · Post by **fmikhele** » January 28th, 2013, 5:25 pm

Got the frame all prep'd to weld. Modified the bottom outlet on the right-side rad using DZ's piece.

DSC00991 by fmikhele, on Flickr

Noticed I have some clearance issues with the lower rad cross hose and the Y

DSC00994 by fmikhele, on Flickr

DSC00993 by fmikhele, on Flickr

Airbox adapter worked nicely

DSC00995 by fmikhele, on Flickr

Post by **AlisoBob** » January 28th, 2013, 6:11 pm

Sweet!!!

http://www.youtube.com/user/500bigbore · Post by **Roostius_Maximus** » January 28th, 2013, 6:13 pm

What's that quad vent pj carb off of?

fmikhele · Post by **fmikhele** » January 29th, 2013, 2:33 pm

Not sure... Just the one that came with the bike! Was planning on finding a 39.5mm off a kx500 to replace it, but they are becoming a bit hard to find these days...

fmikhele · Post by **fmikhele** » January 31st, 2013, 3:27 am

Frames all welded and this is on its way (39. 5mm Keihin PWK)...

e8_1 by fmikhele, on Flickr

fmikhele · Post by **fmikhele** » January 31st, 2013, 9:56 am

Got my crank with a new Pro-x rod back from MCR today, which reminded me to post this. There are a couple left...

Brand new $50 Pro-x rods

[/url] http://www.ebay.com/itm/170969689476?ss ... 1497.l2649

Kuma · Post by **Kuma** » January 31st, 2013, 12:31 pm

Only one left now

Thanks for the tip

fmikhele · Post by **fmikhele** » January 31st, 2013, 2:13 pm

fmikhele · Post by **fmikhele** » February 2nd, 2013, 5:53 pm

Managed to squeeze a little work in on the bike today. Clearanced the engine for the rear shock; needs a final sanding, but the profile follows the shock nicely.

DSC00997 by fmikhele, on Flickr

Got the bike on its wheels

DSC00996 by fmikhele, on Flickr

Also took the heat to the right-side rad outlet to gain clearance.

I have been thinking about the best way to form the tank... Has anyone on here ever tried using a vaccum while heating the tank

Post by **AlisoBob** » February 2nd, 2013, 6:19 pm

http://bannedcr500riders.com/board/viewtopic.php?t=7918

fmikhele · Post by **fmikhele** » February 4th, 2013, 3:35 pm

Decided to experiment with forming an old CR250 tank I had kicking around today. I took a ABS 1 1/2" coupler and machined a quick adapter to fit on the neck of the tank, followed by a piece of 1 1/2" ABS pipe with a threaded ball valve to control the vacuum pressure and another adapter with a piece of fuel line ran through it. The fuel line was for running cool water to keep the area around the shut off valve from getting to hot (Worked Nicely).

photo(1) by fmikhele, on Flickr

image(1) by fmikhele, on Flickr

The setup worked nicely, but the tank not so much.... Holding two heat guns and trying to adjust the vacuum pressure is not recommended

image(2) by fmikhele, on Flickr

Looking at the CRF250 tank the shape is a lot different and less likely to crease. What I noticed from this tank is unlike Bob's method where you want to heat around the area you are forming, direct heat on the area your are forming works better. Needless to say a little nervous to do the CRF250 tank...

freeride588 · Post by **freeride588** » February 4th, 2013, 4:33 pm

I think your making this a little too hard on your self. Grab the heat guns heat AROUND the area that needs shaping press the tank in to where you want it and dump some cold water on the tank to hold the new shape. Done!!!!! Heating the area directly will lead to leaks.

fmikhele · Post by **fmikhele** » February 7th, 2013, 3:10 am

Thanks for the input Kevin. Had an idea and an old tank so I figured I'd give it a try... Just wanted to see if there was a better way.

Ended up using Bob's Method to form the tank, turned out good with no leaks!

freeride588 · Post by **freeride588** » February 7th, 2013, 4:37 pm

fmikhele wrote:Thanks for the input Kevin. Had an idea and an old tank so I figured I'd give it a try... Just wanted to see if there was a better way.

Ended up using Bob's Method to form the tank, turned out good with no leaks!

Good to hear. I know how nerve racking putting the heat to a nice tank can be, I was worried before I started heating my brand new desert tank.

fmikhele · Post by **fmikhele** » February 8th, 2013, 5:37 pm

Maybe its lack of sleep, but am I missing something here or is this not ridiculously cheap for a Hinson Clutch Basket???

[url] http://www.ebay.com/itm/Hinson-Racing-B ... 5f&vxp=mtr

fmikhele · Post by **fmikhele** » February 9th, 2013, 6:10 am

Apparently it was ridiculously cheap it was $73.00 yesterday and now it is $184.94...

fmikhele · Post by **fmikhele** » February 18th, 2013, 12:04 pm

Purchased another airbox adapter plate from DZ and made some hinges

DSC01000 by fmikhele, on Flickr

fmikhele · Post by **fmikhele** » February 19th, 2013, 10:40 am

FYI New Hinson Clutch basket for 05-07 RMZ450 $150 on Ebay right now:

http://www.ebay.com/itm/HINSON-RACING-C ... xp=mtr[url]

According to OEM cycle this will fit the CR500

http://oemcycle.com/Item/product/900078543[url]

fmikhele · Post by **fmikhele** » March 12th, 2013, 9:20 am

Anyone got a 1998 CR250 airbox boot kicking around?

BannedCR500Riders.com

Gen 5 CR500AFX build started on 01.12.2012