BannedCR500Riders.com

Thanks for the great site, it has been very helpful throughout this build.

I want to show our build progress to this forum. A little background. My brother and I are huge motorcycle geeks. Between the two of us we could fill a small dealership. We like all bikes, but take a special interest in Honda. (We bleed red right...) My brother says red invokes fear, and he loves when women shudder and hide their children at the sight of him wheeling down the street. Anyways to be clear my brother is a craftsman, and has done all the fabricating, machining, and welding of this build. I am the financier, instigator, researcher, and parts hound.

We started with a 2009 CRF450R frame, and found the rest of the chassis parts from eBay, forums, and Honda shops. Our donor motor came from a 1986 CR500R.

http://bannedcr500riders.com/board/view ... c&start=75



Brit's build is a good starting point.

Read up, toss some ideas around, and get to work!

brits bike did turn out nice. of course he didnt do one ounce of the work though

AlisoBob wrote:http://bannedcr500riders.com/board/view ... c&start=75

Brit's build is a good starting point.

Read up, toss some ideas around, and get to work!

Thanks for the link, britincali's bike turned out SOLID.

Don't worry about the grips, that is how I like it. ----->







No CNC here.

More of the build.









Dirty 1986 pump.



A little elbow grease.







Well what do you think? We are pretty excited!

Here is number two. Complete 2010 roller.

result , keep the pics coming

looks good. where you getting the chassis ?

K-dogg wrote:More of the build.



Well what do you think?

fuck yeah ...orsome man

Cant see the pics here at work but you're gonna love it man, I did a 50 ish mile loop today and the chassis/suspension saved me from eating shit bad once again, if I was on the gen 1 Id be in hospital now.....


I love this thing

racein01 wrote:fuck yeah ...orsome man

X491

When I did mine I put a joint in the cradle like that and it broke. I redid the hole cradle and have not had a problem since. Not doggen you work it looks great. I hope it works out for you.

m178 wrote:When I did mine I put a joint in the cradle like that and it broke. I redid the hole cradle and have not had a problem since. Not doggen you work it looks great. I hope it works out for you.

This is one of our concerns. We will be testing at a local MX track in the coming weeks.

Where did it break?

When I spliced my OEM cradle to the new tubing on my Gen4 , I placed a solid piece of bar stock inside the tubing.... did the butt weld to join them, then "plug welded" the new and old tubing pieces the the bar stock .

No issues....

If your milling the Y just machine down the end to fit inside the the stock cradle (as per pic) and as Bob was saying just do a couple of plug welds along with the perimeter weld

Is doing a Gen 5 chassis really worth the hassle over doing a Gen 4? Seems everyone likes the 4 chassis way better. I can't comment here as I've never ridden a 5...

Bob.....dude that Kermit video is so classic, it has me sitting here in my living room for real laughing out load with my wife and kids looking at me funny.

Bike looks really nice too man.

Its all about the comedy....

kermit living the good life

Mik329 wrote:Is doing a Gen 5 chassis really worth the hassle over doing a Gen 4? Seems everyone likes the 4 chassis way better. I can't comment here as I've never ridden a 5...

Not sure what it would be like comparing the 500 between Gen 4 and 5. But as far as a Gen 5 450 goes.... Its awesome!

When it first came out I didnt care for it right away. Front springs were way to soft which made it ride way down in the stroke. Gave it a stink=bug feel and was harsh. Every aftermarket suspension company started telling you that you had to buy their linkage to fix it (what crap)...All it took was heavier springs to match the stock rear and presto..a balanced bike. After getting the suspension sorted I had a set up that I was very happy with. The bike is light, small and fast.

If I had not already started cutting up my 2008 CRF250 i would have loved to hack my 09 450 for a Gen 5 500.

Mine has stiffer springs and a procircuit link, it sits level and rides beautiful

Brit, did you try it without the linkage?
One of the guys I ride with changed the linkage as well and to be honest, there was not much of a difference. My first 09 had stock shock with 48's up front and he never got his to work or feel as good as mine.. Same fluid change clicker settings etc.. only difference was linkage?

On my new one I run a pretty stiff set up. Im +2 on front springs and have a Pro Circuit shock out back (Big bladder cap, internals) and it works well. Maybe its not as noticeable here in Texas since we dont ride anything but sandy loam...

Gravel Scratcher wrote:If your milling the Y just machine down the end to fit inside the the stock cradle (as per pic) and as Bob was saying just do a couple of plug welds along with the perimeter weld

That is what was done with the first build.

Mik329 wrote:Is doing a Gen 5 chassis really worth the hassle over doing a Gen 4? Seems everyone likes the 4 chassis way better. I can't comment here as I've never ridden a 5...

Sure, Honda moves on so can we. I do agree the Gen 4 chassis is damn near perfect.

Kermit. My wife was like, "whats he doing?" then, "ewwww".

hahahahahahhahahahhaha