Full tilt Steelie CR500 build - Finally Completed!

2/27/2017 1:55am Edited Date/Time 2/27/2017 2:11am
David934 wrote:
what year bike is it?
Well, it is a bit of a mix. Frame is a 1990 but link and suspension is 92' forward.. Motor is 98. Front end is off a 2007 CRF450
David934
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2/27/2017 2:08am
David934 wrote:
what year bike is it?
Well, it is a bit of a mix. Frame is a 1990 but link and suspension is 92' forward.. Motor is 98. Front end is off...
Well, it is a bit of a mix. Frame is a 1990 but link and suspension is 92' forward.. Motor is 98. Front end is off a 2007 CRF450
since im fan of CR 500, this is dream (and expensive) build for me
great job
3/5/2017 4:16am
Just a very short update. Just test fitting tank, seat and rad panel... Here's a hint of how bike will look when all done..



1
Tokyo_Tiddler
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3/5/2017 4:41am
That looks sharp! Immaculate build.

The Shop

JW381
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3/5/2017 9:53am
Awesome
Byron909
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Round Rock, TX, USA
3/6/2017 2:45pm
In the meantime, let me know what you guys think on the silencer. I kind of wanna run the OEM long job, but consider a 90's...
In the meantime, let me know what you guys think on the silencer. I kind of wanna run the OEM long job, but consider a 90's Pro Circuit short as well...





Really neat bike, and build. I grew up riding 500s in the 90s, so to me the long silencer looks At home. But anytime i dont use a stock silencer i use that mid 90s pro circuit oval silencer like you have. Have a good stash of those.
If you want to be period correct with the oem, youd probably want to cut that silencer down a hair, right?
Awesome stuff. That swingarm is super rad.
Bearuno
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3/6/2017 8:19pm Edited Date/Time 3/7/2017 5:04pm
Just a very short update. Just test fitting tank, seat and rad panel... Here's a hint of how bike will look when all done.. [img]https://p.vitalmx.com/photos/forums/2017/03/05/179775/s1200_IMG_1988.jpg[/img]
Just a very short update. Just test fitting tank, seat and rad panel... Here's a hint of how bike will look when all done..



What swingarm is that in the picture? Looks like a std one, complete with the OEM 'dimple' at the inner bend, but I can see a horizontal weld on the inside, and the top of the swingarm shows no taper.

Various pictures of swingarms on the Bormiparts site show differences between them - just like my various Frames, none is exactly the same. It looks like they use a modified front cast section of the std swingarms ( although the casting looks subtly different to my 91 01 swingarms) but perhaps they use 89 castings , which I can see differences in from my half hidden away 89 chassis on the wall here), and just do a weld across the top to mimic the Works plate / pressing joint.

Yet, in the picture they have of their alloy subframe on a bike, they've no weld across the casting, but it looks like a type of 'Coke bottle' armed SA :

Just questions about differences.

I'm searching up another swingarm, to use the std. front casting for a Coke Bottle SA, with 7000 series sheet and axle blocks, to have no need for post fab heat treatment. Just another side project to do between paying work. It can sit there until I put the bike back to a linkage set up, in it's retirement.

Well, no that won't happen, I'll keep riding it until I cark it, but I'm accumulating enough bits to hopefully do a full build like the French FB bike that Smezmx has put in below, and also the Air Cooled bike 500 I want to do.
Bearuno
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3/7/2017 3:45am
Also, thank you for putting up the picture of the HRC decal part number!

I rang the local shop today, and tagged it in with some other parts I was ordering, and it existed, and Honda OZ had 4 in stock. When I go in to pick them up, I'm going to do a search on Decals - I had no idea things like that were OEM procurable. They were just over $3 AUD each.
smezmx
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3/7/2017 12:14pm
Super Sweet build.i saw a guy from france on fb,who is currently building a mid 80's hrc 500 gp replica.looks to be coming along nicely so thought you'd like to see some pics.












2
maicojoe
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Redmond, WA, USA
3/7/2017 8:51pm
Very cool bike build..... Are you going to race it?

I have a vintage resto-mod, kind of in the same theme, have it kind of look both stock and works type
Started with NOS engine, mild porting, head modified with modern squish band, head cut for both o-ring gasket and standard flat gasket, that way I can change compression by running with or without flat gasket, will run with either pump fuel or race fuel.
The frame is a NOS 2001, modified to take the air cooled engine, de-tabbed as needed. Much better ergos, seat, peg position, steering etc, than the head shaking 1984 frame.
Custom 49mm Showa forks from 2003, open dual chamber forks that are better the an the earlier closed chamber ones. Custom triples and stem.
Brakes are front 2003 RM250, back 2001 CR500
Rear sub frame, seat and side panels are 1991 CR500, for better ergos and the 1991 color matches the 1984 Honda red/orange
The pipe is a modified NOS 2001 low boy, much much better power band, smoother, and revs about 1000 rpm higher, plus it un-shrouds the cylinder jug and head for better airflow or cooling
Cylinder head has two extra fins welded on, but you can't tell by looking.
Modern 39mm flat side carb, custom reed cage and petals, custom CR250 ignition, mostly NOS parts.










1
Bramlett321
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Texarkana, TX, USA
3/8/2017 10:22am
Byron909 wrote:
Really neat bike, and build. I grew up riding 500s in the 90s, so to me the long silencer looks At home. But anytime i dont...
Really neat bike, and build. I grew up riding 500s in the 90s, so to me the long silencer looks At home. But anytime i dont use a stock silencer i use that mid 90s pro circuit oval silencer like you have. Have a good stash of those.
If you want to be period correct with the oem, youd probably want to cut that silencer down a hair, right?
Awesome stuff. That swingarm is super rad.
Period correct is what you're going for but in this case that round PC is what we see when thinking about an early 90's factory CR. Go with the PC my friend.
3/8/2017 12:25pm
Bearuno wrote:
What swingarm is that in the picture? Looks like a std one, complete with the OEM 'dimple' at the inner bend, but I can see a...
What swingarm is that in the picture? Looks like a std one, complete with the OEM 'dimple' at the inner bend, but I can see a horizontal weld on the inside, and the top of the swingarm shows no taper.

Various pictures of swingarms on the Bormiparts site show differences between them - just like my various Frames, none is exactly the same. It looks like they use a modified front cast section of the std swingarms ( although the casting looks subtly different to my 91 01 swingarms) but perhaps they use 89 castings , which I can see differences in from my half hidden away 89 chassis on the wall here), and just do a weld across the top to mimic the Works plate / pressing joint.

Yet, in the picture they have of their alloy subframe on a bike, they've no weld across the casting, but it looks like a type of 'Coke bottle' armed SA :

Just questions about differences.

I'm searching up another swingarm, to use the std. front casting for a Coke Bottle SA, with 7000 series sheet and axle blocks, to have no need for post fab heat treatment. Just another side project to do between paying work. It can sit there until I put the bike back to a linkage set up, in it's retirement.

Well, no that won't happen, I'll keep riding it until I cark it, but I'm accumulating enough bits to hopefully do a full build like the French FB bike that Smezmx has put in below, and also the Air Cooled bike 500 I want to do.
Swingarm is from Bormiparts in Italy and utilizes the center cast parts from the OEM swingarm. It is a copy of the old HRC coke-bottle swingarms from the late eighties and early nineties. This particular Arm I ordered 15mm longer than OEM.
3/8/2017 12:28pm
smezmx wrote:
Super Sweet build.i saw a guy from france on fb,who is currently building a mid 80's hrc 500 gp replica.looks to be coming along nicely so...
Super Sweet build.i saw a guy from france on fb,who is currently building a mid 80's hrc 500 gp replica.looks to be coming along nicely so thought you'd like to see some pics.












Mate, that is a very nice build. That ally tank is a work of art.. I don't wanna know how many hours that went into that... I've always wanted to do a expansion chamber myself. one day....
3/8/2017 12:34pm
maicojoe wrote:
Very cool bike build..... Are you going to race it? I have a vintage resto-mod, kind of in the same theme, have it kind of look...
Very cool bike build..... Are you going to race it?

I have a vintage resto-mod, kind of in the same theme, have it kind of look both stock and works type
Started with NOS engine, mild porting, head modified with modern squish band, head cut for both o-ring gasket and standard flat gasket, that way I can change compression by running with or without flat gasket, will run with either pump fuel or race fuel.
The frame is a NOS 2001, modified to take the air cooled engine, de-tabbed as needed. Much better ergos, seat, peg position, steering etc, than the head shaking 1984 frame.
Custom 49mm Showa forks from 2003, open dual chamber forks that are better the an the earlier closed chamber ones. Custom triples and stem.
Brakes are front 2003 RM250, back 2001 CR500
Rear sub frame, seat and side panels are 1991 CR500, for better ergos and the 1991 color matches the 1984 Honda red/orange
The pipe is a modified NOS 2001 low boy, much much better power band, smoother, and revs about 1000 rpm higher, plus it un-shrouds the cylinder jug and head for better airflow or cooling
Cylinder head has two extra fins welded on, but you can't tell by looking.
Modern 39mm flat side carb, custom reed cage and petals, custom CR250 ignition, mostly NOS parts.










That is also a very nice build. It is not 100% period correct like my own build, but cool! My first 500 was a 1984 CR500. If someone thinks a post 1990 500 is a beast, they should have a go on a 84. Btw, the seat, rear fender and side panels on your bike are pre 1991.
3/8/2017 12:35pm
Period correct is what you're going for but in this case that round PC is what we see when thinking about an early 90's factory CR...
Period correct is what you're going for but in this case that round PC is what we see when thinking about an early 90's factory CR. Go with the PC my friend.
Thanks. That's what I am getting at.. Or at least shorten up the OEM...
3/8/2017 12:38pm
Byron909 wrote:
Really neat bike, and build. I grew up riding 500s in the 90s, so to me the long silencer looks At home. But anytime i dont...
Really neat bike, and build. I grew up riding 500s in the 90s, so to me the long silencer looks At home. But anytime i dont use a stock silencer i use that mid 90s pro circuit oval silencer like you have. Have a good stash of those.
If you want to be period correct with the oem, youd probably want to cut that silencer down a hair, right?
Awesome stuff. That swingarm is super rad.
Thanks for pointing that out Byron. I will have to shorten that OEM down if I go that route.. Cheers.
mchonda2
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178
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8/22/2012
Location
Medford, OR, USA
3/8/2017 1:16pm
[img]https://p.vitalmx.com/photos/forums/2017/02/20/177437/s1200_IMG_2843.jpg[/img]


Awesome build man! I'm looking for one of the HRC type waterpump guards. Do you know where to find another one?

Thanks
Bearuno
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5479
Joined
6/28/2014
Location
AU
3/9/2017 2:19am Edited Date/Time 3/9/2017 5:36am
I was watching some 91 - 94 500 GP compilations, and, 'for more 'period correct' looks you might be better to use the type of long(er), straight, angled up mufflers like DEP and many other Euro brands used at that time.

Noise control was already more strict in the GPs than the US, and, I think, that type of muffler looks like the ducks guts. Suits the 91 through to the 01 plastics well, and I always find a longer muffler makes for smoother power. Reducing a bit of the 'bark' is a good thing too, but they don't restrict power in any way, and still sound good as well.

Also, the end of that PC muffler takes some pretty vicious core samples out if their victims, I kid you not.
3/19/2017 10:00am
Just a short update. Got the clutch housing and cover back from my mate Willy in Italy. As usual, top notch job Willy!


3/19/2017 10:02am
Some of the OEM parts for the clutch and water pump housings

3/19/2017 10:04am
Getting the housing on with new gasket and seals / bearing for water pump.

3/19/2017 10:08am
And all done... Pretty happy with it. Ti hardware from PDE as usual. NOS RHS Radiator mounted as well as NOS rear brake resovoir. HRC type waterpump / case saver guard.

3/19/2017 10:14am
Getting started on the front and rear brake masters. Front is NOS 2007 CR250 and rear is a used but good condition 2001 CR500 unit with new piston and seal kit. Going to use spring return on the rear master itself over the std. spring on the brake pedal. Have to do a bit of modding as usual when mixing old with modern parts.





5/31/2017 12:19pm
Got some more bling in the post today. The young Denton delivered again. Refurbed and Kashima coated A-Kit shock (Ex Sarholz). New Billet link / knuckle and various titanium bolts and shafts. Real happy with the outcome of the parts.


5/31/2017 12:25pm
A few more photos of the parts.









Badd127
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522
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12/2/2016
Location
SE
6/2/2017 3:53am
This bike is absolutely killer! My dream bike. Keep the updates coming, no matter how big or small.
6/2/2017 5:10am
Badd127 wrote:
This bike is absolutely killer! My dream bike. Keep the updates coming, no matter how big or small.
Thanks mate.. Wink

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