Full tilt Steelie CR500 build - Finally Completed!

Chrisb500CR
Edited Date/Time 11/11/2017 12:13pm
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Chrisb500CR 2/20/2017 11:37am
2/20/2017 11:37am
Frame painted and fitted with RMZ titanium pegs and titanium pins. Still need to find some Ti springs to go with it...
Chrisb500CR 2/20/2017 11:40am
2/20/2017 11:40am Edited Date/Time 2/21/2017 2:49am
Here's a 3D model for a top triple clamp I have been working on for quite some time. I spent ages looking for a set of the real HRC deal and finally decided to make one.

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Chrisb500CR 2/20/2017 11:42am
2/20/2017 11:42am Edited Date/Time 2/20/2017 11:53am
And here is a photo of the billet clamp when I got it back from the machinist. The clamp was a lot of fun to have made. I did the autocad drawing and had a mate in Sweden (Thanks Martin) to do the 3D model and then a mate in Italy (Thanks Willy) had it made in a local machineshop.


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Chrisb500CR 2/20/2017 11:50am
2/20/2017 11:50am Edited Date/Time 2/20/2017 11:55am
I had the clamp anodised and then I sanded off some of the anodising to mimic the HRC clamp and plan to machine the sides and front as well to finish it off. Sanding the anodising off is no fun at all. That stuff is tuff.. Here's how it looks now test fitting with Ti hardware and barclamp from the Denton boys. (Stem, lower clamps and forks off a 2007 CRF)

Chrisb500CR 2/20/2017 12:08pm
2/20/2017 12:08pm
Engine is being rebuilt with new top end. Cylinder was ported for broader powerband from before and to preserve the portjob, cylinder was bored to 89.50 and then Silicon Carbide plated. A wiseco piston has been fitted together with new reeds. A new PWK carbie found it's way onto the inlet side as well. One of the Jason Meyer exhaust manifold is fitted to the outlet side and on top a decomb head keep a lid on everything. All Ti hardware from the boys at PDE.







Chrisb500CR 2/20/2017 12:11pm
2/20/2017 12:11pm
Last piston did not like the exhaust bridge so had to pursuade the new piston...

Chrisb500CR 2/20/2017 12:17pm
2/20/2017 12:17pm
Here's a photo of the swingarm that I will be using. 15mm longer than OEM

JWACK
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JWACK 2/20/2017 12:28pm
2/20/2017 12:28pm
Nice work! I have an all original 01 500 I want to upgrade the front end on one of these days. Have you considered making and selling a few more of the clamps you made?
RussB
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RussB 2/21/2017 1:19am
2/21/2017 1:19am
Wow, definitely the beginning of what I'm sure will turn out to be an amazing build, can't wait to see it progress!

That top clamp is stunning, and the Denton Engineering clamp finishes it off perfectly.
The sump and water pump guards look awesome as well, really nicely made and look perfect.

24MX did have titanium RM/RMZ footpeg springs for sale a while back, not sure if they still have them available now but they are out there. Might take some tracking down though.

Keep up the good work and keep those pictures coming!
vmxracer
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vmxracer 2/21/2017 2:52am
2/21/2017 2:52am
Some nice fabrication there.

Is that a Karl Landrus swingarm? You should get him to make an alloy tank
Chrisb500CR 2/21/2017 3:23am
2/21/2017 3:23am
vmxracer wrote:
Some nice fabrication there.

Is that a Karl Landrus swingarm? You should get him to make an alloy tank
I bought a KLP arm for a 89' CR500 a few years back but last year a wildfire took Karl's workshop and I had to source this elsewhere. Bormiparts in Italy did this one. I am tempted to put an ally tank on it, but have a NOS tank that is in the plans so far.. BTW, think Karl is getting back into business with a new workshop setup.
Bearuno
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Bearuno 2/21/2017 2:19pm
2/21/2017 2:19pm
It's refreshing to see a 500 not being turned into an AF.
vmxracer
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vmxracer 2/21/2017 2:26pm
2/21/2017 2:26pm
Bearuno wrote:
It's refreshing to see a 500 not being turned into an AF.
Amen to that

Pit Row

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tuggy450
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tuggy450 2/21/2017 6:01pm
2/21/2017 6:01pm
Definitely want to see a full tilt steelie cr500!
Chrisb500CR 2/23/2017 4:38am
2/23/2017 4:38am
A little setback on finishing up the motor. I am not happy with the silver color of the newer clutchhousings and will have to glass bead blast the housing and have it painted black. In the meantime a little info on the rear suspension setup. I have been searching for an A-Kit damper for ages and found a decent one that I had refurbished and serviced. This is how it came out.

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Chrisb500CR 2/23/2017 4:44am
2/23/2017 4:44am Edited Date/Time 2/23/2017 4:45am
However, In my search I found another A-Kit shock from an Ex. 1995 GP bike. I bought that and sold the one I had already refurbed... One step forward - two back... Anyway this shock below is in the process of being refurbed and serviced. When at it, I decided to have it Kashima coated. When done and installed with some new Ti and Billet bling it should make a nice rearend. This is how I received it

Chrisb500CR 2/23/2017 4:56am
2/23/2017 4:56am
RussB wrote:
Wow, definitely the beginning of what I'm sure will turn out to be an amazing build, can't wait to see it progress! That top clamp is...
Wow, definitely the beginning of what I'm sure will turn out to be an amazing build, can't wait to see it progress!

That top clamp is stunning, and the Denton Engineering clamp finishes it off perfectly.
The sump and water pump guards look awesome as well, really nicely made and look perfect.

24MX did have titanium RM/RMZ footpeg springs for sale a while back, not sure if they still have them available now but they are out there. Might take some tracking down though.

Keep up the good work and keep those pictures coming!
Thanks Russ! I don't wanna take the credit for the Ti stuff. But actually enjoying doing the fabbing. Just hard to find the time for it.
sandman768
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sandman768 2/23/2017 5:09am
2/23/2017 5:09am Edited Date/Time 2/23/2017 5:10am
Subscribed!
CrGuy2T
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CrGuy2T 2/23/2017 5:10am
2/23/2017 5:10am
Team sarholz has a bunch of old Honda factory stuff from the team. They have a few sets of 47mm showa fork kit inserts. Try them out.
Chrisb500CR 2/23/2017 5:11am
2/23/2017 5:11am
Bearuno wrote:
It's refreshing to see a 500 not being turned into an AF.
No Allyframe here mate.. except for the subframe...
Chrisb500CR 2/23/2017 5:12am
2/23/2017 5:12am
CrGuy2T wrote:
Team sarholz has a bunch of old Honda factory stuff from the team. They have a few sets of 47mm showa fork kit inserts. Try them...
Team sarholz has a bunch of old Honda factory stuff from the team. They have a few sets of 47mm showa fork kit inserts. Try them out.
That's where the shock came from
Bearuno
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Bearuno 2/23/2017 7:23am
2/23/2017 7:23am
Chrisb500CR wrote:
No Allyframe here mate.. except for the subframe...
What brand is it? Sadly, most I've encountered / heard of are very disappointing. But, yours is probably a Brit / Euro one, and they know how to make things properly.

I've changed the rear end of my 500 to a non link system using a Ohlins TTX shock. Though I can change it all back to std, as I used a 2nd hand swingarm and subframe for the conversion. That neccessitated an entirely new / different airbox I made out of Aluminium, with a top mounted airfilter. My intentions were to eventually make a monocoque airbox subframe in alloy, but I'm having second thoughts about it, as I think it may end up being a fatigue cracking nightmare. That was, apparently, the Achilles heel of the YZM 500s of 87 / 88. I ride a hell of a lot, and don't want to worry about cracks in the airbox that could lead to a dusted engine. The std steel subframe weighs buggerall anyway.

But, alloy subframes certainly are cool.

For forks, I use 48mm WP CCs. I make them into True CCs, which they are certainly not as std. Makes them a consistent fork. The biggest change they enabled was to have the 18/ 20mm offset clamps, down from 24mm as std ( the offset on the fork lugs of my CCs is the same as the original KYBs). I've used only the 20mm offset position so far, and the improvement in steering and stability is remarkable, over the 24mm offset.

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