2008 Honda CR500

Thanks guys! That little CRF frame isn't going to know what hit it when I light that 500 off.

The 250 project should be pretty straight forward and an easier conversion due to the
smaller dimensions of the 250 engine. So far, I have started the engine build and
started the design work for the frame conversion.

I'm posting some select progress pictures for those that interested.

That is a sweet swingarm FTE. Karl does outstanding work. One of my other projects
is a sleeved down 1978 CR125. I'm building an FMF replica racer for the Marty Tripes
100cc revenge series. I plan to call Karl for the "banana" swingarm the bike will need.

dogger


Finished engine


OE frame before modification

frame after modification

works forks

Works shock

test fit

Thanks guys!

I farmed out the frame mods for the 500, but I can tell you everything was replaced from the downtube to the
footpegs with billet. I started out with a Keihin 39.5mm PWK, but switched to a 38mm after some moto testing.
The airboot is from a 99 CR250. The 500 was my first hybrid so I contracted some outside help to ensure the
job was done right. I couldn't decide between a 250 or 500, so I'm doing both. PM me if you want more info
about what's required to pull this off.

The shroud graphics idea came from the late 90's during the "1-800-Collect" days with the Red, Black and Yellow
color scheme. My intent was to build a bike similar to what Team Honda would field if there was still an open
class. A company called Graphic MX did the work.

As for the current 250 version I'm building, I am using a 2009 CRF250R frame with a 2007 CR250 cradle. If you
try to use the CRF cradle, you will encounter more problems with the 250 engine than the 500. Biggest headache
is with the clocking and clearance issues with the right side case cover bolts. Using the cradle from the CR opens
up the engine bay a little and allows the motor to be oriented correctly.

I just finished the 2000 CR250 engine for the project. Like the 500, the 250 was a scratch build using all new parts.
The transmission is a works HRC unit, the crankshaft was balanced by Crankworks, Hinson clutch with titanium
springs, the cylinder and head were done by Tom Morgan, VForce 3 reed, Keihin 38mm PWK S with TPS and power
jet, Vortex IC and all internals Cryo-REMed.

The 250 engine weighs 19 lbs less than the 500 and the 250 will be using the new "Air" forks which reportedly weigh
6 lbs less than the conventional units on the 500 - that's a total of 25 lbs. The 500 weighs just under 224 pounds at
the starting gate (all fluids, full tank of premix), so I'm expecting a sub 200 lb 250.

Here are some up to date pictures of the 500 showing some of the many changes made after a year of testing and racing.
Better brakes, different gearing, better wheels, different/better linkage, etc. I just finished completely rebuilding the bike
(the reason for the new pictures). The engine now sports an Nikasil Aluminum cylinder liner.







And here are some pictures of the 2000 CR250 engine I just finished:










I'll post some progress pictures of the rest of the 250 bike build later on.

dogger

Thanks guys! Much appreciated.

dogger

Thanks for the very kind words!

REM is a process that started out in the aviation industry and has worked it's way
into motorsports. It's been around in F1 and the like for quite a while and started
showing up in bikes over ten years ago.

Here is a link to the website for the shop where I send everything that does a pretty good
job of explaining what's involved: http://www.evansperformance.com/cryoREM.html

I hope to start posting progress pictures of the 250 version of this bike in the next
month or so. I think your going to really like this one.

Stay tuned.

dogger