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Old 07-21-2014, 03:45 PM   #1
Volotron500 OP
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2005 CR500AFX build

Hi Guys im a long time lurker but first time poster. So go easy on me haha

I have recently started a Bike Build

In a Nutshell is i wanted a Registrable late model CR500E
But anyone who knows CR500s they are up about $12,000 plus!

With a relatively smaller budget i am going to build my own.

What out of you ask? Well i bought a 2005 model CRF450X frame for pocket change (clear title of course) and begun the conversion for Monster CR500 engine



Welding in the engine mounts



Mocking up engine for perfect fitment and engine/ swingarm alignment








(the Engine/ Swingarm aren't mine. Were just used for mocking up only!)
No matter how much i offered he was not selling that engine to me :/

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Old 07-21-2014, 03:59 PM   #2
nevgriff64
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Looks like a really interesting project, Volotron.

How will you be getting round the ADR requirements for registration purposes?

Also, what part of Oz are you in?

Following the build with interest.
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Old 07-21-2014, 04:12 PM   #3
Volotron500 OP
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So the frames done!

I got hold of some cheap 450x parts





So where does that leave me?

I have:
No CR500 engine
No electrics
No carbie
No Airbox adaptor
No exhaust
No suspension
No brakes
No Wheels
And the list goes on!!

Well ive been shopping!

First thing i saw was a roller CRF450r its a 2004 model but managed to pick it up for $850





As you can see its pretty much a complete bike. With recently serviced suspension, all the linkage, bolts for a whole bike, tripple clamps wheels and brake assemblies and so on..

This is still currently in the Post!

So ive ordered some new headset bearings for my modified frame so i can begin putting it together when my bike/parts arrive

I plan to get the modified frame rolling and ready for an engine (when i can get hold of one that is)

Im currently negotiating with a US ebay seller over some 95 model Engine Parts, im only getting the major components that i am not going to replace during my rebuild to prestine condition! New crank, barrel, piston, all bearings/seals, new clutch disks/ plates

Keep an eye on as i make progress
Cheers Volotron500

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Old 07-21-2014, 04:18 PM   #4
Oldfatbeerman
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The frame in the jig with the motor and swing arm , is that an Aprillia V twin swing arm ?
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Old 07-21-2014, 04:26 PM   #5
panhead_pete
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So the frame you started with is fitted with a compliance plate and has rego history?
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Old 07-21-2014, 04:36 PM   #6
Oldfatbeerman
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Quote:
Originally Posted by panhead_pete View Post
So the frame you started with is fitted with a compliance plate and has rego history?
CRF 450 X is a complied bike , provided the frame came from a source that had not cancelled the VIN number or a non repairable write off he is ok . It will still be a hassle with the bureaucratic pen pushers at the rego office , just takes time and patience and probably an engineers cert to say it complies with Aust standards , More for the engine change than anything due to the capacity increase over the original capacity the bike was complied with .

I hope he has a family member that is a Dentist , he will need new fillings in his teeth after every ride on tar . Will be one very big and fast vibrator .
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Old 07-21-2014, 04:36 PM   #7
Volotron500 OP
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Hi Nev, i am from NSW

I hope to get it running and fine tune it offroad for a while
Then will start working on getting it ready for a "Blue slip" inspection

Eg. Headlight, blinkers, mirrors, pressure switch in MX front/rear brakes (for brake light)

I will probably try and get it passed as an original CRF450X
Then work on getting the Engine swap Engineered.

As for running electrics. I am trying to contact Service Honda on their digital ignition and lighting coil. Abit pricey but puts out 130 watts of power
Also has many other advantages. Easier starting, Smoother power delivery

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Old 07-21-2014, 05:05 PM   #8
panhead_pete
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Have you run the frame numbers and does it have a compliance plate? I ask this again because if you dont have that sorted you are wasting your money or building a ICV, if the latter get onboard with what that means to you. A lot of bikes get part finished then dont go further as people think they can work around the system. Not saying that's the case here, just dont want to see this happen to you.

If it was me I'd keep it as simple as possible.

Rear brake light off a generic spring initiated switch off the brake lever. Pick up a front Master Cyclinder with brake switch in built.

Buy some complete take off wiring and switches incl all the switches on the bars for all the lights etc. This might also give you the master cyclinder with brake switch. Often bikes being wrecked on Gumtree. With any luck you will get all the indicators, headlight, tail, light horn etc all in one deal which will greatly simplify the process.

If it needs engineering get the engineer involved NOW! (Once its rego'd I wouldnt tell anyone about the swap nor get it engineered )
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Old 07-21-2014, 05:50 PM   #9
Volotron500 OP
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I think it was an aprillia swing arm in the picture.

Yeah Panhead, you have a good point there.
If i can get all the standard Crf450x wiring that would help alot!
As for the engine it doesnt really have many electrics which is good.

Yes the CRF450X sell in Australia ADR approved and fully road legal.
My frame has the compliance plate and VIN numbers on it.
Which i put through a REVs check before i bought it. And they are clean
Just needs a Blue slip inspection in NSW to be registered



Looks a bit rough unfortunately. But its all there

Heres some info ive been following off the net just for some background for you guys.



Specific to my frame/setup



And heres even a motivational picture for you and i Of to what i expect my Build to be better than.
This is the minimum benchmark

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Old 07-21-2014, 06:50 PM   #10
panhead_pete
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Sweet! Does the REV check also check if its been written off.

I wouldnt spend too much time chasing the wiring and switches for that exact model or that would be helpful. Any late model enduro bike will surfice I'd be thinking.

When its time for rego all I'd be saying is that you had to put a replacement motor in as the original dropped a valve and lunched itself. If you go to the right place they may not notice you also dropped two strokes

Looking fwd to seeing this come together. You may need to source the engine es USA though.

This might help

http://advrider.com/forums/showthread.php?t=941656
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Old 07-21-2014, 07:18 PM   #11
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Well well well, Hello Mr Volotron, I suspect we were talking the other night about CR500's?

Good see the build thread, the CRF stuff is really the ducks danglies and there are a lot of this conversion going on in the states.

I've been looking at the service Honda solution as well, as yet had no response from them, however it may be the best solution as other people are offering small lighting coil systems or the Boyeson and MSD ignition stuff, but not both together. Let me know how you get on with SH as I'm after one of those ignitions, it's really the only part I need.
It's either that or the system Pezz was telling me about the other day that Paul Rooney is using on some of his airhead specials.

If you need CR500 info likie how to tell which year is which etc or a copy of the 92 model service manual send me your email address and I'll flick it over to you.

Cheers

Bill
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Old 07-21-2014, 11:14 PM   #12
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both of you talk to Steve at Betta Bikes in Adelaide, if he cant build what you need I suspect there is no-one else who can

http://bettabikes.com/
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Old Yesterday, 05:36 PM   #13
Tee Dee Mmm
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Would love to do this conversion myself and have thought about purchasing a complete registered CRF -X and just do the conversion and when finished really only a change of engine number needed. Sell off all the unneeded 4 stroke bits to fund the rest, seems like quite a few frame mod kits on fleabay to complete this but I think the hardest part would be sourcing the 500 engine.good luck and look forward to the finished product.

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Old Yesterday, 06:08 PM   #14
Volotron500 OP
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CR500 Video



Indeed we were OLD DOG, Small world Hey.
Will have to keep me updated if you go along with your build
Surely Service Honda will reply now that I would be Chasing 3 Ignition Kits

GordyOZ ive flicked him an email. ill see how I go

Yeah Tee Dee, That would of Probably been the best option, If you could get a real neat one for 4-5G then sell the Engine/Exhaust/Carbie for probably 2K we would probably be even on price but would be alot less mucking around!
If you got a later model would probably help for resale later.

Some goodies for the build arrived the other day too

270mm oversize front brake disc to pull up this big girl!



FMF Gnarly EXP chamber with FMF Powercore 2 muffler


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Old Yesterday, 06:20 PM   #15
tHEtREV
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Quote:
Originally Posted by Volotron500 View Post


Errr, that's not a compliance plate...

If you have an R and not an X, then you have bugger all chance of getting it on the road.
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