2017 CRF500L Rally Build

Discussion in 'Some Assembly Required' started by sock, Jun 30, 2017.

  1. sock

    sock tube

    Joined:
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    I'm stuffing a CBR500R twin into my 2017 CRF250L Rally.
    I own a plated CRF450X and an XR650L but they don't cover the bases for the best dual sport. After reading the other impressive build threads I knew the CRF500L would check all the boxes. Light, powerful, efficient, reliable and of course a Honda! I'm fortunate to work in a machine/fab shop and have all the tools available to do a quality job.

    Here it is with only twenty km on it! Currently has about 1300km.
    20170402_155256.jpg

    I have all the parts coming but I did receive this today
    20170630_102931.jpg
    Old engine out
    20170630_122204.jpg
    20170630_122210.jpg
    #1
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  2. Samtech79

    Samtech79 Two wheeled lunatic

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    Mahahaaaa (evil laugh)
    #2
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  3. RCmoto

    RCmoto Long timer

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    love it!
    #3
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  4. drzdirtrider

    drzdirtrider Adventurer

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    Nice
    #4
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  5. larryboy

    larryboy Stable genius.

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    :lurk
    #5
  6. flipflopdog

    flipflopdog Youth & Talent, no match 4 Old Age & Treachary

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    Gateshead the Grim North of England...!!!
    No messing about eh, from the woods to the workshop, didn't even have time to give her a quick 'pre-surgery' scrub up...!!!! A man after my own heart, get stuck in Sock......
    #6
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  7. sock

    sock tube

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    Temporary flat sump to ease engine fitting
    20170630_155709.jpg
    The point of no return... It was hard to cut up a new bike I paid full price for...
    20170630_162621.jpg
    #7
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  8. Lesharoturbo

    Lesharoturbo Nerdly Adventurer

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    How was fitment prior to the surgery? Same as the CTF250L? Are using those conversions as a guide?
    #8
  9. Bultaco206

    Bultaco206 Back-to-back motos suck Super Moderator Supporter

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    :yikes
    #9
  10. sock

    sock tube

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    The 250L and rally frames are the same so the engine will fit the same as the others that have done this before.
    #10
  11. Lesharoturbo

    Lesharoturbo Nerdly Adventurer

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    Cool! I am watching this with great interest.
    #11
  12. sock

    sock tube

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    Update
    I was having issues fitting the engine in. Turns out the Rally fuel tank and pump is different! The valve cover vent was hitting the bottom of the pump
    20170702_142628.jpg
    20170702_142623.jpg
    I milled it down and welded on a cap which lowered the pipe about 3/4"
    20170703_091351.jpg
    20170703_100444.jpg
    #12
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  13. Lesharoturbo

    Lesharoturbo Nerdly Adventurer

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    That works.
    #13
  14. sock

    sock tube

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    Seems to fit now.
    20170703_133116.jpg
    Engine fits good
    20170703_175338.jpg
    Engine fits with the rally bodywork with a little trimming
    20170703_180933.jpg
    #14
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  15. Samtech79

    Samtech79 Two wheeled lunatic

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    Hows the pinion placement?
    #15
  16. sock

    sock tube

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    Pinion looks good, I don't have any pictures handy but looking at where your lower rear mount is I'd say mine is pretty close to yours.
    #16
  17. Samtech79

    Samtech79 Two wheeled lunatic

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    I think you have the rear of the engine a little lower and further forward than mine but not by much.
    I ground a little bit of that tab on lower rear of the case down so it wouldn't hit the swing arm.
    #17
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  18. sock

    sock tube

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    In order to keep costs and decibels down I'm thinking of using the stock muffler but have a feeling like it would be too restrictive with double the cc flowing through it. Anyone had this apart? Easy to modify for more flow? I'm not super concerned with weight.
    #18
  19. Samtech79

    Samtech79 Two wheeled lunatic

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    I had seen a guy who gutted one on here a few years ago. There might even be a YouTube video if you search for it. If I recall he pretty much emptied the can, rolled some perf and used glass packing. I think he may have riveted it back together but I've slept since then. You could always cut the inlet out and use a larger diameter pipe. I'd go at least 1.75" OD 16g if you're going two to one.
    #19
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  20. sock

    sock tube

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    Found it

    #20
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