2020 Honda XR500R by N.A.P.A.L.M.

Discussion in 'Some Assembly Required' started by larryboy, Oct 1, 2019.

  1. Desert dual sport

    Desert dual sport n00b

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    So then, a revamp to the chassis as well? Very anxious to see the ideas!
    #41
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  2. larryboy

    larryboy Stable genius.

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    Yes, extensive changes are planned. Hoping for a polished looking final product, but the KLR tank may give us a bit of freak show look no matter what.

    :lol3
    #42
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  3. Desert dual sport

    Desert dual sport n00b

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    Haha! Looking forward to seeing it. I ride a drz400 and I really want a bike that can do highway well, yet not be a behemoth off road. Eyeballing the new KTM 390 adv but only if they offer an R model.
    #43
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  4. larryboy

    larryboy Stable genius.

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    The latest parts.

    IMG_20191112_092857623.jpg


    Where I keep them organized.

    IMG_20191112_093847688.jpg
    IMG_20191112_093842399.jpg


    Comparison to a 640 Adventure tank.

    IMG_20191112_093502375.jpg

    The IMS is much lighter.

    Oh yeah, I'm supposed to weigh the CRF swingarm.

    BRB
    #44
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  5. larryboy

    larryboy Stable genius.

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    12.8 pounds for the CRF250L swingarm, that's with the pivot bolt and axle/spacers. It's not a bolt on for the 500's.
    #45
  6. Oyabun

    Oyabun 親分

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    Thx.
    I haven't expected it to be bolt on. Can you please do a few more measurements for me?
    Swingarm outer width at the pivot axle, inside Swingarm width at the wheel axle, pivot to axle distance, and pivot to linkage bolt distance. The later two would be enough as a ballpark, a few mms here or there doesn't count at this stage.
    Thanks once again
    #46
  7. larryboy

    larryboy Stable genius.

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    9 1/2" axle, 9 3/8" pivot. The rest reeks of effort, buy the swingarm, it's cheap and then you can measure whatever you want.
    #47
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  8. DiggerD

    DiggerD DougFir from SuperDuke Days

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    "I'm going to use a little bit of the stock frame where it makes sense... radiator mounts and front engine mount, swingarm and rear engine mounts. It's looking a little easier and quicker than I had thought."

    Good for you Larry.
    I see these engine swaps and can't help to wonder why not use as much of the the frame that came with the engine and then modify the frame for longer forks and swing arm.
    That buys you good drive sprocket location relative to the swingarm pivot and other critical dimensions.
    And so much jig alignment / weldment is all ready done.

    Another thing I see that might be of value is the way fabers are hoisting the engines in place.
    I replaced a bent frame on my 2008 SuperDuke.
    KTM work manual has an engine stand that bolts to the engine and rest on a work bench.
    I built one from a motorcycle front lift stand I made that supported the engine.
    I was able to completely dissemble the bike and replace the frame with this stand.
    I left all the wiring and cabling in place on the engine.
    It was all done by myself without picking the heavy engine up.
    It was all really easy and safe.

    Another thing I thought of on the way in to work today was for mock up clarity, remove the springs from the shock and front forks so you can easily check wheel travel.

    One more item.....you are using the CFR250L rear wheel...does that have a chush drive? Looking myself to add a chush drive to my 2000 XR650R.
    And now ...back to the peanut gallery.
    #48
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  9. larryboy

    larryboy Stable genius.

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    No cush drive on the CRF250L wheel. If the owner feels a need for it in the future he can have one made by Woody's. We're trying to keep initial costs down.
    #49
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  10. oldbmw

    oldbmw havehandlebarswillrideit

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    The Honda CRF450L runs a “Cush” sprocket. I am looking into whether this fits a CRF250L hub. I also contacted JT Sprockets and they are working on making a Cush sprocket replacement for the Honda. If it’s not a direct bolt up to a CRF250L hub, JT may make one for the CRF250L in the near future.


    While running DOT knobs and riding fairly mellow on the street, and being the 500 twin isn’t super powerful, I feel I’ll be okay.
    #50
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  11. DRjoe

    DRjoe Long timer

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    Are you sure its a cush sprocket in the same sense as a cush drive hub?
    Might just be a damped sprocket designed to keep chain noise down.

    #51
  12. DiggerD

    DiggerD DougFir from SuperDuke Days

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    " Might just be a damped sprocket designed to keep chain noise down. "

    Yep, I sent old bmw a pm...that is what he thought too, for chain noise.
    I looked up a 2019 CRF450L on Bike Bandits parts finder...no cush in the hub or sprocket...maybe some rubber for noise.

    Sorry for the hi jack Larry,

    Carry on.
    #52
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  13. oldbmw

    oldbmw havehandlebarswillrideit

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    The crf450L just has a rubber ring going around teeth of the sprocket. Mostly for noise reduction but I would bolt one on if it fits a 250L hub. Might help dampen a little.
    #53
  14. shinyribs

    shinyribs Thumpers for life

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    In my experience, running a knobby tire on the back (actually knobby, not like a Shinko 705) you don't really notice the lack of a cush. But with a more street oriented tire you feel it pretty bad. That's not too say the engine does feel it all the time.

    XR250L's had fairly easy to package cush drives. I put on in a standard XR250R swinger and it only took minimal trimming of some axle spacers.
    #54
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  15. waylongway

    waylongway madmax Supporter

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    :lurk......:drums......:loaded
    #55
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  16. Nixels

    Nixels Face fears - live life

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    :stupid
    #56
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  17. larryboy

    larryboy Stable genius.

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    Oh, it's dumb and dumber.

    :hide

    :lol3


    I'm clearing out other projects that were first in line. Finally got the oil line for the KTM. I'll put that bike together over the weekend, the I can move some bikes around. Then...I can get serious about building this bike!!
    #57
  18. waylongway

    waylongway madmax Supporter

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    You're on the back Nicky....:up

    [​IMG]
    #58
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  19. zeefrenchy

    zeefrenchy Adventurer

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    Nicky always rides on the back, remember that broken ass XT in Benton....:roflyou rode on the back of Larry boy's....
    #59
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  20. alco

    alco Adventurer

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    Hi @larryboy. I am working on a similar build. That is extensive modification of the CB500X frame to fit CRF250L components. I'm now into fitting the CRF250L subframe and tank. Will be looking closely at your progress for ideas. I attached a photo of someone else work to fit the CRF250L swingarm onto the CB500 frame. He drilled new holes for the swing arm bolt. This solves the issue of the CRF250L swingarm being a little bit wider on the pivot point.

    rear swing arm fit.jpg
    rear swing arm pivot.jpg
    #60
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