CRF500L build #3 - The Brit remix

Discussion in 'Some Assembly Required' started by Scutty, Mar 20, 2017.

  1. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    Ok, time for an update on the new front end....
    2018-11-27 20.32.45.jpg
    Well that was a lot more involved than I expected. Getting the triple trees to fit was simply removing old bearings and races and fitting new ones (what a fun task that is) but the problems started with the Highway Dirtbikes fairing/lighting and the front wheel.
    The front wheel turned out to be from a CRF250R and, without the speedo pick-up, the spacers I had didn't fit. Time for a little bodging - using a spacer kit from a 450X and a new 450R dust cover/spacer I managed to get the alignment correct. As soon as the wheel was on and spaced I realised that the rotor that came with the wheel was bent, grrrrrr, so I had to source a new rotor. This turned out to be a good thing as I didn't fancy trying to stop my 155kg bike (plus lumpy rider!) with the standard 220mm rotor. Ebay to the rescue and a 280mm rotor and caliper bracket fit like a treat:
    new brakes.jpg

    Back to the top of the yokes and the issue stemmed (excuse the pun) from the handlebar mounts. On the 250L they are 96mm apart but the 450R is 110mm so the order went into HWDB for a new tower mount and bar clamp (never try and ship to the UK over Easter holidays.......bloody customs.....grrrrrr). Once the new parts arrived it was a simple job to get everything back on the bike:
    new headstock.jpg
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  2. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    In order to keep things on the level I needed to do some work on the rear end too - time to say a sad goodbye to the excellent Ohlins shock and the 250L linkage pieces and hello to Rally parts and a new YSS shock. I just couldn't bring myself to spend the £750 Ohlins want for a Rally shock (over £200 more than the L shock ffs!!) and I'd heard great things about YSS.

    I have to say, after riding it for over 100 miles I am really happy with the YSS performance and the spring they supplied with it - sag measurements were spot on straight from the box!

    The new front does need stronger springs (ordered) but the bike performed brilliantly and I have 11" of ground clearance now - you can see how higher it now sits versus my mates Racetech/Ohlins fitted Rally:

    2019-04-27 11.42.46.jpg

    2019-04-27 13.57.03.jpg
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  3. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    In total I had to change the following parts:
    • Forks
    • Triple Trees
    • Headstock bearings
    • Front fender
    • Front wheel, axle and spacers
    • Front rotor and caliper
    • HWD tower mount and bar clamp
    • Rear shock
    • Rear shock rod
    • Rear Shock arm
    Worth it? Hmmmmm, good question. I really liked the RaceTech/Ohlins combo but, due to the way my exhaust/sump/bashplate ended up, I really wanted more ground clearance. I could've sourced a 250 Rally front end and RaceTech'd that but I know the 450R forks are always going to be superior.

    Time will tell
  4. MotoPolo

    MotoPolo So many places, so little time Supporter

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    Scutty - You'll love these forks - same ones I have on my AR17. So these forks have about 12 in. of travel me recalls. What is your ground clearance? Less than 12 in.? My clearance is 9.5 in so if I bottom the forks my sump case is going to hit the ground. I plan on reducing the stroke on my forks - are you planning to do the same? If so let's share data because I don't know how to do that.

    Bike look awesome
  5. MotoPolo

    MotoPolo So many places, so little time Supporter

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    Just read you have 11" of ground clearance - maybe you are safe and don't need to worry about bottoming?
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  6. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    I've been following your build too, nice work!
    I'm going to switch to stiffer springs then see. I think I might be ok as the rear is 9.4" travel.
    If you check out Levi's build thread he shortened the travel on his forks and detailed how he did it.
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  7. MotoPolo

    MotoPolo So many places, so little time Supporter

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    Thanks.
    Do you know what bike your forks were sourced from? The clamp plates are a bit different than mine.
  8. adv+

    adv+ n00b Super Supporter

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    So to mount the 450r forks you only had to change the headstock bearings? What size are they?
  9. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    The forks are from a 2012 CRF450R, as is the wheel, but the triple trees are from a 2012 CRF250R (hence the need for a different front fender)
  10. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    If you have a complete front end then you can find the bearings you need here:
    https://www.allballsracing.com/forkconversion

    You will need a spacer for the top of the stem, under the castle nut, as the stem thread isn't long enough.
    Additionally you will need to sort out steering stops and a way to mount the headlight and dash if you stick with the standard ones.
  11. AntónioPereira

    AntónioPereira Adventurer

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    Hi Scutty,

    What model YSS shock did you buy? Was it the G-series with the piggyback and hi and low settings? Do you have a picture of it? I'm thinking of one of these for my dr650, that's why i'm looking for some feedback. How much was it, if you don't mind me asking.
    Thank you.
  12. Scutty

    Scutty Talent-limited bike builder and rider Supporter

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    I got mine from Firefox Racing: http://firefoxracing.co.uk/parts-ac...2016-yss-mono-shock-absorber-mz456-420trl-05/

    There is an version with a remote reservoir but its about £650 - I pad £305 all in with a heavier spring (110NM because the bike is heavier and I suffer from cake retention) :D
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  13. flipflopdog

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

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    CAKE RETENTION...…. I can't stop laughing, my sides have burst open...…..!!!!
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