CRF500L full build thread

Discussion in 'Japanese polycylindered adventure bikes' started by michaelkozera, Jul 2, 2015.

  1. michaelkozera

    michaelkozera Long timer

    Joined:
    Jan 11, 2015
    Oddometer:
    1,434
    Location:
    calgary
    so it is time. CRF500L here i come!

    20170704_202703_zpspbvk5yni.jpg


    20170703_202820_zps9p0kbqr0.jpg
    20170627_191144_zpslnhaf7ep.jpg
    this build is a continuation of my crf300L:
    http://www.advrider.com/forums/showthread.php?t=1037914

    the link above/ pics below are my crf300L-EVO1 version/build 2.0










    now let begin with build 3.0................ Dakar style CRF500L-EVO1


    goals of build/why im doing this:

    ive been riding dirtbikes since i was a 8 year old kid and street bikes since i was 16. ive ridden every thing from the smallest of dirt bikes to the biggest of cruisers, to the fastest of sport bikes, and owned more bikes then i have fingers and toes.


    my yamaha R1 was stupidly fun and ridiculously fast but limited to road/ good weather.....

    my ktm690 was brutally fast and very capable off road, but vibrated like a paint shaker and burn more fuel then my car.....

    my yamaha 450 was absolutely incredible off road, but not street legal....

    i briefly owned a klr650 but that thing weighed so much that taking it off road was like trying to wrestler a grown bear......

    and the many other bikes ive owned over the years......

    my crf250L was my match made in heaven. it looks absolutely amazing, its very comfortable, ive taken it everywhere, in all weather, any temps, but there is one glaring problem with the crf250l, its engine although very economical is about as fun as math class. even after huge mods, and 50% more power then stock, it was still lacking.

    my bike doesn't need to be a 200+km/hr bike, nor does it have to be a fire breathing dragon that can wheelie on demand, or spray rocks with rooster tail for days. but it still need a proper motor.


    as i get older ive have started to appreciate the smaller things in life. i want a calm bike, a capable bike, an economical bike, a comfortable bike.


    ive looked everywhere:

    suzuki drz400, bmw gs, honda 650, etc etc. no manufacture makes what i want, what i yearn for.




    my bike needs the following:
    -fuel injection
    -2 or more pistons
    -low vibration
    -tons of TQ/ linear TQ
    -good fuel economy
    -able to hold 110km/hr at any wind speed, all cross winds, and any hill/grade
    -6 gears
    -300w+ stator
    -quiet exhaust
    -catalytic converter is a must.
    -at least 10" of ground clearance
    -minimum 10" suspension travel
    -below 360lb ( or close to)
    -upright seating position
    -comfortable wide seat, but narrow in the front/middle
    -able to stand on foot pegs all day
    -very low maintenance ( valve clearance/oil/tires/ etc/etc)
    -reliable
    -87octane

    essentially i want to make the perfect 50/50 dual sport. ive noticed the market lacks this true 50/50 machine.


    the crf/klx/wr are all 80/20 (off/on road) while the klr/gs is 20/80.

    the ktm 690 or the new crf1000L is probably the closet thing to 50/50 you can get. (ktm=60/40, crf1000l=40/60) but ktm sucks gass and vibrates like a #$%^#$ while the crf1000L altho a very nice machine will be 450lb+ not to mention 1000cc= poor fuel economy.


    is my goal of a true 50/50 achievable? thats what this build is all about! crf500L the bike honda should have made.




    enjoy:

    donner engine from a 2013 cbr500r, 3370km on the engine :)


    got her running, no error, no engine light, everything runs great!



    getting bike ready





    old engine out, new one going in!




    it important to note, the crf250l engine is 87lb wet. while the cbr500r engine is 106lb wet

    since my bike currently weighs 338lb, then i should have a total weight of 357lb+ a few lb for other things, so looking at a total finished weight of 365-370lb




    size is very similar. the cbr500r engine is exactly 2" wider (1" on each side) and 2.5-3" longer from from to back.



    got her all cleaned up and ready for its new multi piston power plant.
    and painted the frame.



    swapped out the fuel pumps, turns out they share the same mount points.





    got the engine mounted in frame. engine is a VERY tight fit.

    and as predicted the oil sump sits exactly 1" lower then the stock frame, thus i will have 1" of less ground clearance once the new sub frame goes in.

    stock ground clearance was 10" , i raised my bike to 12" and now ill have 11", so 1" higher then stock still.




    i cannot move the engine any higher because it will hit the fuel tank.


    the TB fits perfectly, almost like it was meant to be in this frame...........







    i was not joking when i said it was a tight fit.



    got the subframe welded up today. still not done, ive got some work to do on the head tube, and 1 or 2 more cross braces.

    i triple butted the welds for maximum strength.





    got the entire frame welded today, and bash plate on.

    bike now sits at exactly 11" ground clearance.

    i also made some bash guards on the side to protect the engine in the event of a crash. these bash guard also double as structural support for the frame.











    a huge thank you to my friend jurai antonak (welder by trade) which helped me with the welding to make sure it was structural. i am an engineer and i can weld but im no expert when it comes to welding.


    got the exhaust mounted , this part next to the brake level will be wrapped and covered.



    also got the airbox done too. ignition coils are in, and pair valve installed. radiator mounts also welded too





    got the rad mounted and dual pipes aligned and welded on.






    finished up most of the wiring. the harness had to be split and lengthened in several location to fit in its new frame.





    almsot done, took it out for a few mins today for a quik test, got to 160km/hr in 4rth gps confirmed.



    home stretch!

    all done!

    just doing some final stress testing.





    i will have High res detailed pics soon of the final bike!



    update:

    got my speedo healer in, gonna slap it in tonight and make the speedo accurate.

    update:

    speedo healer installed and speedometer is now 100% accurate

    stay tuned!

    UPDATED PHOTOS!!!! year to date:
    #1
    Hannda, Bkadv2, RCmoto and 10 others like this.
  2. michaelkozera

    michaelkozera Long timer

    Joined:
    Jan 11, 2015
    Oddometer:
    1,434
    Location:
    calgary
    enjoy:

    Dakar Style Crf500L Evo-1 serial number: 001 :rofl:rofl
    20170704_202703_zpspbvk5yni.jpg

    Bike specs:

    weight:
    -344.5lb wet with road tires/rims
    -342.3lb wet with off-road tires/rims

    fuel capacity:
    -12.45L

    fuel consumption:
    -2.8L/100km highway
    -3.8L/100km city
    -3.3L/100km combined

    range:
    -380km-ish

    ground clearance:
    -11.4" un-loaded
    -8.5" loaded

    hp/tq:
    -45hp/29.5ft-lb

    power to weight ratio:
    -306hp/tonne

    -actual ( corrected + rider+ Rwbhp):
    185hp/tonne

    lights:
    -Bi-x FXR3.0 with CBI@50w
    -10w TRS LED foglight
    -TRS DRL halos X2
    -lumitrex 30w mini lightbar (BFL-30)




    bike before was 338lb

    so basically the 500 twin added 25lb's, just as predicted.




    crf500l



    crf500l top speed +highway



    crf500l in city






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    #2
    Scubalong, Hannda, Don T and 15 others like this.
  3. Cruz

    Cruz Lost but laughing.

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    Huge project, will follow it closely.
    #3
  4. Chillywater

    Chillywater Been here awhile

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    Was wondering if your leaving in emissions junk that you may not need, depending on where you live? Not even sure how much stuff is added to the bike specifically for California type regulations, but I would think without them you would shed some weight as well as squeeze a little more juice out. Maybe even prevent a future breakdown, by removing some fancy tech that may go bad eventually..

    Not that you'll need extra juice with your new 500, less weight would be a plus though. Would certainly like to know what (if anything) is unneeded on the original engine...

    Good luck
    #4
  5. John Ashman

    John Ashman Adventurer Wannabe

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    God, yes.
    #5
  6. poomero

    poomero Been here awhile

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    Good luck i hope it turns out they way you want it to. If it does this will be an amazing bike.
    #6
  7. SAPB

    SAPB Long timer

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    :lurk
    #7
  8. kyns

    kyns Long timer

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    Well there's your problem.

    Have you measured the counter sprocket geometry yet? That 500 sump looks to hang about 3 or 4 inhes lower in relation to the CS, than on the 250.
    #8
    HOTPASS likes this.
  9. larryboy

    larryboy Stable genius.

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    Über Alles,California
    Before coming in here I thought, if he keeps it under 360 pounds I'll follow along and there you are, shooting for 360.

    :lurk
    #9
  10. Lion BR

    Lion BR I'd rather be riding

    Joined:
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    Oregon
    Last year people were talking about bringing the front suspension of the CRF250L to the CB500X (the almost forgotten Thai project). Now you come here and propose to bring the CB500X motor to the CRF250L frame. Come to think about it, it seems like a better idea. Let's see if you can pull this off.
    #10
  11. Maxacceleration

    Maxacceleration Off the grid

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    Oh God.
    #11
  12. Cruz

    Cruz Lost but laughing.

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    Northside Brisbane, Qld Australia
    :lol3
    #12
  13. rlkat

    rlkat Mine's a whisky

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    Blah
    Big respect to you if you pull this one off. If so, then you will have a cracking bike at the end. Good luck. :thumb
    #13
  14. michaelkozera

    michaelkozera Long timer

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    i want the emissions stuff because ive noticed with the wind screen that alll those nasty gasses ( monoxide, unburnt HC, Nox, Hox, etc etc) get trapped in that low pressure zone behind the windscreen. its not really that big of an issue but it does annoy me sometimes, plus i dont wanna poison my self.

    on the flip side i also want the catalytic converter because it reduces noise, also these engines are low HP but high TQ, and TQ gets made with back pressure. catalytic converter = back pressure= more TQ.

    however if weight becomes an issue i might have to dump the emmisions junk since its about 20lb for all of it

    correct, the cbr500 engine is 3 inches taller ( 1"taller from the sprocket, and 2" lower from the sprocket)

    this my be a problem but i have an idea. the old crf250l frame was about 2" below the crf250l motor, with this new build i will be welding a new bottom frame and i will make the motor and the frame sit flush with each other, thus my ground clearance should not be effected.

    but worst case scenario, my bike has been raised by 2", so if i lose 2" due to engine ill be back to stock ground clearance :p

    i was actually about to buy a cb500x and convert it to off road, dirtbike forks/shocks, 21"/18" rims, etc etc. but in the end i decided not to becuase the total net weight would be 430lb+, too heavy for any real off road. ive iowned a KLR650 and that thing was a fat pig off road. not fun.

    360lb is already pushing it.
    #14
    enduro16 likes this.
  15. Samtech79

    Samtech79 Two wheeled lunatic

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    NorCal
    You could always build a new sump. Your probably not going to run the exhaust that low or next to the sump like stock... A shallow wide sump wouldn't be too hard to build. Changing the pick up should be too difficult either.
    #15
  16. Maxacceleration

    Maxacceleration Off the grid

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    #16
  17. Kawidad

    Kawidad Long timer

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    I like what you're thinking. :feelgood Count me in! :y0!
    #17
  18. Wallachian Spikes

    Wallachian Spikes Long timer

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    I keep watching the Africa Twin & the XTZ-07 threads but, I don't really want an Advbike. I want a dual sport with a mid-size 500-800cc P-twin that will do hours of highway & still get deep into the woods. This project of yours may be the best idea I've seen yet. Hope corporate Honda is watching. :clap
    #18
    enduro16 likes this.
  19. HighwayChile

    HighwayChile greetings from Wa state

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    Bow, WA USA
    best of luck !
    if Mr Honda was alive this would be on showroom floors with Elsinore or SL styling. instead we get the honda of today, bikes by committee and accountants
    #19
    enduro16 likes this.
  20. michaelkozera

    michaelkozera Long timer

    Joined:
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    Oddometer:
    1,434
    Location:
    calgary
    progress!

    swapped out the fuel pumps, turns out they share the same mount points.

    [​IMG]



    got the engine mounted in frame. engine is a VERY tight fit.

    and as predicted the oil sump sits exactly 1" lower then the stock frame, thus i will have 1" of less ground clearance once the new sub frame goes in.

    stock ground clearance was 10" , i raised my bike to 12" and now ill have 11", so 1" higher then stock still.

    [​IMG]


    i cannot move the engine any higher because it will hit the fuel tank.
    #20
    enduro16 likes this.