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Finally finished my 2001 CR250 to CR500AF build!

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Just finished building it this past weekend.

Started with a nice clean 1996 CR500 and decided to build a CR500AF after I found rust/pin holes on the bottom of the downtubes of the steely frame.

Here are some pics of what I started with

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Edited by truthseeker
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YES, I know, my garage is a MESS!! (Told wifey that I will clean it up after the rebuild)

Started tearing bike down to send the frame for mods to Mxdogger on the CR500riders forum.

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Kind of off topic, but when I was looking through pictures of this build I came across these from our garden!

First time ever trying or growing Ghost Peppers!

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Finished removing engine from the steelie and replaced EVERY bearing on the AF CR250.

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Received the frame back from Mxdogger (in Illinois) and the front and rear suspension back from Brian Roth in Sacramento, CA and started installing everything.

I want to say thanks to Mxdogger for the frame mods since it looks just like it came from Honda.

I also want to thank Brian Roth for setting up the suspension exactly how I wanted. He took a lot of time out of his BUSY schedule to listen to me and explain to me, what would be the best setup for my style of riding!   

I installed the new GOLD rims and tires I received from Keith at KSR Wheels (SM Pro Platinum Wheels with Black hubs)!

Cleaned up the frame and swing-arm with WD40 and a "greenie weenie". 

Installed the engine (tried from both sides for about 20 minutes and said screw it, taking the head off). Mxdogger said that I didn't have to take the head off, since it will fit, but patience is definitely NOT one of my virtues!!

I purchased a baking soda blaster and used that to clean the brake calipers and anything else I found that it worked on! This thing works great!! 

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I purchased and installed these graphics on the bike that I purchased from Rich at MXIsland.com

Rich had no problem allowing me to order graphics from different year bikes and making one full set of graphics!

I needed different graphics since I used the following pieces from newer bikes (I purchased a 2003 CR250 airbox and 2003 3.1 gallon fuel tank) and from Acerbis I ordered:

CRF250R:14-15 Front Fender

CRF250R:14-15 Front Number Plate

CR250R:02-07 Side Plates

CR250R:02-07 Radiator Shrouds

CR250R:02-07 Rear Fender

Here are what the plastics and graphics looked like:

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Here is the bike on Thursday 3-23-2017 at 8:44am the Saturday before I went riding in Smith Valley Nevada.

Still have to route, lengthen and solder wires for CDI, modify and put on front fender, number plate, pipe and silencer.

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And FINALLY FINISHED!!

I added and rebuilt the following parts:

- Elevated Technologies Billet 40MM Smartcarb
- Super Awesome Chinese Radiators off of EBay!
- Racetech fork springs
- 2007 CRF 450 Rear Shock with Factory Connection Spring and Intermediate MX Valving
- Motoseat seat cover
- P3 Carbon Pipe Guard
- PMB Kickstand
- Magura Hydraulic Clutch
- KTM Brembo Front Master Cylinder
- Reed Spacer from Roostius Maximus
- FMF Fatty Pipe
- BRP Chain Guide
- New Brake Lines
- Rebuilt front and rear brake calipers
- Modified 2003 CR250 Airbox to fit a CR500 metal frame and air filter cage, using a 2001 CR250 air boot
- Works Connection Skid plate
- Gen3 2003 CR250 Airbox
- Boyesen Clutch and Ignition covers
- Bearings for Steering Stem, Swingarm, Rear Linkage/shock
- GRP Frame Mount to fit Scott's Steering Damper
- IMS Footpegs

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my only complaint is no radiator louvers or frontal protection.... otherwise, really sweet bike and build. On a secondary note, that Ghost Pepper salsa looks fantastic.

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What fuel tank did you use? Those gold rims are eye popping!

If those are simply 2001 CR250 radiators then getting guards shouldn't be too difficult but they're prolly oversized 500 spec radiators. Maybe try some CRF450X radiators and guards next time? The 450X left radiator is longer than the right however. 

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nice colection of parts so far, i always wanted to try out an 02/07 frame with a cr5 in it, so far i have a crf450 and a first gen af 250 converted. 

your going to miss the seat from the old steel frame bike

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shrubi u better get some blowers suckers and headers on them kitty,s my dog wants to chase n catch and ... them.

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1 hour ago, peaceofwork said:

shrubi u better get some blowers suckers and headers on them kitty,s my dog wants to chase n catch and ... them.

My Son said that his friend's cat was eaten alive by their own dog. Bloody mess he said. They only had the cat 3 months. I had a dog who also ate kitties when I was a kid. Dunno why some dogs don't like cats. 

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On 4/1/2017 at 8:51 AM, DEMI said:

my only complaint is no radiator louvers or frontal protection.... otherwise, really sweet bike and build. On a secondary note, that Ghost Pepper salsa looks fantastic.

I have a new set of Devol radiator guards, but I have to modify the plastics for them to fit.  Doing that today!!

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On 4/1/2017 at 9:38 AM, Arctic Pride said:

Nice job, bike looks great, swapped the front wheel?

There was an issue with the spacers fro the front wheel, so I put the original CR250 wheel on so I could ride that weekend.

I received the new one's from Keith @ KSRwheels and it is going on today!

Edited by truthseeker
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On 4/1/2017 at 10:55 AM, shrubitup said:

What fuel tank did you use? Those gold rims are eye popping!

If those are simply 2001 CR250 radiators then getting guards shouldn't be too difficult but they're prolly oversized 500 spec radiators. Maybe try some CRF450X radiators and guards next time? The 450X left radiator is longer than the right however. 

Fuel tank is a 3.1 Gallon IMS Tank.

Radiators and Devol Guards that I am putting on today were ordered for a 2001 CR250.

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On 4/1/2017 at 11:40 AM, peaceofwork said:

nice colection of parts so far, i always wanted to try out an 02/07 frame with a cr5 in it, so far i have a crf450 and a first gen af 250 converted. 

your going to miss the seat from the old steel frame bike

Yep on the seat comment!

The steelie seat is liking riding a couch and the 2001 CR250 seat feels like my mountain bike seat!

My a** was hurting after riding all weekend!

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how did the first ride go, any hickups? i imagine you have to change riding style a bit with that motor 

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First ride was great accept I have silicone radiator hoses and one of the was leaking (the one going from the water pump to the bottom of the right radiator) and even after tightening it and putting on 2 clamps, it was still leaking. I am replacing that today.

Bike feels REALLY TWITCHY compared to the steelie frame, I am going to have to get used to it. It feels more nimble, but not as stable in the sand at high speed. Where the steelie felt big, top heavy, awkward and slow, this bike feels, light, weight feels lower on the bike and it feels faster.

 I almost crashed into 4 strand barbwire after hitting a pretty good sized rock going about 60mph (I was following some friends and the dust kept me from seeing it until the last second).  My feet were bucked up off the pegs and felt like they hit the back of my helmet and while hanging on with just my hands, I somehow stayed on the bike and kept going. 

The vibrations now on my hands, I think are worse! My hands go numb and I don't know how hard I am squeezing the grips.

 

 

Edited by truthseeker

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