Supermoto made from Suzuki RMX 250
Project – https://www.vitalmx.com/forums/Old-School-Moto,22/Project-bike-1986-Honda-CR125R,1299309
- new clutch cover
- new fuel tank
- restored plastic by sanding, heat gun treatment and Plastic Renew stuff
- HRC cylinder
- rebuilt crankshaft (new used) with a 50mm stroke
- new fork seals, clutch/throttle cable, chain and rear sprocket
- new seat cover
- piston with one ring
- Keihin 36mm
- Yamaha footpegs
- IMS shift lever
- custom pipe hanger
- Motion Pro throttle assembly
- front brake system from last generation CR125/250
- Shock mud guard is brand new part for 1990 CR125
Project – https://www.supermotojunkie.com/threads/project-black-diamond-cr-500af-street-build.109288/
donor bikes – 91 CR500 and 07 CRF 450
- 91 cr500 engine stripped and vapour blasted
- rebuilt and balanced crank with prox conrod
- all new bearings and seals
- stan stephens moderately tuned barrel with oversize prox piston 502cc
- pro designs polished billet coolhead with multi compression inserts
- boyesen radvalve and block carbon reeds
- talon clutch basket/ebc drc clutch with standard springs
- boyesen clutch cover
- boyesen ignition cover
- pwk carb
- polished engine parts/head/kickstart/waterpump cover/coolhead/ carb/engine bolts etc
- wrinkle paint finish to casings and barrel
- samco engine hoses
- silicone carb hoses
- modified crf radiators
- cr 250 airboot with custom airbox plate
- new crf 450 airbox and standard filter
- high output coil.
- 07 crf 450 frame
- pro fabricated to fit cr 500engine, powdercoated graphite
- aprillia rxv swingarm,powdercoated graphite
- modified subframe powder coated graphite
- costom made billet headstay
- marzzochi shiver 50 forks pro-action setup marzzochi triple clamps
- ohlins ttx rear shock
- polished crf shock linkage
- ohlins 2.1 steering damper
- all bearings replaced/headstock/swingarm etc
- trail-tech sidestand
- pro-circuit platinum expansion chamber with crf 250 carbon/titanium akropovic twin cans
- goldspeed carbon wheels with polished hubs
- goldspeed ultra road legal tyres
- beringer radial caliper/factory polished
- beringer master cylinder/factory polished
- beringer clutch lever/factory polished
- beringer front disk
- aprillia rxv rear brake
- pro-carbon fuel tank
- pro-carbon tank shrouds
- pro-carbon front fender/shortened and modified
- pro-carbon frame guards
- carbon wrapped rear fender
- crf 450 sidepanels
- new honda rad guards
- driven racing carbon bars
- infinity carbon handguard sheilds with cycra probend handguards
- icon racing billet fuel cap/polished
- sdg step seat
- GFX designs custom graphics
Bike was listed as “locked up”, but very low hr bike. Pretty much everything was original except FMF pipe and silencer and bike was stored inside.
The last time it was ridden it sucked in dirt. Crank was sent to Ken Oconner for rebuild.
In seizure cylinder wasn’t damaged but plating was flaking pretty bad. Cylinder with Pro X cast piston was sent to Powersealusa.
The chassis on the bike was clean and original. Just a good cleaning and regreasing. Shock bumper was missing, so it was dropped off for a rebuild.
Carb had 58 pilot and 178 main. Previous owner also had a reed spacer on the intake with an FMF gnarley pipe.
For Racetech fork springs owner had to make make a pvc spacer as the new springs are 40mm shorter than originals, stock springs had a lot of preload on them, owner went with a lot less at the RaceTech recommended 4mm preload.
- Pro X rod kit
- replaced all bearings and seals
- new seat
- Boyesen reeds
- yzf pegs
- SFF forks
- Excel rims
- PC raw pipe
- OEM clutch cable and intake bolts
- Works Connection frame guards
- Racetech fork springs
- DEP works pipe, R304 shorty silencer,
- 2008 CRF450R front brakes,
- Vforce 3 reeds, new plastics,
- chain and sprockets,
- brand new 2018 YZ250 wheels,
- Tusk 270mm adapter to get 2008 CRF450 calipers,
- Red Label is making the graphics,
- GUTS seat,
- Tom Morgan 295cc ported, milled head,
- Magura Clutch,
- R-tech kit, blue Luxon clamps, and 18 YZ450F front plate and fender,
- R-tech tank,
- Acerbis blue frame guards,
Owner found one in Yamaha for less then $2,000 and it was a bit of a mess. Front brakes barely did anything, didn’t run right, chain was shot… just a mess.
Frame was really bad shape, slow spinning wire brush on the end of a drill was used, a Dremel and some scotch brite pads.
Had to order the Tusk 270mm adapter to get the 2008 CRF450 calipers mounted. Brakes work fantastic now that it’s bled with new system!
After Magura Clutch install pull feels quite a bit better and reduced effort to pull.
After bottom end modification it will be 76mm stroker that will make YZ315. Tom Morgan was building it, along with flow benching reed cage and carb. He uses stock crank, balances it and uses OE Yamaha rod kit since OE is proven reliable.
A big bore pulls more air volume thru the intake tract and also requires a smaller throttle opening to create the same torque. This raises the vacuum in the carb which causes a larger pressure differential between the float bowl and the venture. This pulls more fuel thru the same size jet. The A/F ratio is the same but people mistakenly believe that it is leaner because of the smaller jets. The main change that you will make when increasing the engine displacement is in needle clip position and air screw setting. The main jet stays very close to the same as with a smaller bore
1-1/2 out on AS
- Engine Displacement – 499
- Engine Type – liquid-cooled, two-stroke
- Cylinders – 1
- Horse Power – 62
- Transmission – 5-speed
- Torque – 64.7 N-m 16.6 kg-m. 47.7 ft-Ib) @6000 RPM
- Dry Weight kg – 100
- Fuel Tank (gal) – 2.6
- Fuel Tank (liter) – 9.9
- Oil type – 10W/40
- Front Tire – 80/100 R21
- Rear Tire – 110/90 R19
- Wheelbase – 1491mm (58.7in)
- Wheel travel Front – 300mm
- Wheele travel Rear – 330mm
- Overall length – 2200mm
- Overall width – 815mm
- Overall height – 1205mm
This 1992 Kawasaki KX 500 was long coming project, because owner were looking for right motorcycle over year till this gem poped up. The goal was to update the brakes, wheels, suspension, clutch and all around fit and finish. And end result speak for it self.
- 2011 Kawasaki triple trees got the stem pressed out and the KX500 stem pressed in
- changed fork stops
- the Brembo brakes and wheels are off a 2013 KTM
- EXCEL Rim
- new impeller drive gear old on the end of the crank shaft was beat to death, mushroomed and had broken teeth
- made bracket to utilize KX 450 sliders
- custom made wheel spacers
- 450 cover
- rebuilt shock, race tech gold valve and bladder cap
- hydraulic clutch
- cerakoted engine – tungsten color
- ported cylinder and cleaned up power valves
- new clutch basket
- seat cover from MotoSeat
- resotred PRO Circuit pipe
Simple way to upgrade the clutch pull arm for a little more leverage. Take a yamaha 450 pull arm shaft and this billet arm thats a tad longer, weld the splines to your 500 arm.
Looks like this bike was gently trail ridden for maybe 20 or 30 hours. The only wrench this bike ever saw was the rear axle nut to adjust the chain. It was pretty clear that the wheels had never been removed from the bike and the original “Claw” tires still had most of their tread left. The grips and levers looked almost the day they left the dealership.
Obvious that this bike not only had not been raced, but it doesn’t even look like the bike had ever been even in a small crash.
The paint on the fuel tank was unmarred and no sign of even the slightest knee scuff marks. The same goes for both unmarred engine covers. The seat still looked brand new, no cuts or scratches. Most bolts still looked quite new and the trans oils looked pretty good after sitting in a dry place for probably close to 40 years. There was a little bit of fading on the front fender, but other than that, the plastic all looked good.
There was no dry rot on any of the rubber parts either which were still supple like new. There were remnants of a mouse nest in the airbox, but this bike is pretty much a time capsule from the past. The few minor scratches on the swing arm and left side plate looked more from having things piled up against it in a garage than riding. This bike is 100% original.. no parts were broken or missing.
In the end the best match for the engine paint was the RAL 3020 Traffic Red form LVP.
For the slightly lighter colored frame, the Tahitian red from National Autobody & Paint Supply was a dead ringer except it only comes as a base coat which is a flat finish and needs a gloss clear coat.
- rear motor mount bracket fabbed by Ray Carlstedt
- replica HRC bolts,
- upper motor mount bracket,
- RC-replica swing-arm spindles,
- stainless RC replica motor mount bolts,
- CNC exhaust flange that will prevent spooge dribble typical of the stock bike,
- vintage D&G front fork air caps,
- RC replica white gas cap,
- VMX fenders,
- heavier .48kg springs from Race Tech 15 weight oil,
- shock guard to protect the shafts on the Fox Air Shox
- motor is getting a full rebuild with oem crank
- powdercoated frame
- powdercoated subframe
- black wheels
- cerakote hubs
- purple shock
- new zinc plated bolts
- 96 oem graphics seat cover from Evo mx
- Pro Circuite pipe
- new r304 silencer
- 06 kx450 forks (rebuilt)
- 07 kx450 wheels, hub, rotor
- axles, spacers & 07 kx450f brake system
- EBC 280 kit brake kit
- evo 96 decal kit
- custom carbon fiber skid plate
Specification for bike (CR500RN)
– Overall length – 2183 mm / 85,9 in
– Overall width – 825 mm / 32,5 in
– Overall height – 1240 mm / 48,8 in
– Seat height – 964 mm / 38,0 in
– Wheelbase – 1489 mm / 58,6 in
– Ground clearance – 343 mm / 13,5 in
– Dry weight – 101 kg / 222,7 lbs
– Type – Semi double-cradle (steel)
– Front suspension, travel – Inverted telescopic fork (adjustable) , 310 mm / 12,2 in
– Rear suspension, travel – Swingarm Pro-link with mono-shock (adjustable), 320 mm / 12,6 in
– Front tire size – 80/100-21 51M
– Rear tire size – 110/100-18 64M
– Front brake – Single disc, 2-piston caliper
– Rear brake – Single disc, 1-piston caliper
– Fuel capacity – 9,0 l / 2,38 US gal
– Trail – 119 mm / 4,7 in
– Type – Water-cooled 2-stroke
– Cylinder arrangement – Single cylinder
– Bore & Stroke – 89,0 x 79,0 mm
– Displacement – 491,4 cm³ (29,9 cu-in)
– Compression ratio – 6.8:1
– Max. power – 64,6 hp (47,5 kW) / 6000 rpm
– Max. torque – 72,2 Nm (7,3 kgm) / 6000 rpm
– Carburetor – 1x 38 mm
– Clutch – Wet, multi-plate
– Transmission – 5-speed constant mesh
– Final drive – Chain
– Primary reduction – 2.520
– Final reduction – 3.500
I – 1.750
II – 1.388
III – 1.150
IV – 1.000
V – 0.870
– Ignition – CDI
Rear shock bumper and bladder was from OEM, Racetech seal and dust cover. Nitrogen tank with 160psi.
Front forks – NOS Racetech .44kg springs. Honda OEM sliders, seals, dust wipers.
MSR poly bushings for the Scott risers .
UNI filter and a gas tank strap from 2004 CR250R.
The wire harness were cleaned up and back in place and installed KTM pegs with minor fab work.
The radiators got some chemical cleaner which worked great at getting in the fins and small areas. Fins where straightened by two screw drivers. All the radiator hardware, clamps, hoses, etc… are in good shape except for the two hoses that attach to the cylinder head which were replaced.
This project was made with budged in mind so many parts are reused!
- 06 YZ450
- .47 springs, 375cc of fluid
- new swing arm, old was to damaged and cracked
- front brake from Honda CRF – master cylinder, hose and caliper with a 270mm rotor.
- rear brake master cylinder from YZ ’04
- right side frame guard of ’98
- came with log rod motor
- later model rear brake master cylinder
- Boyesen Rad Valve
- Enzo subbies
Front wheel in good shape with spacers, rotor, axle and brand new front tire for cheap from eBay.
There was added some material to the steering stop so that the later-model clamps would make full contact.