May 19th, 2010, 09:47 PM | #1 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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CR500 AF 2-Stroke Street Racer
The CR500 engine is back, being repurposed in a different frame.
I began building a SV650/CR500 street racer hybrid since over 2 years ago, I lost interest in that project late last year and turned out a lighter more interesting plan out of the easiest tried and true CR250 dirtbike conversions you see just about everywhere on the web. I began to purchase nearly all of my parts off of ebay; I only bought things that are serious deals. Lots of my items were listed incorrectly so nobody could find them, but a couple special searches over the course of a few years and you can find anything. I guess I'm an ebay junkie, haha. I LIKE CHEAP! Anyways, its all built around a '99 CR250 frame that I got for $35 with shipping. It was fairly easy to get the CR500 engine mounted in this frame. Only 2 new mounting tabs needed to me made, all the rest of the mounts and swingarm bolt lined up perfectly. I still have to create a solid headstay, though. With a 2006 GSXR600 front end that I intended to put on the SV with steering the stem swapped out from a CR250 triples, and had a bushing made for the GSXR top tree to fit. I had a tab made and welded to the frame for the GSXR steering stabilizer, too. CBR600F3 wheel is on the front with CBR1100XX Blackbird discs (same diameter of the discs that would have been on the GSXR front end) drilled to fit and bearings swapped to fit onto the GSXR axle. The discs are offset a little, but that offset along with the F3 wheel the discs fit PERFECTLY between the GSXR calipers... I couldn't believe my eyes! No additional spacers or machining required! The rear swingarm is a CR125 part that came powdercoated and has the right spacers in it to fit the CR500 engine. This was the trickiest part of the project was to fit a CBR600F2 wheel(the F2 is slimmer than the F3, this is important, same style though) onto the CR250 axle. The bearings were the right size, but the width of the sprocket carrier was too massively wide. Lots of machining went into that wheel and the cushdrive to make it fit and get the chain alignment right. An R6 rear brake caliper and bracket were on hand in the parts bin, so it was made to work on the other side with a bushing made from a CR250 wheel spacer and some minor machining to the bracket.... It was a TIGHT fit for all of this, but it all works wonderfully together! So I had some Battlax tires fit to it, and began to assemble it all in the shop. Rather than have a CR250 rear shock converted to street by having it resprung and revalved (EXPENSIVE!) I opted for a cheap ebay ZX10 shock that is already set up for street and made it fit instead. I created a adapter template out of wood to extend the shock and brought that to a machinist have one cut from billet. I'm a heavy guy so this should work OK. The wheelbase is a few inches shorter than my SV650, and the projected wet weight when complete is 220lbs. The Formula 450/Super Single/450Moto bikes that are being developed in parallel to my design of this project are VERY similiar! But I think mine is way cooler! Also, Roland Sands built a cafe-racer similar to this about the same time I got started on mine, I didn't even know it existed until last summer. I'm a little bummed that mine wasn't first! LOL!
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May 19th, 2010, 09:48 PM | #2 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Here's a couple videos, first is a slideshow of the project parts and mockup assembly, the rest of the videos actually show live-action assembly progress
Link to original page on YouTube.
Link to original page on YouTube.
Link to original page on YouTube.
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May 24th, 2010, 12:57 PM | #3 |
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That beast will rip. I had a CR500 MX bike in the 80's and it was a blast.
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May 24th, 2010, 01:16 PM | #4 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
I'm excited about this project, but I've just run into a problem... my brand new 150 tire isn't a 150 at all.... it measures out to a 160 even though its labelled a 150!!!!!!! WTF! Bleh! This pisses me off because now the tire hits the chain which we did all that very meticulous measuring and machining for to make this all work... blah! No room to make changes... might have to install a 140 tire.... if its oversized like this one it'll probably clear just fine. I'm gonna see what else I can do, photos and another video are to follow.
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May 24th, 2010, 02:45 PM | #5 |
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Name: J.G.
Location: Austin
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Looks great so far - I bet it will be blast to ride.
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May 24th, 2010, 02:59 PM | #6 |
ninjette.org guru
Name: Josh
Location: CT
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Nice job, Duck. I remember reading a blog some time ago that mentioned a conversion kit for MX-Street bikes for a "cheap" track racer. (I guess they never heard of a 250 haha) Anyway, your bike looks like it will be a lot meaner!
EDIT: found it http://www.450gp.com/EN/vehicles.html |
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May 24th, 2010, 03:14 PM | #7 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
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May 24th, 2010, 03:31 PM | #8 |
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Name: Josh
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I love the idea. I found a news article on the kit about a year ago on some blog and thought how cheap and awesome it would be, until I found out that the kit alone is right around $6500+shipping from Spain. If I ever do something like that, I will go your route as well. A least there are some pretty decent aftermarket fairing companies out there if you plan on putting some on.
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May 24th, 2010, 07:21 PM | #9 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
Just keep in mind I have just under $2k in parts right now, because I was a cheapskate. I probably have about another $2k in maching alone, and my tires were a trade out.
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May 24th, 2010, 08:00 PM | #10 |
ninjette.org guru
Name: Josh
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SNEAK PEEK, SNEAK PEEK! You definitely have my attention.
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May 24th, 2010, 08:06 PM | #11 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Nah, I don't want to answer questions as to what it all is yet, lol. That will probably be the first and most repeated question.
What is it? Pffffft!
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May 24th, 2010, 08:12 PM | #12 |
ninjette.org guru
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May 24th, 2010, 08:35 PM | #13 |
ninjette.org certified postwhore
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Just keep one finger on the clutch at all times. I am sure you know but the 2 stroke gets its oil from the premix and in some situations you might be off the throttle (therefore no gas/oil), but the engine is still spinning.
Cool project. |
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May 24th, 2010, 08:43 PM | #14 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
The idea is to run the bike significantly richer, and mix the oil heavy to help compensate. That should help for what its worth!
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May 24th, 2010, 08:47 PM | #15 | |
ninjette.org certified postwhore
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Quote:
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May 24th, 2010, 08:54 PM | #16 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
I haven't found a damn thing!
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May 25th, 2010, 06:29 AM | #17 |
ninjette.org guru
Name: Josh
Location: CT
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Only thing I can think of that might work is the oil injection system of Tomos mopeds. They are designed to run all the time, but you might be able to work something out. You can get them pretty cheap too because at high rpms it doesn't provide enough oil alone, so people strip them off and sell them.
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May 25th, 2010, 06:59 AM | #18 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
The oil injection system was notorious for failure.... lol, pass...
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May 25th, 2010, 07:00 AM | #19 |
ninjette.org certified postwhore
Name: Greg
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The Yamaha autolube system metered oil based on throttle position and engine rpm (driven off the crank - I think). so even if the throttle was backed off, but the bike was blasting down a hill or something the crank speed would make the pump continue to feed oil.
Last futzed with by backinthesaddleagain; May 25th, 2010 at 09:30 AM. |
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May 25th, 2010, 07:14 AM | #20 | |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Quote:
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May 25th, 2010, 08:15 AM | #21 |
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Just give me a call when it's done and you need a test pilot.
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If everything seems under control; you're just not going fast enough! |
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May 25th, 2010, 10:10 AM | #22 |
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Duckman,
Your projects are great! It's fantastic that you can explain every detail, even why a certain bolt was used. I always enjoy reading your stuff.
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May 25th, 2010, 10:22 AM | #23 |
ninjette.org certified postwhore
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I forgot to say, "nice garage"!
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If everything seems under control; you're just not going fast enough! |
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May 25th, 2010, 10:47 AM | #24 |
ninjette.org Monkey Spank
Name: Kevin
Location: Illinois
Join Date: Apr 2009 Motorcycle(s): 2008 250R Track-Bike Woodcraft clip-ons and rearsets FZ-6 track bike Posts: A lot.
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Not sure if this will help, but most snowmobiles are oil injected. Might wana look that way if all else fails.
Cool project. Id love to see something like that at the track. For your next project you can wedge a 350 or 400 2 stroke twin out of a banshee into a 250 frame. Id love to try that on the track.
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Black 250R Full Area P QC Dyno Jet Kit 100 main 41T Rear Sprocket |
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May 25th, 2010, 11:13 AM | #25 | |
ninjette.org certified postwhore
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Quote:
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February 13th, 2011, 10:16 PM | #26 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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February 13th, 2011, 10:16 PM | #27 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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February 13th, 2011, 10:17 PM | #28 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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February 13th, 2011, 10:17 PM | #29 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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February 13th, 2011, 10:21 PM | #30 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Ahhh, almost forgot. I have a new Youtube channel ONLY for my motorcycle toys and other gearhead projects.
Check out DuckmanCycles, and SUBSCRIBE for updates! http://www.youtube.com/user/DuckmanCycles
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February 14th, 2011, 05:34 AM | #31 |
ninjette.org dude
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February 14th, 2011, 07:42 AM | #32 | |
ninjette.org guru
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Quote:
So one manufacturers 150 is another's 160 and vice versa. It is best to see if you can find the factual measurements that the magazines often do where they measure the tire from edge to edge across the curve of the tire.
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2009 KLE650 LSL bars, Full Muzzy PC-V 1995 900SS/CR mildly modified |
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February 14th, 2011, 09:37 AM | #33 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Yeah, I've learned that quite well over the past year, even been told so repeatedly, LOL!
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February 14th, 2011, 02:49 PM | #34 |
IC2(SW)
Name: Kerry
Location: Pensacola
Join Date: Nov 2008 Motorcycle(s): . Posts: A lot.
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Hey Glenn, thats gonna be one freaky crazy ride!
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March 21st, 2011, 11:44 PM | #35 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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March 22nd, 2011, 04:22 AM | #36 |
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I think you will need a pilot's license for that rocket
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March 22nd, 2011, 01:01 PM | #37 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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Someone on another forum told me it would be slow among other horrible things, lol.
I agree with you! Especially when the wheels leave the ground! :-D
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June 20th, 2011, 04:34 PM | #38 |
Da Duckman
Name: Duckman
Location: Pensacola, FL
Join Date: Nov 2008 Motorcycle(s): '08 250R, '06 Chopper, '80 Puch Magnum II, '01 SV650, '99 CR250/CR500AF Sportbike. '02 CRF450/CR500AF Dirt Posts: 480
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We're back! 2 more updates!
If you're a youtuber, you might want to subscribe to DuckmanCycles for more on this project! http://www.youtube.com/duckmancycles
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June 20th, 2011, 05:20 PM | #39 |
ninjette.org member
Name: Tai
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bad ass.
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June 20th, 2011, 05:34 PM | #40 |
wat
Name: wat
Location: tustin/long beach
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duckman, you're my hero. bike looks amazing so far. keep it up man. can't wait to see it rolling.
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