ATC500R build thread

[JasonB]

Figured the trx guys might enjoy this thread too. And since the bike is based on an 95 atc250r frame it belongs here   Frame and 88 cr500 motor came from Mike (MrClean). I tore down my 310 originally to use for parts so this bike could live, i am in the process of building both bikes right now for a little sahara trip in OK March 26-30.

Engine in tub



The culprit. Frame and motor


Donor 310


Stripping frames

[JasonB]

Earlier in process


Suspension etc and Motor in, just tightening stuff down still



Bills 500 conversion Pipe and roller
IMG]http://i2.photobucket.com/albums/y42/sleepin-mr2/508B05B5-1E2D-4AF2-8228-A3180F277922-622-00000113BC9C6E27_zps5906be25.jpg[/IMG]
 Pipe hung super low, just ran it for a bit and swapped to an FMF Gnarly


Decomp head

[JasonB]

[JasonB]

[JasonB]

cr500 knuckle, my machine shop guy turned it down to accept a blaster kicker that would clear the fenders.

[JasonB]

bike set for tear down and refresh after a good 15-20 hours of abuse in 2013. note the FMF Gnarly pipe that was modified to fit the conversion set up.

[JasonB]

[JasonB]

the right side crank case clutch cover from the newer 90 and up models was required since the 1988 case half I had didnt allow for the larger updated clutch basket width. For the new Rekluse clutch I had to pick this part up, its shiny and honda fresh



measured out the bore on this cylinder and found it to be right at 89.1mm which is basically stock bore size. The other pic below shows us a pro-x piston though, so someone had it apart to throw a new piston in at some point.

[JasonB]

450R rear end for the swap.came with adjustable dog bone, parking brak block off, extended axle, etc

[JasonB]

Cases at MRE for TWIRP port job and other stellar work. case repairs pictured, my cases were pretty beat up.

[JasonB]

among other reepairs and mods done by MRE, the exhaust flange was jacked up and all three holes needed re done as well. new o ring manifold below as well
Ended up needing the exhaust flange machined and the threads in all three holes there needed some love. Also upgraded to an oring exhaust flange. Pretty gangster.






Tasty port work

[JasonB]

Mmmmmmmmm tasty MRE Reed cage with carbon fiber petals


motor all wrapped up and ready to ship back to me about three weeks ago

[JasonB]

this month i have ordered a set of inverted tripple trees/forks offered by Jason Hall. He said the inverts should be done early this week. He has a set of 2001 cr125 forks that he is shortening 3" for proper ride height and rebuilding as well.

APT has stated my new 38mm cast smart carb should arrive on the 28th of this month.


The bottom gusset is actually already flipped on this Billy frame for the 500 motor, so I didn't have to notch it for clearance.


See this picture for what the normal 250r frame looks like and the highlighted marker spot is what needs to be cut for clearance so there's no binding and you get full suspension travel.
[ATTACH=CONFIG]186637[/ATTACH] picture above compliments of Auusiedunne from OZ forums

I slapped a coat of primer on it because the frame was an ugly mess, now it's a little less ugly the bike will be torn back down after the little Sahara ride in march so I can powder coat the frame and all associated parts.


2007 450r swinger assembly bolted on, need to find a rear shock to run.

[JasonB]

Cr125 rotor and brake assembly for my inverts

Motor showed up from MRE. Waiting to unwrap it until this weekend, want to go to Erics to get the crank and assemble it. check out the sweet clutch and stator covers

[JasonB]

Stem and front hub bearings, heavy duty t handle metric Allen keys set

Dexter checking out my new 8 paddle extreme skat tracks and front duro tire

New 10" wheels for the paddles