M
So I thought I would post up a thread about this years build. I had always intended on doing it but I decided to hold off until I rode the bike a bunch of times because if it turned out to be a total turd why waste any more time on it. This years basic plan was to build a strong running snow bike that didn't need exotic fuels and cost $20,000.00. After considering all my options I decided on the CR500. I bought the bike from a guy who restored it from top to bottom with a new top end by Adam Millar, new levers and bars, FMF Gnarly pipe and a new PWK 38mm Air Stryker carb. Cost $3300.00 with a bunch of stuff I can sell so net $3k.
Being that it is a 92 it had the craptastic 43mm forks which had to go. After doing a bunch of research I bought a set of WP 48mm forks off of Ebay for $200.00 and rebuilt them. This saved me on a couple of fronts but the best part was my KTM fit kit from the last 2 seasons bolted right on. I also had to buy a front wheel axle for $13 off Ebay. Obviously the triples weren't going to work so I used a set of CRF450 $42 and had them machined out to accept the WP forks. I'd do that differently next time as the machine shop raped me on that but anyways. The best way to add the CRF triples to the steely is with the All Balls conversion bearings. Total cost on the fork job close to $600.00 but worth every penny.
Next up was carb heat and air intake. There was no way the Avid heater was going to work on my frame so I built my own heater (we did 2 mine and SB's). Cost, many hours not so much material. I used the Frozen Boost reducing coupler and made my own filter cage, $30.00.
The bike came with a brand new in the box head so I sent it to Adam and he added the decomp which IMO is a mandatory mod on one of these. He also did the squish. Like $250 or somewhere in there.
I added a Trail tech temp gauge and made my own fittings for the sender $42.00. I have also changed out the 7/8th bars for a set of Renthal Fatbars with adapters. $19.95 Ebay. I have a new light as the ones I was using although plenty bright have a tendency to get torn off by trees.
Electrical power on the CR500 is a problem. Currently, no pun intended, I haven't decided on a plan for charging I may just do the Stealhey lighting coil which will charge at 2 amps DC. I made a battery box out of aluminum and bolted it to the TS spine with a 5S in there. I have a battery tender and charge it every couple of rides. So far so good. The LED light draws next to nothing and I have a head lamp. I also added a Princess auto/Harbor Freight water proof box for tools on the spine. $29.00. These things are the bomb and come in 3 sizes for dirt cheap.
I also had to buy a new seat. The guy I bought the bike from was way short and cut the seat down, it was like sitting on the frame, fawk me. Gripper seat $65 off Ebay shipped. Nice.
I extended the tunnel on my kit while I was at it and got rid of the joke snow flap BS.
After a few rides I noticed I was pushing coolant so I added a coolant recovery bottle from an Apex/Rx1. Seems to be working pushes it out then sucks it back in. I have since switched to a 1.6 Bar Moose Racing rad cap from the stock 1.1.
Riding impressions. So far I am quite pleased with how everything is working. Right off the bat I noticed the 30 lb weight saving over my KTM. The bikes rips harder than any other bike I ride with except SB's CR500 and absolutely dominates my KTM 520. It does vibrate like a bastard but its nothing you can't get used to. Note here, Loctite EVERYTHING and I mean EVERYTHING.
Future upgrades. I think I will pulse inject the carb. SB and I were out yesterday ripping around and his 500 idles like a Lexus or BMW and mine idles like a big block Chevy with a huge cam. Same carbs, pulse no pulse, it's very impressive. That bike flat out rips. I may still build a tunnel cooler and drop one rad, haven't decided yet for sure. Coming soon Bold New Graphics.
So far I'm into it for about $4k or a bit more. Pulse injection will be $500.00 by the time the smoke clears but well worth it for the added smoothness and power.
All in all I'm pretty happy and I think it shows you can be in the game without breaking the bank. Sorry for the long post.
Feel free to add any CR500 related stuff to this thread.
M5
Being that it is a 92 it had the craptastic 43mm forks which had to go. After doing a bunch of research I bought a set of WP 48mm forks off of Ebay for $200.00 and rebuilt them. This saved me on a couple of fronts but the best part was my KTM fit kit from the last 2 seasons bolted right on. I also had to buy a front wheel axle for $13 off Ebay. Obviously the triples weren't going to work so I used a set of CRF450 $42 and had them machined out to accept the WP forks. I'd do that differently next time as the machine shop raped me on that but anyways. The best way to add the CRF triples to the steely is with the All Balls conversion bearings. Total cost on the fork job close to $600.00 but worth every penny.
Next up was carb heat and air intake. There was no way the Avid heater was going to work on my frame so I built my own heater (we did 2 mine and SB's). Cost, many hours not so much material. I used the Frozen Boost reducing coupler and made my own filter cage, $30.00.
The bike came with a brand new in the box head so I sent it to Adam and he added the decomp which IMO is a mandatory mod on one of these. He also did the squish. Like $250 or somewhere in there.
I added a Trail tech temp gauge and made my own fittings for the sender $42.00. I have also changed out the 7/8th bars for a set of Renthal Fatbars with adapters. $19.95 Ebay. I have a new light as the ones I was using although plenty bright have a tendency to get torn off by trees.
Electrical power on the CR500 is a problem. Currently, no pun intended, I haven't decided on a plan for charging I may just do the Stealhey lighting coil which will charge at 2 amps DC. I made a battery box out of aluminum and bolted it to the TS spine with a 5S in there. I have a battery tender and charge it every couple of rides. So far so good. The LED light draws next to nothing and I have a head lamp. I also added a Princess auto/Harbor Freight water proof box for tools on the spine. $29.00. These things are the bomb and come in 3 sizes for dirt cheap.
I also had to buy a new seat. The guy I bought the bike from was way short and cut the seat down, it was like sitting on the frame, fawk me. Gripper seat $65 off Ebay shipped. Nice.
I extended the tunnel on my kit while I was at it and got rid of the joke snow flap BS.
After a few rides I noticed I was pushing coolant so I added a coolant recovery bottle from an Apex/Rx1. Seems to be working pushes it out then sucks it back in. I have since switched to a 1.6 Bar Moose Racing rad cap from the stock 1.1.
Riding impressions. So far I am quite pleased with how everything is working. Right off the bat I noticed the 30 lb weight saving over my KTM. The bikes rips harder than any other bike I ride with except SB's CR500 and absolutely dominates my KTM 520. It does vibrate like a bastard but its nothing you can't get used to. Note here, Loctite EVERYTHING and I mean EVERYTHING.
Future upgrades. I think I will pulse inject the carb. SB and I were out yesterday ripping around and his 500 idles like a Lexus or BMW and mine idles like a big block Chevy with a huge cam. Same carbs, pulse no pulse, it's very impressive. That bike flat out rips. I may still build a tunnel cooler and drop one rad, haven't decided yet for sure. Coming soon Bold New Graphics.
So far I'm into it for about $4k or a bit more. Pulse injection will be $500.00 by the time the smoke clears but well worth it for the added smoothness and power.
All in all I'm pretty happy and I think it shows you can be in the game without breaking the bank. Sorry for the long post.
Feel free to add any CR500 related stuff to this thread.
M5
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