01,
I built a TRX500R from the ground up, 86 TRX salvage yard frame, 87 CR500 salvage yard engine, bike is entirely gone through. over 10,500 invested. Runs like a raped ape on steroid rage! I ended up with having to replace all case halves, rebuild crank, new bearingsseals, shift forks, Hinson clutch, hydraulic clutch-too darn hard too pull cable, sent head to Trinity for port/polish/bore, about 75hp, with 50/50 gas, running boseyn RAD reed cage, 39 mm Keihn carb.
Back to install-Larger is an ARSEHOLE, called them before I started this project 4 years ago-they didn't sell the conversion kit anymore, they wouldn't even sell me the plans, it toke over 12 phone calls before they returned my calls, and then they told me tough shiat! Screw them. I mounted the 500 motor on the swing arm pivot bolt-slide it all the way to the left and the sprockets will line up perfect. Then use on of the stock collars in the 500 motor mount and it is the perfevt length spacer for the right side.
Now fab front motor mounts, reinforce everywhere on the frame you might think it needs it! Yes it vibrates like crazy, but once you start riding the adreniline kicks in and you forget all about that! Some guys have mounted the motor in rubber or poly bushings, I read about that too late....it might help. Spray bomb the frame until you ride it for a season, so if it has weak areas you can correct it without a big hassel. The pipe is another ordeal, I used a FMF CR500 pipe for a 98 model, CR racing wanted $500 dollars for a custom pipe...right!! All I did was modify/replace the 2 small down tubes by the radiator, and some slight mod to the exhaust can...no problem....alot cheaper!!
My quad is quite unique, RPM rear end parts from a ATC250R, Bomardier radiator (1/3 the price/twice the size..very cooool!), 400EX plastic, tons of new TRX250r chassis parts, billet this and that, cromoly swingarm/a-arms/steering stem. I only have about 6 hours on the bike, but the more I ride it, the more I'am thinking about keeping it. I've left modify Banshee's in the dust. The quad really shines in the rough stuff..set up like a desert runner. It's hard to drag because of the wheelie factor....did I mention wheelie in the first 4 gears at will!
One last thing....it is a typical CR500...a biatch to start, I'm still learning. Definitely not a girlie's man's bike!! A lot of work...maybe worth it. I'll be at Dumont for the clean-up if you want to check it out. I'll be camped with the v8Rail gang, big red International medium duty semi truck. E-mail me, I can send you more pics/info. I'm starting to get my grove on the bike, and I plan on kicking some major ARSE on this trip. Stop by.
THE BOMB