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Project Bike Spec ... The List

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Posted by: Okiewan

As votes/comments are tallied, decisions are finalized, we'll add them to the list here. Note: the only way we will go with something NOT chosen by the members, is if we simply can't get it, or get it in time. We are at the mercy of the vendors.

Completed Bike Pics Here

Bike: Service Honda CR500AFX
Application: Off-Road (California Green Sticker)
Total Project Cost: $14,080. (MSRP)

About the AFX (Built by AJ Waggoner, DRN Moderator)
-A stock CRF250X is disassembled, the frame is modified by placing it in a jig, then cutting out and replacing portions with specialized pieces that are TIG welded in place.
- 18" rear, kickstand and lights are retained.
-The radiators and air box are modified.
-The rear brake pedal and linkage are modified.
-The throttle assembly & carburator are specific to the AFX
-The engine is hand assembled at Service Honda by a select group of technicians to Honda standards from OEM Honda parts
-The exhaust is specific to the Service Honda AFX from either FMF or Pro Circuit.
-Suspension modifications are handled by MX-Tech; there are various options available specifically designed around the CR500AF / AFX power delivery as well as rider specifics.
-Handlebars, grips, throttle tube, gearing & chain are chosen by the owner and installed during assembly.
-Several different triple clamp, flywheel weight and fuel tank options can be specified.
-The wiring harness is specific to this bike, created by Service Honda and hand assembled.
- The CDI is specifically built for Service Honda for the 500
-The AFX includes a high output multi-pole stator with rare earth magnet flywheel and halogen headlamp and L.E.D. taillight.


Aftermarket (DRN Selected and Specified):

Porting/Head Mods: Forward Motion (Eric Gorr, DRN Moderator)
The CR500 engine design dates from the mid 1980s. Since then there have been significant advances in 2-stroke engine design. The Honda doesn't have a powervalve so makting a wider powerband is greatly dependent on cylinder porting. The stock engine has a monster mid-range hit then falls flat on top. Using TSR PORT2000 software, we redesigned the porting for a wider powerband. The base of the cylinder is turned down on a lathe .75mm in order to lower the transfer ports, then epoxy is applied to the transfer port windows to reduce short-circuiting of the mixture out the exhaust port. More epoxy is applied to the rear trasnfer port ducts to increase the area ratio and the port velocity. Finally the exhaust port is widened 15mm and raised 4mm, this serves to soften the mid range hit and extend the top end. Fuel consumption is also improved with these mods because more fuel air mixture is trapped and burned in the combustion chamber rather then spooging out the exhaust.

ADMIN NOTE: Big Bore. Are you kidding? We'll stick the the rock-solid reliability and simplicity of the 500. 60HP or so is enough don't you think?

Suspension: MX-Tech w/ Enzo Sub Tank System , By Jeremy Wilkey, DRN Moderator
Jeremy Wilkey enlisted his collogue John Lakovich to help him with this special project. John has a specific expertise with West Coast Off-road and its unique requirements. Together they came up with a comprehensive valving plan that addresses the specific needs of the AFX and the rider. MX-TECH always believes in building a stable and balanced package, never trading control over a section for single bump compliance yet, a special valving style was used to allow for maximum plushness while still maintaining reasonable low speed compression characteristics.

In the forks MX-TECH linear fork pistons where used along with their proprietary “Solid Clamp midvalve” Which uses a low lift design with a relatively soft shim spring rate. The midvalve in combination with the basevalve creates a plush and stable damping characteristic, that provides the rider a very predictable feel. The rebound was changed to add steering control in tighter, slicker conditions. Finally Enzo Racing Subtanks where added. MX-TECH Inc. recognizes Enzo as the original and best Subtank System available. For a subtank system to work properly it must buffer the air spring over successive hits. The Enzo tanks Do Not use a check valve that would reduce the buffering effect. For this reason the Enzo’s have the most benefit for those who want maximum plushness in big bumps or successive hits.

The shock must be able to handle the large changes in inertia due the massive torque produced by the AFX. Valving is critical and MX-TECH used a linear piston to give the bike a maximum level of comfort and stability. The shock uses a special end cap to better bring attention to the quality of work done on the inside, and match the general perception of quality and attention to detail that this AFX represents.


1) Rekluse Auto Clutch w/manual override.
2) Scott's Underbar Stabilzer
3) ProTaper Oversized Bars
4) SealSavers
5) Pipe: FMF with 96dB & S/A
6) BulletProof Designs Custom rad guards
7) E line Pipe Guard
8) Wide Ratio gear set
9) IMS Pro Pegs
10) Clarke Oversized Tank
11) Fastway Handguard System
12) DirtBike Gear Tool Bag
13) SH fabbed rear master cylinder guard
14) SH speedo/tach /odo
15) Bridgestone heavy-duty tubes
16) Speed Bleeders
17) magnetic drain plug
18) Excel Rims (Black)
19) Bull Dog stainless spokes
20) Guts Racing stepped seat with gripper cover
21) Michelin M12 / S12
22) ProTaper Half Waffle Grips
23) SH Rear Shark Fin Protector (Billet)
24) SH Billet Clutch and Ignition Covers (rock protection)
25) Honda Cooling Fan
26) Rebel Gears #525 Chain/Sprocket Conversion Kit


Just Bling:

1) Purely Custom red annodized/engraved brake master cover
2) DRN/SH custom graphics (shroud and fenders)


Posted by: DWreck

Wow, this is going to be an awesome bike. I can't wait to see the pictures.


Posted by: kmccune




Posted by: YZ165




Posted by: Patman

I can't imagine a sweeter bike! For those that are not aware an AF/AFX is not just a simple engine swap. The bikes are about as hand built as you can get, even more so than a factory SX/MX bike since the frame is pretty heavily modified and that's a no-no for the factory boys and numerous parts are specific to the SH bikes.


Posted by: gwcrim

Can I have it when you're all done?


Posted by: Vic

Quote:
Originally Posted by gwcrim
Can I have it when you're all done?


If your check clears, sure.


Posted by: Okiewan

Updated.


Posted by: Okiewan

Let's see.. a 500 ported by Eric to smooth the hit and pull on top, with Auto Clutch and a Wide Ratio tranny in a 250X frame?

Uh... remind me whats the big deal about thumpers?


Posted by: likelite

what are thumpers????


Posted by: YZ165

Quote:
Originally Posted by Okiewan
Uh... remind me whats the big deal about thumpers?


They don't need any of that crap to be just as fast Okie.......


Well....maybe no AS fast.....but close.....


Posted by: Okiewan

Quote:
Originally Posted by YZ165
They don't need any of that crap to just as fast Okie.......
A little early to be PWI no?


Posted by: geraldo

Are we going to see a team in the Baja 1000 next year with one. Does service honda hire riders for an event like this? I think it would be a good promotion. I Don't see why they would not, it would be about 70lbs lighter than a 650r.


Posted by: AJ Waggoner

Although not *our* team,
there is a team in Baja this year..on a CR500AFX.


Posted by: motometal

Quote:
Originally Posted by Okiewan
Let's see.. a 500 ported by Eric to smooth the hit and pull on top, with Auto Clutch and a Wide Ratio tranny in a 250X frame?

Uh... remind me whats the big deal about thumpers?


I just KNEW you would come around. I'm so happy, I think I peed a little...


Posted by: Okiewan

Tmi, Tmi


Posted by: MACE

Is there a DR ride status thread?

Hi, y'all.


Posted by: 91kx

Where does the wide ratio tranny come from?


Posted by: AJ Waggoner

the WR kit we (service honda) bought from Mad racing,
and we bought thier entire inventory.
Its only a few kits,left over from when IMS made them years ago-
so its an extreemly limited supply.



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