[Revhead]

Hi All Alan from the UK
starting a complete rebuild of an 04 that my son purchased off the "BAY" "excellent condition, oil changed every 2 rides , new clutch , recent top end rebuild , low hours blah blah blah.....! It lasted 4 hours before BOOOOM . "Dad it's broke come pick me up" From the middle of nowhere!!!
So we get the bike home and I'm thinking of driving 300 miles to give the lying seller a good shoeing but instead get the tools out only to discover that there was a new clutch and that the piston looked nearly new (apart from the bits of shrapnel now stuck to it) the cylinder got it big time aswell , further investigating revealed the 3rd piston circlip had smashed the reed valve to pieces and feed it to all the bottom end bearings , yep you read it right 3rd!!!! 2 connected to the piston and the 3rd one that he'd dropped into the cases and left there after changing the piston .....total rebuild time
So him being 21 and always wanting more it had to bigger bader better than all his mates ,I did suggest a CR500 conversion but mutterings about old fossils (me or the engine? not sure) and I look that's normally reserved for the dog when she chews his nikaddivans (which ever shoe it is this week)put pay to that idea
So on ebay he jumps (with my card) and orders himself a 511 stroker kit ,cylinder works 100mm Vertex 12:1 Hotrods + 3mm, steel inlets and exhaust valves, oversize radiators with an "i'll pay you back payday dad" (yea right and I'm the pope son) Now seeing as he's about as much use as a chocolate teapot with a set of spanners it's going to be down to me to make the beast. As I have a background in working mainly on 2 & 4 stroke road race bikes I don't know a whole heap about CRF's (other than what I've read on the internet,mainly here) and I have a very boring desk job, I thought I'd share the build here and pick your brains with any issues I run into along the way
The plan would be to get the bike fully UK street legal without making it "look" like a road bike, it's already plated but only for daylight use.
So I've made a wiring loom to go with the 80watt lighting stator , added a reg/rec to convert to dc , lipo ytx5 battery ,led rear light , led turn signals, horn, temp sender ,fan switch , 2x 110mm 15 watt fans, fuel sender, left switch gear all wired to a cheap Chinese ss182 speedo unit (well I wouldn't want to make life easy for myself)
So my first question would be.. do the 05 radiator and side panel plastics fit the 04?

[JimDirt]

Welcome to the site !!

It sounds like you have yourself quite the project ahead , .... one question .... how did your son get hold of your Credit Card in the first place ??

As to your question , no the 05 shrouds have a different bolt pattern , and the tanks will not swap out either , as the frame spar angle is different from 04-05 , as far as direct bolt on 02-04 is it . same goes for the Radiators , the hose connections are in different locations 05-08 , as far as i know..

Anyway , keep us posted on the progress , and if you run into any snags , hopefully someone here will be able to assist you in a solution .... , just keep in mind that some items on the bike might be European only in origin , as opposed to what might be found on the same U.S. model , so not everything will be the same , i would guess mainly electrical components , but we will come to that bridge when we are ready to cross it

[Got-Beef]

Welcome Alan , where you in blighty ??

Uk lad myself from the north east , currently looking at buying the same cylinder works kit as you

Has it arrived , you planning any modifications to the head .cam carb ??

[Revhead]

Hi Got-beef
Been a bit busy with a pair of R6's so this moved to the back of the que for a bit , but back on it now
I'm down in sussex not far from Gatwick .
The head is staying standard at the moment (apart from a light port polish and steel valves)
Will be modding the airbox and accelerator pump
Once's it's up and running , will look at a cam swap and making some Aprilia RS 125 wheels fit for road work ( he's currently killing MX tyres on his KTM on the road in 5 days) They'll have to be quickly switchable back to the dirt wheels though .
Should be able to give an idea of the difference the kit makes in the next two weeks