'83 ATC 480R Starting The Fabrication

[Bigbore]

I wasn't sure if I was going to do this or not... But some of you guys are trying to do the 480 conversion on the Gen 2 and I'll try and make it easier for you.

Anyway, My '83 R needs a new set of rings so I figured I'd work on building a set of motor mounts and spacers for a CR 480 / 250R conversion. I'll tear my '83 to make the conversion parts then put my 250 back in.

This one is a little more involved than the ‘ 82, but shouldn't be a problem. The 480 motor fits in the '83 frame fine. The lower frame motor mount bolthole can still be used. The rear mount will need more fab work than the conversion for the '82. The front mount is also going to take a little more ingenuity since the '83 only has 1 through bolt mounting to the frame. I will probably work on a small set of supports going to the front skid plate boltholes. The larger problem is the head stay mount. There isn't anywhere to mount it to.

Since the airbox isn't going to work with the new motor, it might work to make a crush bushing with a 10mm hole. Install the crush bushing in the downtube just ahead of the gas tank hold-down bolt. Drill a 10mm hole in each side of the downtube, then install a head stay bracket.

The best part is it should be a completely bolt in conversion.

I'll work on it over the next few days and post more photos of the progress.


Here are some photos of the motor resting in the frame.

[JasonB]

very informative! I would def like to buy the conversion for the 83-84 this winter to use for my cr480 drag bike if I decide to go ahead with the project. For some reason I had thought you were using the second gen as the original bike for your conversion kits, not the first gen. Good work though, and will there be any issues with the exhaust plumbing?

ps I really like those head lights! That bike looks nice man I like the accessories

[Dammit!]

I've only ridden one CR480 in my life. I was only about twelve at the time but man that thing was mean. I can just imagine how much fun that would be in a trike.

I've been trying to remember what year it was. I always want to say it was a 1984 but did they even make them that year?

[Tri-ZNate]

When you make all the brackets and such you have a money order here with your name on it . This is the easy way out for me. I was hoping you were gonna do this project soon

[Huffa]

I've only ridden one CR480 in my life. I was only about twelve at the time but man that thing was mean. I can just imagine how much fun that would be in a trike.

I've been trying to remember what year it was. I always want to say it was a 1984 but did they even make them that year?

Nice fab jobs you do bigbore, what color is that frame, a grey or a silver, I like the headlights too, very cool. OH, and the PRM products too, since I just ordered them myself, the skid plate I really like, very heavy duty.

, the 480 was made in just 82 & 83 , 81's were 450's and 84 were 500 liquid cooled jobs.

[3Razors]

1985 was the first year of the liquid cooled cr500.

1984 was the only year ever of the air cooled cr500.

Cool project by the way!

[Huffa]

1985 was the first year of the liquid cooled cr500.

1984 was the only year ever of the air cooled cr500.

Cool project by the way!

Your right, then it was a 85 I had, 23 years ago I guess I can be excused for forgetting what year I had !

[Bigbore]

Nice fab jobs you do bigbore, what color is that frame, a grey or a silver, I like the headlights too, very cool. OH, and the PRM products too, since I just ordered them myself, the skid plate I really like, very heavy duty.

, the 480 was made in just 82 & 83 , 81's were 450's and 84 were 500 liquid cooled jobs.

Thanks!

The frame is a metallic gray/silver powder coat. I wish I would have gone with the aluminum metallic instead... oh well. The headlights are 5" 55w stainless steel Pro Comp's. They were $50 each I think. The mounts were easy. PRM's skid plate's and grab bars are top rate!

[Bigbore]

very informative! I would def like to buy the conversion for the 83-84 this winter to use for my cr480 drag bike if I decide to go ahead with the project. For some reason I had thought you were using the second gen as the original bike for your conversion kits, not the first gen. Good work though, and will there be any issues with the exhaust plumbing?

ps I really like those head lights! That bike looks nice man I like the accessories

The other thread is for the Gen 1. That's the one I want for me. The Gen 2 is to help you guys out. Not sure on the the pipe yet. I'll get the mounts done then see what can be done. Sure like the hydroforming thread though.

[vegas250rr]

I like what your doing here !

[JethrowMan]

hey thats great i am going to order both! i love them air cooleds and have a 82 and 83 int he works i just hope that my ct racing custom pipe fits on that 83 480

[Bigbore]

I like what your doing here !

Do you remember the '82 250R from Las Vegas craig's list back in May for $250. It's the one I used for the '82 480r build.

[vegas250rr]

must have missed that one.... DMAN DMAN DMAN

[wizzard]

If your going to make it that easy, I guess I have no excuse not to build my own conversion.

[protraxduner]

Does the kickstarter clear the frame in either one of these conversions.