Garage 11 — CR500AF Programme
CR500AF Conversion
Built In Pakenham
Honda’s 60hp CR500 two-stroke, rebuilt and fitted into a modern CRF chassis. Three build levels, custom jetting, and every bike set up before it leaves the workshop.
60hpTwo-stroke output
2020+ CRFModern chassis
4–6 wksTypical build time
What You’re Buying
Three Ways To Build One
Every CR500AF starts with your goals and budget. We source or assess the donor chassis, rebuild the CR500 engine, fit it properly, jet it for your conditions, and hand back a running bike — not a project.
Entry Level
Into the CR500AF world without the premium spend. Reliable and ready to ride.
- Used CRF chassis
- Rebuilt CR500 engine
- Standard cases
- Full service & setup
Billet TSR Cases
For riders who push hard. Billet cases add strength and precision where it counts.
- New or low-hour CRF chassis
- Billet aluminium TSR cases
- Enhanced durability
- Premium components
BRC Counterbalance
The ultimate build. Counterbalanced bottom end for smooth, refined power.
- Your choice of chassis
- BRC counterbalanced engine
- Vibration-free performance
- Custom spec throughout
Built To Order
No Two Are The Same
Every conversion is specced around the rider — chassis year, engine condition, jetting for your altitude and conditions, suspension set for your weight. We build them one at a time and each one leaves running properly.
The Engine
60 Horsepower Of Two-Stroke
The CR500 delivers unmatched acceleration and torque — a true weapon for experienced riders. Whether you’re tackling motocross tracks or conquering off-road trails, this engine stands above modern motocross engines for its raw and visceral power.
Every engine we fit is gone through properly. With correct maintenance and a slightly rich fuel mixture, it remains one of the most reliable two-stroke engines ever built. We also offer full engine reconditioning — replacing worn cylinders, cranks or pistons where needed.
Optional Upgrades
TSR Billet Cases
Durable and lightweight for optimal performance.
BRC Counterbalance
Reduces vibration for a smoother ride.
Decompression Head
Easier starts without compromising power.
V-Force Reeds
Enhanced throttle response and efficiency.
Exhaust Options
Pro Circuit, DEP or FMF systems to amplify performance.
Fuel & Setup
- Recommended fuel
- 98 octane or race fuel — Elf 102 for peak performance
- Jetting
- Each bike is jetted specifically to meet the customer’s needs and riding environment
- Cooling
- Radiators modified to fit the CRF chassis, ensuring optimal temperature control
- Clutch
- Standard clutch fitted; aftermarket options available on request
The Chassis
Modern Frame, Legendary Engine
Built around the 2020-onward Honda CRF chassis, the CR500AF delivers a seamless blend of stability, precision and rider comfort — the ultimate upgrade for experiencing the CR500 engine as it should be.
Two-stroke power. Modern geometry. Nothing lost in translation.
Precision Handling
Modern geometry enhances stability and cornering.
Lightweight
6061 aluminium reduces weight significantly compared to the original steel frame.
Custom Mounts
Machined from 6061 aluminium, ensuring a perfect fit and long-lasting durability.
- Engine mounts
- On entry-level conversions, we remove the standard mounts and weld in new ones for a secure fit
- Billet cases
- No frame modifications needed for billet cases, ensuring a straightforward installation
- Cooling system
- Radiator outlets modified to match CR500 coolant ports; airbox upgraded to a custom carbon unit
- Brakes & wheels
- Modern CRF components come pre-installed, ensuring reliability and stopping power
- Suspension
- Tailored to each rider’s preferences for optimised performance
- Conversion time
- Typically 4 to 6 weeks, depending on the condition of the engine
Start Your CR500AF Build
Tell us what you’re working with — engine condition, chassis preference, and what you want out of the finished bike — and we’ll map out the conversion and cost.
Build Enquiry
Background
Why The CR500 Still Matters
Introduced in 1984 and powered by the biggest two-stroke engine Honda ever produced, the CR500 dominated motocross and desert racing alike — Baja, Hatta, Finke. Production ended in 2001 as four-strokes took over, and its status has only grown since.
- 1984Debut
The CR500 Arrives
Immediately a force in motocross, powered by the biggest two-stroke engine Honda ever built.
- 1997New Era
Aluminium Twin-Spar Frames
Modern chassis arrive, eventually creating the platform that makes the CR500AF conversion possible.
- 2001Final Year
End Of Production
Honda discontinues the CR500 as four-strokes take over professional racing.
- NowRebirth
The CR500AF
The engine lives on in modern aluminium chassis — old-school power, modern handling.
Only the KX500 came close in its era. Today’s 450 four-strokes may match it on paper, but they don’t deliver the same visceral hit — which is exactly why riders still build them.
Who We Work With
Parts & Performance Partners
BRC Engineering
Counterbalance bottom ends and two-stroke performance upgrades.
Elf Racing Fuel
Elf 102 fuel, recommended for optimal CR500AF performance.
Two-Stroke Exhausts
Expansion chambers and silencers for CR500 and other two-stroke builds.
Two Stroke Performance
Decompression heads, jetting solutions and premium CR500 upgrades.
