Carson Brown's BBR Honda CR500 Two Stroke Build - Dirt Bike Magazine 

#dirtbike #offroad #twostroke #motorcycle
Carson Brown loves to ride dirt bikes! It doesn’t matter the year, make or model, he just loves two wheels and an engine. Lucky for us, we like showcasing his talents on said dirt bikes. Lately, Carson and his dad, BBR Motorsports cofounder Duane Brown, have been resurrecting older iconic two-strokes. This 1997 CR500 build started about two years ago when, in Duane’s words, “Carson just showed up to the house with this beater Honda CR500 in the back of his truck one day saying he wanted to rebuild it.” Naturally, Duane was 100 percent on board and the sparks started to fly.This build started out just like every other build-with a complete tear-down and inspection. The frame and subframe were reinforced by Duane himself, then sent off to American Powder Coating to make it pretty again. The aluminum gas tank was completely hand-fabricated by Duane and Carson. This unit is slimmer and shorter than the plastic OEM Honda version. The engine did receive a lot of attention from Bryan Hugaburg at Red Barn Racing. As a matter of fact, we could write an entire story on just that. Here is an overview on the engine building process directly from Hugaburg: “Starting with Built 500 billet aluminum cases, these were needed for Carson’s build, as his OE center case was cracked where the main-shaft bearing seats in the case. The bearing would literally fall out of the case. Turns out, this is a problem with OE CR500 center cases and one of the reasons why Built 500 makes their cases. I had to grind slightly just under the cylinder deck for clearance to the connecting rod. They may clear an OE rod, but they didn’t clear the Crank Works Pro Rod.f you ask the Browns about this build, they would say it’s all about the engine, and on any other CR500 build we would have to agree with them because the specifications are insane. But, in our minds, this build has it all-custom-fabricated aluminum parts in multiple places throughout the build, A-Kit factory suspension from the era, CNC-machined billet-aluminum cases from Built 500, custom engine covers, and off-the-shelf products from Pro Circuit and Boyesen with a ton of engine performance produced by Bryan Hugaburg at Red Barn Racing. veryone who came in contact with this bike smiled and shook their heads in disbelief. If those facts aren’t enough to get your blood flowing, don’t worry, because we have more.
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