WE BROKE OUR YZ500 BUILD... Not good 🤦‍♂️ (in the middle of a magazine test) | 2023 Yamaha YZ 500 

Josh is a great Family friend.He used to rebuild all my sons bikes before my son got paralyzed.We have a track at our house and Josh and his brother designed it and used to ride here alot.Josh can ride good too!And a real good 2 and 4 stroke Engine Builder,Suspension Builder and Turbine Builder!!

Very cool experience and it was so cool to meet Charles, Mark and Ron at Dirt Bike, Travis with his awesome pics and videos and cross-cup observations, Jay Clark, Rado and his son from Dirt N Iron, JB from JBI was so cool to talk to throughout the day and then got to meet Gary Jones and have him look at the bike and talk to him for a bit. I also fell over halfway up Mount St Helens in front of Josh Hansen on Charles' RMZ so that was also fun and not a good spot to crash.11/10 would recommend!

A little Tip, You should NEVER start a 250 or larger engined bike on a bike stand. When the lever hits the peg it’s just a hard stop and the only weak links are the primary cover and kickstart shaft. When you have the bike off of the stand, your suspension can absorb some of the shock that would normally be pinpointed on the shaft and case! Us old-school guys are well aware of these issues.

I hate when I break my shaft...😅🤦‍♂️😳 I am sure you'll get it sorted and rippin Charles.👍

Total bummer dude! I think it is really nice of JBI to have a sink right next to their casting couch in the shop though!

Charles, the earlier 00/01 Kickstart shafts were 20MM vs yours at 18MM, maybe you could also have a machineshop re-inforce the insides with a smaller shaft and weld it up.

Big bore problems lol, but absolutely awesome your getting it sorted out and now she’ll be tested and approved 👍🏼

Not to make light of the recent struggles you've been through, but it's almost comical how hard the universe seems to be working to stop this build from completion! We never know why, and we likely never will. but I trust there was a good reason. Congrats Josh - I'm jealous!

I like the longer videos. ! Good way to get my morning going. 👌thanks for taking us behind the scenes Charles. Getting to see what kind of guy JB is , makes me wanna send all my suspension work to him. Good luck with that damn kicker 🤟

Gratitude alarm is a fantastic tool ... I need one!

Dude love that you show the behind the scenes stuff, bad and all (JBs shop looks amazing, cool dude). Just have that much more respect for you and the awesome people you work with. You got the grit when things get tough to keep pushing forward, shit happens, but it's how you handle it when plans go sideways that matter the most. Adds to the suspense!! Great content as always!! Can't wait to see this baby flying!!!

Awesome! Love how you stand by your product! Keep up the awesome work.

Minor set backs happen, awesomeness is forever! The YZ500 is cool as foooooooooooook!

You killed it on this build and great job rolling with the punches on the trip.

Love to see how the magazine guys acknowledge the professionalism, passion and attention to the details you put in your creations. Un fuerte abrazo friend!

Josh is one lucky guy to say the least and mxrevival i cant tell ya how much i respect what your out here doing with the platform youve created regardless your reasoning behind it all whatever it may or may not be its a pleasure to watch and not to mention the fact you're just giving this badass bike away after knowing the amount of countless hours of attention to detail you had to of spent only to turn right around and hand this machine over to josh who was a complete stranger to ya until now. Shows theres still hope in this world that actual good genuine people still exist so God bless you my man and i cant wait to see whats next!!

Great video!!! I really enjoy videos like this when you give us behind the scenes looks at some of the great people behind these builds and I really love that you shared the idea of the Gratitude Alarm!!! I am going to implement that!!! Maybe when you get everything ready to go you should deliver it to PA. I would make the trip to meet you!!!

What a great 👍 video and journey on the big bore yz !! I own 2 yz490s and can't imagine your bike !! What awesome details on bike and video, I need that gasgas ⛽ 5 hundo !!!! Best channel on the tube by far !!!

Thanks for taking us along

Brilliant on JBI with the try it out method!

Ace work just fucken AWESOME!!!!! from Aus btuz!!!

With all due respect brother. I really hope the dude that one that truly awesome bike understands what he truly has one. As an avid old time racer. I would give my right nut to own it . And believe you me. Even though im 61 years old. I would be riding it as much as possible. And would never get rid of it. As far as the kick starter problem. Maybe the stock shaft is not strong enough to handle the compression on the 500. I know they make compression releases that mount on the head that close on start up so to release stress on the starter shaft.

Now you know why CR500s had flutes cut into the cylinder to bleed off compression when kick starting. I had one and remember learning the procedure to kicking that big bastard.

That weld came out nice 🤙🏼 glad you got her Rippin' man! 🙏🏼 Awesome job by everyone who had a hand in it. I've gotta get my dang 05 kx 250 suspension sent of to JBI and ask for some of that sweet lookin' red tube coating

Better than factory, Killer Build, that pipe is aggressive looking how its shaped and hugs the Bike perfectly, uncomparable to the one on the YZ. That hard candy dark blue frame by the kick start brings the bike together, the whole bike flows like its one..Outstanding build, this is what a real dirt bike should look like, i would love to see someone ride this on the Red Bull straight Rythem. 👌

When you do the next BRC build on the Austrian bike you can install an electric compression release. I wired mine so when I hit the starter button it just actuated, I also wired a button in case I wanted to use the kicker. Also the kicker kit for the 300 has a tiny kicker and you can use the full size kicker with a little messaging.

The good and bad times of making special dirtbikes (This bike is special Charles) Don't mind short or long videos (watching this at 12.30am in Oz) Why the hell are there not more viewers/subscribers to this channel is beyond me. I'm watching from Melbourne, Australia. COME ON ALL YOU USA PEEPS......like, subscribe, and spread the word on this channel.

Charles quit dragging we into it when you broke it... 😝😝😝

500 compression just to much for that hollow shaft ....may have to go to solid billet .....i have a question i hope you will take the time to answer ....i have an 06 WR450 (steel frame) that is my baby....question is .....will the new plastic kit you used on this bike work on my 06 WR450F .....i have all new plastic ....but would love to know if and what i would need to buy to do this to my bike ....ps think its super nice of you to put all that work in and give the bike away ....says alot about your character.....so i subscribed and gave you big thumbs up

You are the man Charles thanks for the gratitude alarm set for 6:50am

🤘🤘🤘🤘

You need to put a 2001 yz250 clutch case and kickstart shaft on it it's bigger shaft and takes a yzf450 kickstart

Another great video!!! I'd love to see the BRC500 shootout in Dirt Bike Magazine!

What's that thing that always seem to happen?? Either way Charles, great job on the build!

I believe this was an issue in this year of bike.. I had it happen to me back then with the 250 motor and to fix and prevent it happening again I put the kickstart shaft, the crankcase cover and kickstart off a 2001 bike. The shaft is a lot thicker on the 2001 bike and everything I bought just bolted straight on. Maybe an option? The 500 could use the bigger kickstart shaft, but the crankcase cover could be an issue.

Invent animate is so sick!

Just a heads up on the Dunlop stickers you need to run them and create friction/heat for them to transfer and adhere properly. This was per dunlop themselves.

I think the hollow shaft is undersized for the 500cc. Probably the hollow shaft is also hardened too hard and breaks because it is not elastic. I don't think a full shaft is the correct solution. The outside diameter cannot be increased because it is limited by the clutch cover measurements. The best solution would be to make a new clutch cover, or modify the existing one, to allow bigger diameter but it is almost impossible to practice. The solid shaft doesn't convince me, the hollow shaft is more robust. The only solution is to decrease the internal diameter, changing the type of steel and make a less exaggerated hardening. Consider having a hollow shaft built ex novo. This is according to my experience.

That's just how it goes with 500's if parts are not vibrating off they are braking. But its worth it when you get to ride one.

Great video, Sorry about your dilemma. Hopefully you can get the kick starter shaft issue resolved. I know the cost is huge but will the BRC kit accommodate an electric start?

Have you been using the compression release when starting it?. I always use the compression release on my KTM BRC 500, Riley is a fan of the compression release making life easier on parts. Also wondering it you can Machine a plug to press into a kicker shaft to reinforce it. EDIT: Continuing through the video I see see you were using it.

Hope you figure it out Charles. The little what we saw, she purred, so clean and beasty. Did you put her on the dyno aswell?

Put a 01 Kickstart or put a steel rod down center. They are known to snap.

WHAT THE… Broken shaft, engine codes, plastic blew off the bike, the craziest is the rain in Cali!

My 1991 KTM 540 DCX never broke a kickshaft, nor did it have a compression release. It might have had a solid shaft, but I don't remember. Is the break occurring on kickback, ie. the timing is off?

Gotta say broken kickstart shafts make me worried for how the electric start is going to hold up on the mc500😢

You end up getting a solid shaft into this thing in the end?

I hope BRC find a solution. Didn't see enough of it in action!

I’d love to see one of these turned into a street legal, by Dirt Legal, Supermoto. That would be sick. Imaging rolling up to the Rock Store, on Mulholland on a crowded Sunday, on one of these.

Channeling that Blondie song “ One way or another” .

It just needs dialed in. This will be an awesome bike eventually.

YZ490's chewed up kick starts and kick start internals like there was no tomorrow. I didnt watch much of this, so it was probably explained but I missed it, but why was a flexy old 2001 steel frame used ?

is the sound of air rushing when he first kicks it a sign of how much compression it has?

Making a video is killing your time lol. Sweet bike i forgot about it since you didn't let me win it.

ya ya just machine a solid cromo shaft and forget about it.

Hmm , a 250 kickstart shaft won’t stand up to a 500 compression stroke . Good to know.

Guys do you think back suspension yz 125 2006 fit yz 125 2002???

All of the dick jokes are freaking hilarious! 😂

Someone should have a shaft made from better quality material as that one was only designed for a 250

Josh seems a nice guy but how will he get a leg over tthat bike?.

Maybe get a trailer or van.

Cool bike, don't know how anyone can sit through that whole vid tho😂

should got cr 500

The BRC kit is flawed in a number of ways. First off, its a 500cc engine/power on a transmission designed for a 250cc engine. The size & durability of the parts are not designed for the that big of an engine. The gear ratios are not optimally spaced for the power of a 500cc engine & again, are undersized. When you have a cr500 or kx500 teansmission apart, you can see both the gears, bearings & shafts are much bigger in a real 500 engine. Obviously, the kick start isn't up to the task either. The BRC port layout is not sorted very well either. The Lectron & Smart Carbs are also a poor choice. They lose power vs the Keihin & Mikuni. The claims that they dont need to be tuned once set is also a total myth. Lastly, the BRC power claimed by BRC is WAY over inflated. They are about 52-53rwhp. Not hating, just saying. Facts are facts. Facts, dynos & failing parts don't care about peoples feelings. So if anyone has their panties in a bundle over what I shared, get over it. It is what is what it is.

This whole build was about the shaft.

you almost don' want to ride it

No YZ- 500cc! Yamaha = personal Japanese name! Makes it illegal - and label it - Yamaha.

I love your movies, err I mean videos. But, they’re just to damn long.

That ain't no 2023. 2004 at best

And Yamaha - help get rid - "of Dirt Bike - mag(magic - piracy Co.)! Hamaha = feminine verse. You cannot bore, any 250cc - into 500cc. 125cc = 750cc bore? But don't - work as. You masked - out the, real people? Key = EO Piracy

Need to get a solid shaft made up by an engineering shop and send it for hardening

Charles we appreciate you too. Now time to find someone to make a better kick starter shaft. I got a guy in Czech Republic that could probably make it. I’ll check! @bgatz what do you think?