I just finished building my TRX500R. I used a 1986 250r frame and a 85 Cr500 Engine. I tried my best to reduce vibration using rubber mounts and filling the handlebars with silicone. After taking it for a ride I realy can't complain too much about the vibration. I will recommend using loctite and lock nuts everywhere you can. They do vibrate but I think it's worth it for the power, it kinda makes it feel "alive" and being that it's a "Frankenstein" I think that is a good thing. If anyone needs any help let me know. I tried to get a lot of pics of my build. The first ride showed me a few things I had done wrong. I fixed them and will do it again tomorrow.

 

Congrats man, I'm thinking of doing the same for my ATC. What did you do for exhaust?

 

my bro in law has a 500r 3 wheeler frame converted to 4. biggest POS i seen and vibrates like mad. it is quick but only has 4 gears.