SuperMoto Junkie banner

First Supermoto Build - crf450r

83K views 263 replies 33 participants last post by  sPo0keY 
#1 · (Edited)
So now that I have some time I figured I would get this thread going. this is my first supermoto build and I've been collecting parts and working on the crf450 for awhile now. I'm traveling alot right now for work so I have pictures of all the parts and what not, just haven't had time to put the in photobucket so I can upload them...should have some time to do it this coming weekend and i'll post them in a new post.

I bought it quite a few months back and road it as a dirt bike for a while, and they around the road in my development and the mountain behind me. here are some pictures on the bike as it was before i tore it down. limited work space haha (single car garage) and had to clear my other toys out to have room for it.





I was riding it like that but broke it down recently and had some powdercoating done and I'm going to clean some parts up.

I will get some pictures of the frame, swinger, subframe and all the little stuff i had coated. ended up going with a gunmetal gray color, but had the coater do it without the metallic flake, just to make it a bit different, because of this though it's a bit more gray then i expected but I like it!

I may miss a few things below as it's a long list and I tried to mention everything I have (from memory :headscrat)

Parts I have for the bike that are either on it or waiting for the assembly.

-Marchesini wheels
-Goldspeed tires
-QTMI bracket from a KTM since i run different forks
-320mm Brembo floating rotor
-Brembo Rear Wave Rotor
-Brembo Cast caliper
-Custom machined rear wheel spacers for my marchesini's along with rotor and sprocket spacers to gain chain clearance (have great pics of these that i will post up)!
-TRX450 master cylinder with brake wires
-Marzzochi 50mm shiver forks (black)..these thing are HUGE!
-Andreai upper and lower triples for the 50mm forks
-All new bearing for the stem, swingarm, linkage and so on.
-Stainless brake lines for the front and back brakes
-Supermoto front fender
-New plastics for the whole bike (black)
-Custom graphics from dirtdigits (mostly white and grey, I wanted a black background though)
-Acewell billet/LED gauges/temp adapter and sensor/mount
-Acerbis dual road hand guards and LED light strip (going to wire them for front blinkers)
-Renthal twinwall bars
-Twin Air filter
-14/42 road sprokets
-SDG step seat
-Aprilia RVX swinger/linkage/rear brake set up
-Lightspeed carbor fiber left/right frame guards
-Wave racing carbon fiber skid plate w/built in fluid tank...it's a frame and case skid all built into one
-TrailTech 70W stator/flywheel kit (going to run a different battery though as i don't like the idea of AA's)
-2002 CRF450r cam...this has the same duration as a comparable hotcams stage 2 cam
-Front and rear axle sliders...SME fronts and no name rears
-LED tail light with built in tag light
-MT-03 headlight with custom made billet brackets and fork clamps
-Full 35W high/low Bi-xenon projector headlight kit with LED white angle eye from the retrofitsource (their sportbike stage III kit)...going to need to shave some things as i need to gain 1/8" of clearance
-Complete new bolt kit for all the body parts
-Dual Jardine exhaust set up from a 250r
-DASA header system (with step pipe to mate up to the 250 y-pipe, there is a .5" diff in diameter)
-Racespec shifter and brake pedals from the UK...basically the same as hammerhead but cheaper....even with the shipping and conversion rate
-New handle bar combo switch that has....
-Turns​
-light off/running (LED angle eye)/high/low​
-kill switch​
-horn​
-high beam indicator​
-Two of the CRG splitter mirrors
-Two superbright LED turns for the rear
-Keyed ignition switch
-IMS 3.2 gal tank in black
-Head ported/polished with upgraded valves/springs/seats/guides/seals, and my 02 cam installed and bench slimmed.
-CRFonly's wide ratio transmission

PARTS ON THE WAY/BEING WORKED ON:
-Re-jetting due to exhaust change and headwork
-NEED to set sag on both front forks and rear shock, it's off badly
-Building a custom wiring harness since I don't want to drop $300 on one although that would be a lot easier!
-Cleaning and prettying up the engine thing
-detailing the engine as it's VERY VERY dirty

THINGS I'M THINKING ABOUT DOING THIS WINTER
-new ignition mapping
-Boyesen quickshot or modding my stock one to function better
-Hydraulic clutch conversion

Alright that about wraps it up for now, any questions or comments feel free....although i know i haven't giving you much yet :bannana: I can also try and answer any questions you have on the parts i'm using or where i got them :thumbup:
 
See less See more
3
#144 ·
Got a picture of the headlight (carefully resting on the front fender) for your guys. When it is actually mounted it will be a little higher and at a slightly different angle since I had to lean it back so that it would not fall! I think it looks different and I really like it! let me know what you think, good or bad :thumbup:



 
#145 ·
also.....

I picked up something really sweet, thanks to Rob! Carbon Fiber side panels for the crf450 that were made and molded specifically for dual exhaust. We believe that they were made either by/for Leo Vince's dual set up for our bikes (to bad that the exhaust they were made for is damn near impossible to find!!!). they are amazing looking in person! Need to build up some of the mounts so they sit flat on the sub frame but they are a welcome addition to my project. They actually arrived on Xmas Eve just haven't had time to take pictures until tonight. they are also a little shorter and not as long to show the exhaust cans off more then the OEM number plates.





RIGHT SIDE



LEFT SIDE



I'm smiling ear to ear just posting these haha :bannana:
 
#147 ·
Lol thanks I think I agree. Plus too much isn't a good thing either. I'll have to figure something out for the air box sides since they are a duller black and I'm not really sure to put a decal on them because I don't want to litter it with decals either haha.

Maybe a solid white background or a glossy black decal...any suggestions guys?
 
#150 ·
Carbon looks good with those pipes! Also, that headlight is bad ass looking. As for the airbox- yea I say ditch the faux carbon. Take the decals you've got now and trace the outline onto some universal black backgrounds for the airbox. It will keep it black and glossy and if it gets scuffed, cut a new piece. :) my $0.02
 
#151 ·
Got these in the mail today. Hot rods crank bearing and seals.



I also decided on the stock height crank and order a new hot rods crank today. And while I was shopping I found a great deal on some levers. So I now have a complete set of ASV levers on the way complete with clutch perch and dust covers. Went with no hot start on the perch though cuz I'm going to get the knob right on the carb from Tokyo mods thanks to a pointer from a friend. Looks sweet and cleans the bars up nicely too. Pics of this stuff when it arrives next week.

Right now I'm the process of looking up part numbers to order all new OEM bottom end gaskets and seals.

Rotor spacers should be back in from being shaved down a bit either tomorrow or Monday so I can finish up the rear wheel and have a complete roller, which is good because I can move the whole bike to the side of the garage to clear some room to start the engine rebuild!
 
#155 ·
Thanks!!

Small update. Picked up a few small washers and bolts. Got my new d2s bulb in and a few connectors for the headlight wiring too.

Hot rods crank came in today, pumped about that, now just waiting on the gaskets to get here. Then I can rip into the motor!

Also decided on how I'm going to wire the HID setup on the bike. The d2s ballast is on it's way back to exchange for a AMP ballast. Picking up a pair of 28" AMP extensions as well for the ballast and high low solenoid and a AMP to D2S adapter. This will allow me to hide all the HID wiring in the air box completely out of site :D I will have to shorten the positive and negative leads for the battery wires but that is easy with new terminal ends. Hoping to have all this back in a week or two.

Side note....still waiting on my oem connectors and ASV brake lever and clutch lever with perch.

Also order a billet throttle tube, billet red case saver, new throttle and clutch lines, pro filter stainless oil filter with black billet cover and about 45 feet of braided wiring loom to cover all my wires with haha. I'll snap a pic of the crank tonight sometime and post it up.
 
#157 ·
Sweet, can I ask what price you got it for? - Like to compare to the +3 crank I bought.
 
#159 ·
Nice! That does seem like a good price :thumbup:. Just double checked and my stroker crank ran me $327 from the dealer.
 
#162 ·
ran tracking on my ASV lever set and they are out for delivery today :bannana:

also got the rear rotor and all that sorted out last night. just have to trim the front fork guards tonight and i'll have a full roller, then it's time for the engine. Hoping some of my parts sell soon so i can buy some more fun stuff for this bike! if anyone needs any 04-07 cbr1000rr parts let me know i also have these for sale as well...

-Front wave rotors
-75% complete set of OEM Repsol fairings
-Remote brake adjuster for brembo masters...this would work on sumos as well :thumbup:
-full main wire harness
-both seats
-2 air boxs
-2 radiator bottles
-TONs of nuts and bolts, axles, engine hangers, special nuts, heat sheilds, sprocket covers, cush drives, clutch slaves, 1 clutch master, front and rear calipers and more

if you know anyone help me out :clap:
 
#163 · (Edited)
got the ASV lever set in! slapped them on the bike, but no pic of that yet. here's a picture of them when they came in. I have to work out the bushings on the brake side, they are very very tight and keep the lever from pivoting freely...going to do alittle grinding/sanding to get the surfaces smoother and gain some clearance. only need about .5mm or so for it to all work out perfectly. will post a pic of them on the bike tomorrow night after I take care of this.



got a nice order coming in tomorrow too.
 
#164 ·
Xmas continues at my house! and will continue through the weekend and into Monday, I scored a few great pieces for the bike at a great price! Maybe i'll post a teaser a little later tonight. :clap:

This was all waiting for me when I got home today from crfsonly.



Red Hammerhead case saver



Protaper Tri-compound grips



Profilter stainless oil filter and billet cover



Billet throttle tube with removable end cap.



Motion Pro throttle cable set up.



Pro Taper blister cushions

 
#165 ·
don't really like teasers haha so take picture one and picture two and add them together! second picture is more candy colored but close :bannana: it was also reworked and revalved for just under my weight (got it used), should work out great. pictures aren't mine, took them from google, i will post up once it arrives monday, along with the boyesen water pump (black in color) that I picked up from the same guy.



 
#166 ·
got a bunch of little stuff in today. all my wire connectors and braided loom and a little surprise from Rob (Rob is building the CRF 450 PROJECT bike)

Wiring loom, got it in 1/4, 3/8 and 1/2 sizes, about 20 feet of each just to make sure i had enough.



Black nylon spacers 22mm outer x 10.4mm inner x 20mm long. I'm going to use these to cut down and fill the gap between the carbon panels and the sub frame. I might find some other uses for them as well haha.



Connectors



2 wire OEM honda turn signal connectors with terminals. 2 orange male and female and 2 blue male and female. this is how Honda wires their bikes from the factory, Blue for the left side and orange for the right side for example.



OEM sealed 4 wire connector. got this to replace the the broken female side of the TRX brake switch wiring



A Bunch of extra terminal ends since i'm probably going to re-pin and re-wire the keyed ignition switch



3 wire OEM honda connectors and terminals. going to use this for the tail light.



Female side H4 socket connector for my HID set up with terminals



and finally all the seals for all the connectors



Now onto the Pro Taper pad that I got, it was already cut out and centered to fit the acewell guauges, fit like a glove too. not sure i can use the cover, which i cut to fit the gauges as well, since apparently my bar clamps are alittle wider then stock so the Velcro straps barely close and want to almost pop open from stretching around the clamps. I think it looks nice though with just the pad since after cutting the cover you aren't left with much but the sides!

i still have to mount the thing, right now it's just held in place by the pad. my plan is to just a pair of 1 1/8 seat clamps from a bicycle since they are easy to get and cheap! and then just use a small 90 degree aluminum elbow from the bike clamps to the mounts on the back of the gauges.

couple different shots...let me know what you think! :D





 
#168 ·
I also finally, after alot of debating with myself, decided on a battery for the bike. I'm going to go with the Ballistics Evo2 8 cell battery. I was between the Ballistics, Antigravity and Pulse batteries. The Evo2 just provides everything i want for a better price and the specs are actually better the the others it turns out too. Plus with the lower price I might pick up the quick disconnects as well. Another great thing about this battery is that it only loses 10% of its charge after 1 full year of static non-use, which is amazing!

Link to the battery:
http://www.ballisticparts.com/products/batteries/8cell.php

Specs on the battery (you can read more about them if you click the link):
-Dimensions (Metric): 114MM (L) x 61MM (W) x 112MM (H)
-Dimensions (Standard): 4.5" (L) x 2.5" (W) x 4.25" (H)
-Negative Terminal Location: Right
-Weight: 768 grams (1.7 lbs)
-Voltage (Charged): 13.6V
-Amperage: 15 Pb-eq A/H
-Pulse Cranking Amps: 275 CCA
-Operating Environment: -18°C (0°F) to 60°C (140°F)
-Typical Applications: 1000cc and under multi-cylinder motorcycles and 550cc and under singles cylinder dirt bikes, scooters, and ATV’s.

Link to the quick disconnects:
http://www.ballisticparts.com/products/accessories/quickDis.php
 
#169 ·
and as for turn signals in the rear since i decided i didn't want to go with the K&S LED mini staulks I have I think I have finally decided on what i'm doing here as well. I was going to get some nice billet flush mount LEDs (Watsen Design or the one from VSM) but after talking it over I believe I'm going to run 2 setups. One for inspection and one for the rest of the year.

Going to keep the set up i have now and run the K&S mini stalks for inspection and get an Edge2 integrated tail light for the rest of the time.

I also am expecting the Open Barrel terminal chrimper to arrive soon, picked it up to build my harness.

got alot of stuff arriving between today (hopefully) and monday! i'll post up as they come in.
 
#172 ·
Hmmm, just thinking. Those will go on the bars between the bar clamps? How will they go on? I don't think they will slide around the radius maybe. Will they hold up to prying open if needed? :headscrat
 
#173 ·
Thanks man! appreciate it. I agree on the forks :thumbup: and the light was just something i thought up and have wanted to do something custom like that for awhile so I took the plunge.

I have actually been following your builds for awhile, I have to say that I love that Harley you built, i'm not typically a Harley guy but that thing was really cool :clap:
 
#175 ·
earlier tonight i picked up the little elbows I needed to finish mounting my Acewell. And while I was there I decided that it would be a good idea to search for some industrial strength velcro so that the straps on the bar pad cover could be extended a bit. Well I found some, and when I was standing there I saw some velcro wire straps too. I thought that would be sweet instead of using wire ties haha....we'll see how they play out.





And a picture of how these little seat post clamps are going to be used in order to mounts the gauges.

 
#176 ·
took everything out to the garage and popped the bars off and slipped my little clamps and elbows on...



after some sliding, adjusting, fiddling etc....got it all lined up and here it is! Turned out great i think. and it is very solid....gave it a shake and the entry bike shuck instead of just the gauges lol.







Popped the pad cover on. the gauges are about 50% recessed into the pad. I was going for a bit more recess and I might still adjust for more, we'll see.





Decided to use the pad cover for a more finished look. After extending the velcro I think it actually worked out well. I was just looking at these pictures and noticed that the pad angle is off a bit, as in they are sitting perpendicular on the bar clamps. this is due to the angle of the gauges, so tomorrow I will pop it off, adjust the angle on the gauges and re-install so that perfectly straighter.







Also took a little time to get the ASV levers completely installed and functioning. after a little sanding, little grinding, little sanding, little filing i got the brake level bracket all cleaned up and the bushing on the level seated correctly so that it all fit just like it should. I also played with the spacing of the multfunction switch and the clutch perch/lever, think it's where I like it now. I don't have any tension on the lever (obviously haha) so it just hits the back of the switch housing when it's pulled, hoping it won't once i have everything back together and get the correct tension on the lever.





 
#177 ·
Looking great! I had similar issues getting everything to work out right on the left side of the bars. My clutch ended up on the outside of the switch housing for clearance, but I'm running a slightly different setup. Liking those asv levers- think I need some for my dirtbike build. :)
 
#178 ·
Yeah that is my plan too if it hit at all. Plus the shorty lever is REALLY short when you add the switch in there haha.

I love the ASVs...they are the unbreakable kind too so they full rotate up and are spring loaded to come back down in the event of a crash.
 
#179 ·
Sorry if I missed it, are those the MXBonz handlebar clamps?
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top