Crf450r 03 sumo build.
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Thread: Crf450r 03 sumo build.

  1. #1
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    Default Crf450r 03 sumo build.

    My first sumo project... Let's see how she comes along.

    Price of bike 600$ cash needs crank
    Price of crank 300$ +/-
    Price of plastics and discontinued graphics 105$
    Price of sumo wheels tires brakes 1200$ +/-
    Price of labor free fifty free!

    Pictures of my bike when bought
    Graphics off eBay
    And what the graphics look like on a bike.

    Next wheels, crank, bars that match graphics which I have in stock at the shop.

    Will post pics when new plastics arrive!

    Doing a 05 air box swap.
    07 front number plate swap.
    07 side number plate swap.
    07 radiator shroud swap.

    Now that's legitness!

    Hope you guys enjoy and I will post info on fab needed to fit 05 box to 03 subframe for you fellow 03 crf.. Owners!!!



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  3. #2
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    Awesome project! Keep us updated!

  4. #3
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    Will do brother thanks for the interest in the build!

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  6. #4
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    Subbed, Looking forward to seeing this project!! What are you thinking for wheels? Are you going to rebuild the whole top/bottom end or just replace crank? Nice price for the bike..


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  7. #5
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    The top end is brand new.. The bikes kickstart locks up on occasion.. And past experience on him dad when that happens crank is always bad.. So I have yet to start it I'm going to open her up check crank could just be bearings or a washer in wrong who knows... Wheels are going to be warp 9 gold wheel black spoke black hub silver nips.. Top end being new and he said it was just rebuilt I talked to the builder this bike was a price when he built it.. Had the suspension rd built and tuned.. Has a stage 2 cam.. Gonna mild port and Polish head.. Leave everything stock.. 14/42 gearing for my super light weight I'll keep most bottom end power and gap enough for highway speed.. But that's pretty much it I beleive.. Plastics will be in in a few days.. I'll keep you all posted.. Box mods going to be fun I think * sarcasm *

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  8. #6
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    Past experience. On crf. That*

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  9. #7
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    these are the bars in going to run.. I'll also be selling some of my old still good parts for anyone interested.

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  10. #8
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    Well started tear down process today.. Might pick it up later or tomorrow who knows.. Got life stuff to do plus lazy time and sleep time but anyways.. Drained all the fluids. * actually they did it themselves for me? No coolant in bike no oil in clutch side barley any in stator side * pulled all plastics and radiators and exhaust... Exhaust side port on head looks. Like dick.. Obviously gonna need to re-jet it.. Suspension was re valved and shimmed by jm suspension rebuilt rear shock with 5.4 spring stage 2 cam all new steering bearings and hub bearings. Found a lot of aftermarket shinie stuffs mmmm yummy. Full triple clamps applied racing a loudmxracing airfilter hooha billet fancy shiny clutch cable clip applied bar risers and clamps. Found a awesome "custom" rust patina chain. Very nice and ebc red pads all the way around. Sooo let's see what we find when we open her up enjoy the build err I mean de build tear down mass destruction. Project and thanks for following! Will include pics and info on the updated shrouds and airbox with mods needed to complete or if such bolts directly up. Thank y'all and stay rubber side down pimps and pimpettes!! Keep it gangsterr!!IMG_20161112_1548119.jpgIMG_20161112_1548229.jpgIMG_20161112_1550438.jpgIMG_20161112_1550500.jpgIMG_20161112_1550571.jpg

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  11. #9
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  12. #10
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  13. #11
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    IMG_20161112_1642455.jpgIMG_20161112_1643051.jpg

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  14. #12
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    Well guys continued my exploration today and discover my decompressor arm broke in the valve cover. So turns out I probably do not need a crank I assume that the peices were loding stuff up when starting. So I think I'm going to finish pulling the other side case. Pulled stator side today and found no metal peices going to pull clutch and see if I find any there and if not putting it back together and brap brap brrraaaaappppppp!!!!!!IMG_20161113_1554565.jpgIMG_20161113_1555134.jpgIMG_20161113_1555295.jpg

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  15. #13
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    Are you gone rebuild the engine? Or you sure the heart of the engine is clean?

  16. #14
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    I was originally planning on rebuild because assumed crank was bad but it was rebuilt 8mos. Ago. I'm still inspecting bottom end cases on the outer ones for metal but I belive I have found all of the big peices from the decompressor.

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  17. #15
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    Just going to be a bitch to start without the decompressor lol

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  18. #16
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    IMG_20161113_1827406.jpgIMG_20161113_1848118.jpg well guys... Got it started tonight... That compression stroke is a bitch without that decomp.. Assembly bout to order one off eBay 30$. Taught my brother a little about rebuilding motors today as well and in the process discovered some more billet shinie goodness... a hinson clutch set up!!!!! Woot woot!!!! Man o man bike don't need a crank bikes got a ton of goodies already bolted on went from needing a 300$ part to a 30$ part this bike really turned out to be a diamond in the rough!!! I reallyy hope you guys are enjoying this build as much as I am!!! Should have the plastics in soon aswell and should be getting my warp9 golds very soon aswell!!!! Thank you guys for your feedback and interest and comments if anyone is in the west texas region feel free to contact me and mob it up with us at pro moto garage check us out on facebook aswell!!!!

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  19. #17
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    Congrats man, great news. I'm stoked for you


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  20. #18
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    Thanks man.... Gonna spend the night at the shop and finish putting the water pump and radiators on and what not... Yes I burped it off without these things on... Only ran it for like 3 seconds.. No harm done.. Do it all the time... Omg I'm so excited!!!! Yussss!!!!

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  21. #19
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    Well my plastics graphics still have not arrived :( but on the bright side.. I found half the auto decompression set up here at the shop XD and ill be ordering my wheels in a few days aswell so she's just chilling in the shop naked :/ thinking about seling my excel dirt set. Also have a mega bomb pipe in the shop for it to. I think it needs a weld but hell yeah. If it works good probably sell my power bomb pipe. Let's seee.... oh yeah also end up selling my old set of plastics and air box. Umm.. yeah if anyone is interested hit me up. Ill post pictures AS SOON AS I GET THE NEW PARTS!!!!!!

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  22. #20
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    IMG_20161118_0823251.jpg

    We just got a letter we just got a letter we just got a letter! Wonder who it's from?!

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  23. #21
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    Looking good so far and good news about the crank!

    Keep the pics and updates coming!

  24. #22
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    Will be posting the air box conversion later today at 6 guys stay tuned!!

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  25. #23
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    IMG_20161118_1914339.jpgIMG_20161118_1914434.jpg

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  26. #24
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    2008 air box swap is so simple.. All you need is a dremel and half a brain stem lol

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  27. #25
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    IMG_20161118_1918139.jpgIMG_20161118_1918189.jpgIMG_20161118_1919386.jpgIMG_20161118_1919494.jpgIMG_20161118_1919456.jpg

    Its basically the same airbox just with a longer tail.. you will see some molding lines cut on the longer one and then trim off the top because its molded slightly different for a mor boxier sub. The 03 is more triangular on the upper part.. just cut for clearance... not the boot mounts guys -_- and then drill your mounting holes and presto changeo you've made the 08 airbox fit the 03 sub without swapping subs and without cutting your sub. I don't really see why anything would cause an airleak anywhere the number plates don't " exactly " mount up but hey its a dirtbike. If you want the updated look without swapping subs and shit just buy the plastics and cut and drill... only reason I wewnt this way was because the graphics are discontinued and extremely hard to find. Other than that just buy the acerbis updated plastics kit lol

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  28. #26
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    IMG_20161118_2126156.jpg now known as project zip tie

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  29. #27
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    IMG_20161120_1522356.jpgScreenshot_20161120-231942.pngScreenshot_20161120-231948.pngScreenshot_20161120-231957.pngScreenshot_20161120-232006.png okay guys.... I got the bike all put together today.... Plastics held on with zip ties hence the code name.. And I just won the auction for the wheels!!!! Floating rotor 5.0 rear wheel 160 tire 44 tooth rear sprock and wrapped in michilin pilot power 2cts!! Woot!!!!!! I will have the finished results coming soon gonna clean up the cuts on the plastics put the new bars on put the decompressor in when it arrives and try and get everything a pick and span.. Have a new chain in stock in the shop I'm prolly gonna rob as well as some new grips for the bars.... Everything else left to do is purely cosmetic.. I'm so excited anyways.. Y'all keep in touch might try and do something super stupid fancy like a black and gold glitter flake swing arm? Now that my friends would be different lol or I might Polish the shit out of the frame and swing arm.. Haven't decided yet any suggestion please submit!!! Thanks for the feedback and following guys!!!

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  30. #28
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    Great job! Let us know how it rides.

  31. #29
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    Definitely powder coat. Not a fan of the polished look on the crf's. Not black powdercoat tho that's been pretty overdone, try like a dark red, gold, or white.

  32. #30
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    Yes I was thinking like racing bronze flat gold frame flat black swinger maybe?

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  33. #31
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    And I agree black is already over done thinking about doing a solid white seat cover

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  34. #32
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    well bad news for me.. replaced decompressor assembly and still same symptoms. needs a crank :/ well follow the build for the transformation!!! might aswell do it right since i cant cut corners lol

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  35. #33
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    That sucks that it ended up being the crank - at least after the rebuild you will have a brand new engine.

  36. #34
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    yup lol i aint tripping i was honestly worried about it anyways being an 03 with stock crank lol

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  37. #35
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    mmmmmmmmmm those wheels!

  38. #36
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    yes sir lol theu come in today!!!! but im out of town:/ so ill put them on and take a pick... any of yall run a non supermoto cut fender? how do they look... trying to figure out if i should cut mine or not.

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    IMG_20161202_1845204.jpgIMG_20161202_1845098.jpgIMG_20161202_0922354.jpgIMG_20161201_2155453.jpgIMG_20161201_2155346.jpgwell got them on with the 160 rear tire.. pain in the dick btw. now just waiting on a crank :/ oh well looks pretty sitting in the shop tho. good mantle piece!

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  40. #38
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    20161213_180545.jpg20161213_180537.jpg20161213_180534.jpg20161213_180529.jpgwhat yell think about my home cut super moto fender?

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  41. #39
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    That worked out just fine m8!

  42. #40
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    Awesome. Front fender is perfect.
    TM Racing....

  43. #41
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    I thought so. Someone told me I needed to cut it back more like a 6inch long fender I was like dude... I'd just rather take it off than cut it that far... I think this is perfect for supermoto and moto... it's like the perfect length for both. I like it lol fuck that dude

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  44. #42
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    Currently tearing down the motor to see why it's binding up.. timing was off one tooth and valve lash was waaaaaaaaay out of spec had my hopes so high!!!! And same problem -_- tear down initiated

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  45. #43
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    Okay so I got the motor tore down. The cylinder is in extremely good condition!!!! The black trim on the piston is still there... I did see some piston and valve kiss marks tho Wichita concerns me as to that maybe being the binding issue. But anyways.the crank.... yes sir she's a factory crank. Has minor discoloration telling me it has been over heated but it has very good free play for being as old as it is... still run able but I'm replacing it anyways. The valves are aftermarket. Didn't check brand but hopefully kibble whites!!!

    I will tear down the bottom end tomorrow and see what I discover.

    I will be valve lapping the the valves and probably just do a mild port while I have the head off.

    I'm going with a stock stroke crank for reliability and a stock bore if that's what's in it.

    Well I will update yell tomorrow on the bottom end details!!!!

    Will also be polishing the frame and swing arm so stay tuned guys!!!20161216_182146.jpg20161216_182159.jpg20161216_182152.jpg20161216_185933.jpg20161216_185940.jpg

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  47. #45
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    Damn this thing is going to come out cleeeeeeeeeean!!! Mmmmmm sexy

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  48. #46
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    Well guys my crank and piston rings came in!!!20161220_200926.jpg

    But sure enough they sent me 100mm piston rings! When I have a 96mm bore :/ so I had to rummage around the shop to find a good still in spec compression ring. And sure enough I found one.

    I got the bottom end actually tore down and discovered my main bearings wear super over heated and didn't spin worth a damn.

    They where in a permanent bind.

    Replaced those

    My crank was actually still very runnable but I want absolutely no bottom end problems so replaced it anyways with the fresh off the press hot rods oem spec crank. Replaced all the seals and bearings.
    20161220_200826.jpg

    20161220_212050.jpg20161220_212057.jpg20161220_215108.jpg

    As I finally got the bottom end wrapped up and placed back in the bike. I had to wait for my piston rings and valves to come in wich arrived in the 22nd. Only one of my intake valves was bad but both had piston slap marks so I replaced all 4 just because I was already there. So I had to wait. Mind you I had to have this bike running by the 23rd to take it with me for christmas so when they arrived at the shop I still had to work and couldn't actually start until after work.. I didn't start on the bike until about 10 o clock.

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  49. #47
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    Now 10 o'clock arrives and I get started. This is when I realize I've been sent the wrong rings!!!! Oh lord what do I do. No one carries piston rings in Midland or odessa so I start searching all the junk parts boxes for a piston ring that fits and is in spec.. I found a perfectly good brand new set of 96mm piston rings!!!! Only one problem... they were namuras!!! And no sir thank you I think I'll take my chances with the old one!!!! So I kept digging and found a yfz450 piston with a good in spec ring per my bikes requirements!!! Oh praise Jesus hallelujah!! So I put that one in realized I lost my circlip so I got one off a trx450 piston and got the cylinder on. Got the bike timed and now to lap all the valves and replace all the valve seals! Sure enough I found a bent exhaust valve!!! Praise the Lord I decided to spend the extra 40 bucks and replace the exhaust aswell!!!! I replaced all 4 with kibble white black diamonds and got all of them lapped and seated nicely. Got it all buttoned up while my fiance was cleaning the carburetor for me. Gotta love that woman. Putting up with all my foul mood swings and temper tantrums. So we got everything buttoned up. My caliper adapter came in on time. Got my front brake to work. The chain adjusted. No oil leaks * this never happens on my motor builds* and the bike running!!! Popping like crazy but running. I can tune when I reach my destination!!! So we got everything finished and loaded in the truck at 2 am. Then started our long drive to Rockdale tx. From midland... we arrived at 10 am. Up for 24 hours doing a bike build and traveling to our destination! I've got it tuned right bow now I need to adjust my float height as its running out of fuel pretty quick for street use. But it's rideable. 3rd gear clutch ups are like butter. Granted I can't ride them very far but I've only got maybe 1 hour of actual total ride time in on it! So now I will be posting the cosmetic bolt on stuff and fine tuning! Follow our shop on facebook and Instagram! And everyone in the ftm worth area were having a huge event with prizes look up swamp ass mini ride on facebook! And the shop name is pro moto garage on facebook aswell as Instagram! Thanks for all your feedback and Interest I hope yell are enjoying the build as much as I am!!!!20161221_000501.jpg20161216_182146.jpg20161222_145126.jpg20161222_203433.jpg20161216_182152.jpg

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  50. #48
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    20161224_155415.jpgriding out at memas!!! I'll try to get some riding shots if I can!!!!

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