Earlier this year, I snapped up a cheap 2004 WR450F, with dirt and SuMo wheels.
It was a non-runner, sitting in a garage for about 3 years.
I saw the bike roughly 3 years ago for sale, but at that time it came with 2 frames, and was about 50% more expensive.
This bike came with a TON of spare parts, including a complete wiring harness, extra gas tank and full plastic kit, spare carb (which I regret selling, I'll make a post about that), a complete second rear brake, and... a FULL Tusk Enduro Lighting Kit.
I'll try and make posts about progress that I made to it a while back, till current state. I've already been riding the bike, and put about 2000 km on it, and fixed a bunch of stuff that I list below.
Picture below, is how the bike was as I bought it, in it's non-running state.
And some of the parts I received with it.
The bike also is grandfathered in to be road legal in Ontario
Install Enduro Lighting Kit and Vapor Dash
Fix Suspension (Front too hard, rear too soft)
Partially re-make the entire wiring harness, and remove erroneous items (Clutch switch, kill switch, wires for ignition light, etc...)
Paint/Powder Coat the frame black
Paint the engine to make it looks nice
Dye all the plastics black
Buy/Install Seat Concepts seat
Possibly new rads and rad guards
Possibly get a nicer headlight
Replace steering stem bearings
Maybe get new tires (The Pirelli's are 10 years old, and never used, but not dry...)
Upgrade to Fat Bars
Get proper hand guards (Zeta or Emperor Racing that mount to the bar clamps)
Big maaaaybe is upgrade the front brake
As well as one day get a new carb (This is a long story)
Snow is going to fly any day now, which means I'll be pretty busy with work, so I've got all winter to finish or get this project back on the road.
This WR450 replaced a Husaberg FS550 which I rebuilt the motor over last winter to flip the bike, sure the WR is a little slower and a little fatter, but it won't need nearly as much maintenance.
The second thing that needed to happen to get the bike running right, is ideally a new carb.
The bike came with 2 carbs, one really dirty one, and one clean one.
Now, for some reason, I didn't look inside the dirty carb, and just assumed that it was older and probably had more junk inside to clean out of it.
So I sold it, to recoup some money and make the bike a little cheaper, I was considering flipping it at first like the last bike I had, and what better way to make some additional profit, than to sell the spare parts.
Well, that was a bad idea, the clean carb turns out to have a worn slide, which is preventing me from raising the idle any higher than 1600 rpm, or else it hangs because the slide catches on the wear marks in the carb body.
It also had a secret hiding in it, some funny guy at the factory decided to do something very mean.
The check valve for the AP nozzle was pressed in all the way, not allowing any flow, in or out of the nozzle.
Had to drill and put a screw in the valve to pull it out, and re-insert it so that the valve worked.
Yep, wish I hadn't sold the other carb when I found all this out.
While I wait for the rear spring, I've decided to take on the wiring harness.
Anyone who has ever owned a WR450 knows about the horrible rats nest behind the headlight, and all the silly connectors stuffed between the rads in the triangle opening of the frame?
Well, I want to fix that.
For starters, I removed the neutral switch, clutch switch, and the kill switch since I have an R6 start/stop switch.
Since the safety switches were removed, I also removed the 2 diode/relay things.
This ended up removing 7 connectors in total from the main harness, and an 8th one is going as well, I just need to order a 4 pin Deutsch connector and crimping tool.
The ECU now has 7 wires that are not in use, so I combined the remaining 5 from the dual 6 pin connectors into just 1.
Will also be replacing a bunch of the ugly bullet connectors from the Tusk harness, so it's easier to remove/install stuff, and also waterproof.
I integrated the tach sensor into the harness while I was in there, why not right?
I wrapped the entire harness with some fancy wiring harness tape, so it doesn't become a gooey mess like it was before.
Originally I planned on combining the Tusk harness into the main bike harness, but I decided to leave it separate, in case there is a time when it becomes a race bike, you can just remove the entire lighting harness and lights as one.