Yet another WR450... Rebuild.
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Thread: Yet another WR450... Rebuild.

  1. #1
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    Default Yet another WR450... Rebuild.

    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

    The List:
    Get Running
    Install Enduro Lighting Kit and Vapor Dash
    Fix Exhaust
    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.
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  3. #2
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    The first thing I had to do to get the bike running was check the valves.

    Bad previous owner, bad....

    This guy must have put in a + instead of - on his calculator and got the wrong shims.

    Had to swap around the smallest shim I had to measure the clearance and determine that I needed 3 shims in the end.

    The bike wouldn't run at all before I did the shims.
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  4. #3
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    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.
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  6. #4
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    After I got the bike running as best I could, I installed the Tusk Enduro Lighting Kit, and the Vapor Dash.

    Also found a good deal on a Leo Vince system that was sitting around for 10 years, the stock can sounds so incredibly bad.

    Selling that other carb nearly paid for the new exhaust.

    When I installed the Lighting Harness, I also bought an R6 start/stop switch, to clean up the bars.
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    Last edited by Borg; 11-12-2016 at 07:58 PM.

  7. #5
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    So, at this point I was fairly happy with the bike, except the the suspension.

    I rode it for a few months with horrible suspension, just taking cruises to the local 60km~ away coffee shop at the twisties.

    This winter I decided I need to do something about the suspension on the bike.

    It came into the house, and decided, I've got all winter, lets make this bike nice, and unique-ish at the same time.

    First thing I did was fix the forks, the bushings were shot, and the seals were "All Balls"... Chinese junk.

    New OEM Seals and Bushings, the forks are nice and smooth now.

    I've always had the issue of the forks feeling too hard, and the rear shock was waaaaay too soft.

    Rear spring is currently in the mail, and I hope the stock fork springs are stiff enough and they work well together.
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  8. #6
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    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.
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  9. #7
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    I've got the bike mostly torn down, I'm just waiting on a new rear spring in the mail.

    Once the spring gets here, I'll re-install the shock and linkage, and vaguely check the sag, to decide if I'm going to get new fork springs or not.

    I'm hoping the new seals and bushings made the fork acceptable for me, and the rear shock spring is stiff enough.

    Before I could put weight on the pegs and just the rear shock would compress... not good, weight on pegs should make the fork and shock move.

    In the mean time, I decided to attempt straightening the left radiator.

    One of the previous owners had made an adaptor, so the shroud could reach Hah.

    Had a 1" aluminum strip so it would reach, now it reaches without that.

    Spent all of 5 minutes with a block of wood and a hammer, as well as an adjustable wrench to re-shape the tab.

    If I see a good deal on eBay or something for some aftermarket rads in good shape, I might buy them, but they're not really that important, this bike won't be ridden WOT all the time, it's just for cruising some twisty roads and going on some adventures once in a while.
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  10. #8
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    My new rear spring came in the mail today.

    Factory Yamaha spring with the pink (5.5kg/mm) indication on it.

    I didn't put all of the bike back together, but just enough to test out the forks and shock with my weight on it.

    The rear is still a tad soft, but I'm still able to pre-load the spring another ~8mm or so according to the manual, so I'm probably good to go.

    The forks, oh my, they are 1000x smoother now... I had a hard time bouncing/weighting the front end at all before I did the seals and bushings, now I can easily push down and then lift the front off the ground.

    I guess the steering stem bearings are toast... but my linkage bearings look reasonably good, enough that I'll re-use them.

    This suspension setup makes me want to add a YZ-cam.
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    Subbed
    2003 wr450- (sold)
    2007 wr450-
    "girls only want boyfriends who have great skills, you know like nunchuck skills, bow hunting skills, computer hacking skills, wheelie skills"

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    Quote Originally Posted by knuckleduster271 View Post
    Subbed


    If anyone knows where to find some relatively affordable engine plugs, I'd like to replace the shitty plastic ones in the left side of the engine with something other than a giant slotted piece that gets mangled by every previous owner.

    Oh, and a decent plastic skid plate that replaces all the existing engine guards. Maybe I should see how well the Beta XTrainer stock one fits on the WR Haha, I replaced that one with an Enduro Engineering one.

  13. #11
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    Started working on the stator...

    De-soldered the yellow wire.

    Have no cutting wheels left for the dremel

    Pulling the left side cover was a good opportunity to drain some of the sludge left in the bottom of the engine that doesn't quite drain out normally.
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    Finished modding my stator.

    Also unwrapped half my wiring harness to remove the AC wiring for the headlight.
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    Pulled the motor out.

    They really secure it in there... 3 motor mount points and the swingarm pivot.

    The Husaberg only had the swingarm pivot, and then 1 set of motor mount plates in the front, nothing holding the top at all.

    My son and I started stripping the paint, whatever they painted this frame with is a bitch to get off... last time I stripped paint on anything it bubbled up and scraped off super clean.

    The motor is surprisingly light though, doesn't feel any heavier than the Husaberg motor surprisingly.
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  16. #14
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    Went for a drive today, picked up some brand new take off Renthal Fatbars for $40.

    The Applied Racing top Triple Clamp I bought on eBay decided to come about 30 minutes away from my house and then go back to the US for some reason.

    Hope it fits when it arrives, since the 2004 WR has the 46mm forks, I hope they listed the year correctly.
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    Applied Racing triple clamp arrived today, along with the Baja Designs regulator/rectifier, pre-wired for the WR.

    The wires are much shorter than stock, but should still reach.

    The triple clamp came with some bar clamps, will probably just use them, they're factory Yamaha ones I think.

    I also got a horn from BD, because the only thing that broke on my Beta in ~600 KM of trail riding is the horn... and the bike is too quiet to get your friends attention by blipping the throttle when they're in front Haha.
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  18. #16
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    My Disperse Dye sample came in the mail today.

    Used about 8 litres of water, 1/2 Oz of dye, and kept it at low boil for 2 hours.

    The blue is a piece of a fender, turned out perfectly black.

    The caliper guard, is a little bit light in tone, more dark charcoal grey.

    The brake line holders are a slight bit brown, but I believe the small amount of dye might be the culprit there, or maybe I'll just boil them in dye again when I order more dye.
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  19. #17
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    Quote Originally Posted by Borg View Post
    Pulled the motor out.

    They really secure it in there... 3 motor mount points and the swingarm pivot.

    The Husaberg only had the swingarm pivot, and then 1 set of motor mount plates in the front, nothing holding the top at all.

    My son and I started stripping the paint, whatever they painted this frame with is a bitch to get off... last time I stripped paint on anything it bubbled up and scraped off super clean.

    The motor is surprisingly light though, doesn't feel any heavier than the Husaberg motor surprisingly.
    Aircraft stripper works pretty good at removing paint. Give it a try, found at almost and auto parts store- dont get on your skin though...
    2003 wr450- (sold)
    2007 wr450-
    "girls only want boyfriends who have great skills, you know like nunchuck skills, bow hunting skills, computer hacking skills, wheelie skills"

  20. #18
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    Quote Originally Posted by knuckleduster271 View Post
    Aircraft stripper works pretty good at removing paint. Give it a try, found at almost and auto parts store- dont get on your skin though...
    I used some gel stuff... I kind of just want to get everything blasted, but the best price I've found is $80/h and it's really far away.

    Most places are just telling me $250+

  21. #19
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    Decided to re-boil my dye mix and see how many more parts I could turn black.

    The pure white plastics might be an issue, so I may end up having to buy new number plates.. but the fork bottom guard is a harder plastic than the number plates I think, so might be why it turned out grey.

    The sprocket guard, caliper guard, and the other dark grey parts, don't turn out black, but I probably won't bother using those parts anyway, same with the fork bottom guard.

    The cable guides, and fork guard guides turned out good though.

    The rubber plugs for the swingarm also turned out great.

    Not bad for a free 1/2 Oz sample of dye.
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  22. #20
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    Cut another sample off the ruined fender.

    This one had a crap ton of glue on it from a graphics kit.

    I cleaned it off kind of half assed.

    I've re-heated the dye mix about 4 times now, and added water several times because it boils off into the air.

    It didn't dye this large piece quite as well, but I think it's because of the glue residue that seeps into the plastic, and a lack of dye left in the water.

    Not bad for 1/2 Oz Sample, did way more than I expected it to.

    Anyone want to buy a black gas tank? I've got 2 tanks, going to dye both of them.
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  23. #21
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    Decided to give a cheap china clutch lever a shot.

    $40 CAD shipped, figured why not.

    It's quite well made, and very beefy, while still being lighter than factory, also has 2 cable positions.

    Not 100% where/what I'm going to do with the hot start... I may remove the cable and run a second choke knob, the bike does start with E-Start while slowly opening the throttle anyway when it's hot.

    I also went full-retard on eBay, ordered a used Brembo caliper and master cylinder...

    Found some cheap rad guards, to replace the busted up ones, and SS brake line for the front.
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  24. #22
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    Picked up a KTM fender yesterday to go with my headlight.

    Also picked up my parts from powder coat, everything looks pretty good, probably could have done better masking stuff, but not a huge deal.
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    Mounted the fender and headlight just for some motivation.

    Need to install new steering head bearings, and swingarm bearings before I start putting it back together.

    Was thinking of getting WR450EXC decals made just for fun Haha.
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    Well, got the engine covers back on.

    It was a huge pain in the ass to clean the blasting media out... don't think I would use that powder shop again, they did a good job coating, but not masking or cleaning.

    Also, they assured me the swingarm bearings would be fine to leave in, and then they didn't mask them off either.... so they are buying me new swingarm bearings.
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    And we will have pics of a roller, when? Tuesday?

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    Whenever I get the new head bearings in, and when the shop gets the swingarm bearings in.

    That's literally the only reason it isn't already a rolling chassis.

    Also waiting for my dye to come in the mail so I can make the tank, shrouds, rear fender, and side panels black.

    Not sure if the white side panels will turn out, might have to buy new ones, they're pretty rough anyway.

    Seat concepts is on it's way too, gonna be comfy this year finally.

  29. #27
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    Yeah, waiting on stuff sucks sometimes. Just dropped a motor in my truck and eBayed some crap figuring I plenty of time. The high pressure power steering hose took forever and the low pressure lines took forever and a day. And the high pressure line was buggered up anyways.
    You need a couple new plugs for that cover, my OCD.

  30. #28
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    Yes I know.

    Previous owners butchered them.

    I can't find any cheap black ones... do you know where to get some?

    I sanded the silver off of them for now, but I doubt it'll make it to the street with those plugs, can't have that ugly shit messing up the fresh black look.

    EDIT: I just looked harder on eBay... found some for $40 CAD shipped, with allen heads, not that stupid slot BS.
    Last edited by Borg; 12-11-2016 at 06:25 PM.

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    Gotta love eBay. keeps my a$$ poor. They should have a blocking feature, like gamblers addicts have. But I've scored some super deals. Did I need some of the super deal crap I bought, hell no, but I own it now. I figured you had a plan for them.

  32. #30
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    I had an epiphany today.

    Realised when I had the shock spring off, that I could compress the shock and it didn't rebound back.

    Put my bicycle shock pump on the schrader valve.... 0 Psi... great.... pumped it up to 150 psi... take the pump off.. Hsssssssss

    Turns out someone loosened the valve core? Or if I want to be hopeful... someone rebuilt the shock and forgot to tighten it? Yeah I'll sick with that for now.

    Good news is, that new spring I got should need less pre-load

    I doubt I'll ever fill it with nitrogen, it's only being used on the street.

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    Or it was rebuilt and the pressure pushed out the Schrader valve threads. Never count your epiphanies before the hatch.

    Sent from my XT1254 using Tapatalk

  34. #32
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    Nah, I tightened the valve core, it was loose.

    Got my black plastics in the mail today

    And one of the brake parts I decided to go with.

    If it's too wooden with the caliper I bought, I'll just replace the reservoir pipe and lever and probably sell it.. can probably make a profit off it.
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    ok.. I'll follow along.. I may pick up an 04 WR450 soon....

  36. #34
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    Picked up this Brembo 4 pot caliper from a KTM 640 Supermoto for quite cheap, included a SS brake line, that I won't be using, anyone want to buy it?

    I already know I'll have to grind it down, do the KTM's really have that much wider front ends?

    Also new rotor you can see in the background, because the EBC rotor will not work with a Brembo caliper. EBC rotor and adapter for sale!
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  37. #35
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    Did a bunch of measuring...

    No way that caliper will work even if I take off 3mm from the back.

    Anyone want to buy a KTM Duke II Caliper?

  38. #36
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    Been super busy with work...

    Got some stuff in the mail again.

    Taiwan Pazzo Knockoff levers, they shipped really quick, and they look AWESOME... paid $28 CAD for them shipped.

    Bought a set of an R1 since I want to use this Brembo master cylinder. So if anyone needs an R1 clutch lever let me know :P

    Tusk bar clamps to replace the GYTR ones that came with my upper triple clamp, bolts were too short on them and non-removable.

    Flatland Racing rad guards to replace the broken in several places ones that came on the bike.

    Galfer line was on sale... why not.

    New throttle tube, mine is broken-in pretty bad.

    Gotta start building this bike.... but still waiting for swingarm and head bearings.
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    Quote Originally Posted by Borg View Post
    Been super busy with work...

    Got some stuff in the mail again.

    Taiwan Pazzo Knockoff levers, they shipped really quick, and they look AWESOME... paid $28 CAD for them shipped.

    Bought a set of an R1 since I want to use this Brembo master cylinder. So if anyone needs an R1 clutch lever let me know :P

    Tusk bar clamps to replace the GYTR ones that came with my upper triple clamp, bolts were too short on them and non-removable.

    Flatland Racing rad guards to replace the broken in several places ones that came on the bike.

    Galfer line was on sale... why not.

    New throttle tube, mine is broken-in pretty bad.

    Gotta start building this bike.... but still waiting for swingarm and head bearings.
    The newer r6 throttle tubes are where its at👍
    2003 wr450- (sold)
    2007 wr450-
    "girls only want boyfriends who have great skills, you know like nunchuck skills, bow hunting skills, computer hacking skills, wheelie skills"

  40. #38
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    Quicker turn?

    I don't need that.

    I've got the new swingarm bearings sitting on my desk, just need to take it to work and press out the old and in the new ones.

    Then I can put the motor in and start assembling.

    Hopefully next weekend I can pickup the new seat, and head bearings, handguards, and a few other things.

  41. #39
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    Finally had some time after working 12 days straight with some 18+ hour days in there. Tow truck life is tough some times.

    Got the new head bearings and swingarm bearings installed.

    Motor is in now!

    The swingarm bearings must have loosened up after being powder coated... I used a 19mm impact socket and hammered out the old ones, they came out really easy.

    Put the new ones in the freezer, and barely had to tap them in with the socket again, worked awesome.

    Most annoying part was sanding all the powder coating off for the swingarm and linkage bolts.

    I've gotta buy a big bin/can for the Dye next, and dye the plastics black, I'm really hoping the white number plates work out, no idea why that particular plastic piece is so expensive.

    Also replaced the shrader valve in the shock, it was leaking, and since it's just being ridden on the road, I probably won't bother with the Nitrogen charge.

    I also found out that fancy clutch lever won't work with the factory cable... it doesn't use enough length from the adjuster to the pivot, so I'll have to figure something out, maybe I can get the cable shortened?
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    Getting there.

  43. #41
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    Couldn't resist putting more parts on it!

    Anyone have any tips on shortening my Leo Vince pipe? It's really long, and I'd like it to not look so ridiculous when this bike is done
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    Husqvarna or Skihl chainsaw, wouldn't trust the Husky much though.

  45. #43
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    Wife has a Husky saw, it's a pile of shit, I bought her an ancient used Stihl saw and it works 100x better even though it's like 4" shorter bar.

  46. #44
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    Got the speedo mostly mounted up, need to get some nicer bolts with nylock nuts so it doesn't vibrate loose.

    Not sure on clutch cable routing yet, also need to possibly get the cable shortened to work with my China clutch lever.

    This morning I shortened the Tusk Enduro Lighting harness, it was about 10" too long, and I didn't like the bunched up mess, or the tape they used to wrap it, so that happened too, didn't take pictures of that, looks the same as before I shortened it pretty much.

    The Vapor power wire is wired into the lighting harness, as well as new wiring for the headlight to run on DC power, both of course are switched with the key. As mentioned in a previous post, the tach sensor is wired into the main bike harness.

    There is so much more room behind the headlight now, it's glorious.
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  47. #45
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    Got something special in the mail today... FTE caliper.

    I must have the dumbest front hub in the world... this caliper still might need the rotor spaced out 1mm or so.

    Also got my new timing plugs in the mail from Taiwan.
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  48. #46
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    Now those look 1,000% better.

  49. #47
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    I sure felt better looking at the engine after installing them The 10 and 6mm allen heads are a nice touch too.

  50. #48
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    Just to get all scuffed up from the toes.

  51. #49
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    334

    Default

    My feet aren't that big!

    Free to good home timing plugs
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  52. #50
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    334

    Default

    Yesterday I finally picked up my Seat Concepts kit.

    While I was doing that, he had a bunch of NOS items.

    Got some SCAR footpegs, and a KTM black/silver anodized gas cap that fits on my Beta, and used the black vent tube/cap on the WR to replace the ugly faded blue one. Was only $60 for pegs and gas cap.

    I got the gas cap because the Beta one has a funky rubber seal that always gets caught in the threads... making it near impossible unless you're the Hulk to get the damn cap off, this aluminum one doesn't do that.
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