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
#3 · (Edited)
Yes they do and I paid $123 shipped from Italy and it tool 4 days to get here! That is significantly cheaper then lightspeed and others and the quality is better then the lightspeed frame protectors I have as well.

Email them through the website and a a very nice man will email you back and set you up with anything you need. I paid with PayPal.

I think I'm going to get the rear caliper protector and chain guide as well.

Skid plate is amazing quality to you WILL not be disappointed I can promise you that.
 
#5 ·
Of course I have pics coming I'm just on travel now. I'll post up pics of each part and all the coated stuff as well as my process during re-assembly too.

And thanks :D I tried to list everything I have bought or done. More so people can follow what I have put on the bike then anything else.
 
#6 ·
Bored and on travel = just ordered the wide ratio transmission! The head is out being ported/polished, upgrading the valves, seats and carriers as well as the springs and having my stage 2 cam installed. Looking for low to mid 60hp at the wheel and the ability to run highway speeds at a comfortable rpm :beer:

NOW I just have to decide to keep it 450cc or get a big bore?! Decisions decisions haha...
 
#7 ·
Parts coming faster then expected! 490 big bore on the way...got a great deal on a new in box kit from a forum member. This bike is gonna rip!

Question tho...

Should I go with stainless valves or upgraded titanium valves with the big bore? Also do I need to replace crank bearings or anything like that? I had planned to use the stock rod/crank and leave all that alone? Let me know what you guys think...

I wonder what HP this thing will put out when I'm done with it :confused: anyone have a good estimate?
 
#9 ·
Gave the shop and call doing the head work and firmed a few things up...

Full port and polish
APE intake/exhaust valves (oversized exhaust, stock size intake)
APE heavy duty springs
APE titanium retainers
Replace guides
Install stage 2 cam
Bench shim

He said he just dyno tuned a crf450r with the same head work done with same cam...it laid down 62 hp!

I should see alittle more with the big bore and other little tweaks. And then some more again if I get a custom ignition map and get the timing perfect!

Haha soon I'll be in the cr500 hemisphere! I may be dreaming alittle but don't pop my bubble :D
 
#11 ·
:clap: i got the tracking number thanks!! I guess we know who I got the big bore kit from now huh haha. I will be working on this over the winter, can't move to fast, i want to enjoy the process :bannana: that and some parts take time to come in, like the head, I should have that back by the end of the year so about 6 weeks out.

I'm about to upload a over 30 pictures, going to try and split them out a bit into a few posts...
 
#12 · (Edited)
Powder Coating Tease

Here is the color i went with, it's kind of a mix between gunmetal gray and anthracite gray, I didn't go with the metallic flake, and asked for a satin finish on it. it's about 75-80% gloss as opposed to 90% (makes a huge difference) taking it from a mirror finish to a slight shinny finish. It's dark here so these are with my DSLR in the garage. it's actually a bit darker in person/sun light as the flash washes the color out as i'm sure some of you know...



And one inside to show another facet to the color...this is one of the radiator mounts I had done with all the other little random pieces.

 
#14 ·
Body parts

first up is the Acerbis dual road hand guards with LED lights built in



decided to use the OEM fork protectors, just stripped the graphics and cleaned up a bit, once new graphics are on you won't be able to tell they are used.



LED tail/tag light



Complete new set of body bolts VERY Shinny haha

 
#16 · (Edited)
Controls etc...

Race Spec shifter and brake levers...both black with red tips. have to have alittle RED in the build, after all it is a Honda, you'll see other little splashes of red in some other places too.



1 1/8 Red bar clamps



New D.I.D. Non O-ring chain and a 14 and 15 tooth front sprocket. I have to get a rivet master for the chain as i HATE clip style masters and that is what these come with :hmmm:



TRX450 brake master...replacing my brembo master as this one is just as good and it has a mechanical brake switch...there is no replacement for these, hydraulic pressure switches are a last resort for me especially in the front.



Brembo casts 108mm space caliper and QTMI bracket from a KTM haha....interesting fact. Marzocchi and KTM run the same PCD on their caliper mounts, you just have to shave a bit off of the "V" section because the shape of the "V" is difference between the two. Saved hundreds with this as I didn't have to get a radial lug for the fork leg and I don't have to worry about a leaky fork bottom now either!! You will also catch a glimpse of the front steel braided brake line here too, I have one in the rear as well.



CRG Blindspot/road splitters (these are great as they fold in as well)

 
#17 ·
Lighting and Electrical

MT-03 Headlight and custom billet brackets (in black) and the billet fork clamps as well.




K&S LED turn signals for the rear...these are top notch, still debating on these as they are kind of bigger they i thought, but they are VERY nice and BRIGHT!



Complete HID Bi-Xenon protector kit w/4300k phillips ds2 bulb and LED white angle eye (going to use it as a Daytime Running Light DRL)



AND A BREAK OUT OF EACH PART IN THE KIT:

Projector shroud, Projector centering ring and angle eye LED ring



Phillips 4300k Bi-Xenon bulb



HID relays and wiring



H4 wiring lead and plug



HID Ballast



Bi-Xenon Projector



Handlebar Combo Switch. Has Turns/Kill Switch/Light on and off and DRL/high and low switch/LED high beam indicator/Horn. Comes completed wired with great quality wires and heat shrink as well as the male and female plugs and leads on the female side to run to the bike.

 
#18 ·
Lonely Engine mod

here is the only engine mod I have in house right now...a lonely 2002 crf450r cam. This cam has the same basic properties as a Hotcams stage 2 cam for those that didn't know that! and guess what....it's a heck of alot cheaper :clap: Waiting on the wide ratio trans and the 490cc big bore to come in, i'll add them once they arrive.

 
#19 ·
Wheels/Chassis/Custom spacers

Got some VERY nice space for the wheels as mine didn't come with them. they offset the wheel a bit to the right so that the chain guard doesn't hit and then there are spacers to space the rotor and sprocket as well to adjust for the movement of the wheel to the right. You would NOT believe the quality, fit and finish of these...they are amazing. He even machined in a 1mm lip on the inside edge to grab the dust seal and hold them in place while taking the wheels on and off. Thanks Rob!! :rock:

Wheel Spacers







Rotor Spacers






Sprocket Spacers



And last but not least a little teaser of a rolling chassis! this was taken after tear down, prior to powdercoating. the wheels and forks are just in place. Both wheels just have axles through them holding them on but i think it still looks really cool so I will post it!

 
#46 ·
Got some VERY nice space for the wheels as mine didn't come with them. they offset the wheel a bit to the right so that the chain guard doesn't hit and then there are spacers to space the rotor and sprocket as well to adjust for the movement of the wheel to the right. You would NOT believe the quality, fit and finish of these...they are amazing. He even machined in a 1mm lip on the inside edge to grab the dust seal and hold them in place while taking the wheels on and off. Thanks Rob!! :rock:
Welcome! Glad to help out a fellow SMJ member. And it's a perk that you just so happen to have one of my favorite bikes, so I enjoy it that much more :D
 
#21 ·
Ran into some problems today...I'm replacing the swing arm and linkage bearings, and the swingarm bearings are COMPLETELY stuck. I have a puller with a 3 lbs hammer, wouldn't budge them. soaked them with some lub and tried to pull them out, didn't budge. them i used a really long extension and a socket and tried to beat them out, didn't move again! :headscrat I'm going to try to heat it a bit and have at it again, but it looks like i might have to drop it off at my buddies shop and have them pressed out. we will see what tomorrow brings, I have a few days until the new aprilia ones come in anyways.

Positive note...

I got the subframe mounted. Kickstand is on. And i got the triples and forks mounted up as well.

I have to chase the threads on the upper hole for the foot peg brackets because they weren't masked off completely and there is powdercoat in there which won't let the bolt go in all the way :rant:

Slowly coming along...I will post some pictures later tonight of what i did today.
 
#23 ·
That Jardine double exhaust looks pretty sick. Do you have a special left side number plate that's bulged out more than normal to fit that exhaust? As far as I know, only the 2013 CRF450R has a bulge on the left side for a double.
I did a lot of reading and chatting with people whole have done it...most of them on the UK supermoto forum and got some tips. Basically you just have to dremel out the webbing on the back of the number plate and use a heat gun to gently heat and mold it a bit. Shouldn't take me more then 30 minutes or so :D
 
#24 ·
Small Update

So today as mentioned above I got the triples and forks mounted as well as the sub frame. And ran into a snag with the swing arm bearings, THEY WON'T BUDGE!! :damn:

First off a few tools I picked up, after all a man can never have too many tools :bannana:

Bearing puller/slide hammer, covers something like 10mm-35mm.



Metric Tap/Die set covers from 6mm-24mm both fine and coarse threads and all sizes in both taps and dies. VERY Nice!



Anyways here's a pic of attempt number #2 I believe to remove the bearings.



And here are 2 pictures of what is assembled so far. Sorry to the chaos/mess, but i have a 1 car garage and half of it is occupied by our patio furniture right now (it's almost winter and "Super Storm Sandy" forced me to bring it in early this year). So i have limited work space and a TON of parts haha.


 
#29 ·
Some more parts!

Came home from work today and found these two things waiting for me :bannana:

first up is the black clarke 2.8 gallon tank and associated hardware I picked up brand new, but for a steal...apparently someone ordered it and paid but couldn't use it and wasn't able to get a refund so now it's mine for a nice price!



Second...my 490cc big bore kit came! also scored for a GREAT price thanks to a smj member! looks great and I can't wait to start the engine build and get it in there. Oh and excuse the little white packing material on the cylinder and piston box...I was excite to take a picture and was running late ha.

 
#30 ·
Also...AND THIS JUST IN....

I got my swing arm bearings out. After a helpful PM with another member and a look around the internet I almost bought a swingarm bearing tool to remove and install my bearings. Decided I really didn't want to pay the $40-60 people were charging, plus shipping and really didn't want to wait for it to ship and get here! So i did some more surfing and decided to DIY my own tool...best part...it's cost me $7 and that is only because i got enough for 2, in different sizes! Made a 1/2" and 3/8" version.

Tool consists of:
PURCHASE
-One 12" piece of 1/2" threaded rod ("All Thread")
-Two 1/2"x2" flat washers
-Two 1/2" nuts for the rod
OWNED ALREADY
-21mm deep well socket
-30mm deep well socket

21mm socket drove the bearing out, and 30mm socket acted as a stand-off so that the bearing had room to slide all the way out of the swing arm. No heat or hammer needed :clap: Took me about 15 minutes to get them both out with 2 of my bigger adjustable wrenches, now I just have to wait for the new ones.

These suckers were in there TIGHT!





I get great joy out of doing things on my own and not having to pay someone to do it, especially when it all comes together and was as easy as this.
 
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