WR 450 Dirty/SM build thread

[R7]

Another project I guess?

No surprise, but I picked up a 2009 WR450 to replace the 06 KTM 525 I sold.
The plan is to make it a street legal dirtbike with an option to swap over to a SuperMoto. I have the SuperMoto wheels and brakes from my YZ450 so there's no real expense added on that end.

Here's what I'm starting with, the day I picked it up from the dealer. Big thanks to Manny at Razee Motorcycle Center for another awesome deal





First up was to make sure the SM wheels fit OK. I thought there was an axle size change in 2009 but only the 09 YZ450 got that upgrade. Both front and rear axles are the same size on both my bikes
The rear wheel went on perfect and I need nothing extra. For the front wheel, I need a new spacer to take up the distance from not having the speedometer pickup there. No big deal, I had the spacer i needed in a box.
The thought has crossed my mind to pick up a used complete front offroad wheel from ebay, and lacing on a 17" rim just so i can use the stock speedo? Not sure yet though, it won't be accurate anyways.
The only other part I need as far as SM goes is a new front calliper bracket for the Motomaster brake kit.

I started to strip the bike down to figure what i need to wire it up for lights, signals and a horn. I've got a good sized list of parts i need to order and plan on making the trip to the dealer tomorrow to get that taken care of.
I like the looks of the stock tail light and the fact it has the 3rd wire for a brakelight, however it's to much work to rig up a plate holder and signals to it.
I had the EvoTech tail tidy off my SXV from the last trackday, and just for shits and giggles, I held it up to the bike. It's a close fit, almost as if it was made for it?





It's a little more than I wanted to spend, but I know it's a quality part and think the end result will be worth it. I'll be ordering that this evening.

I also bought 4 OEM turnsignals from an SXV, thanks again typeone Figured being LED they would be bright and keep me from getting my balls busted, and help keep the battery up from the low voltage draw. I don't know how durable they will be offroad, but my KTM ones were about the same size and I never broke one of those.

I'm also just waiting confirmation of a R6 signal switch. I used one on my KTM and never had an issue with it, looked factory, and fits the bars better than some of the aftermarket switches. Hoping to grab an R6 horn as well

Things I need to order from the dealer..
..LED turn signal flasher
..3 hydrolic brake light pressure switches (one for the rear, one for the front dirt, one for the front SM)
..Cycra probend hand guards with SM sliders
..Cycra low profile plastic guards
..GYTR AIS removal kit (de-restrict kit)
..Mirror brackets, the type where you just replace half the clutch/brake lever mount
..An assortment of weather pack electrical connectors (just like the OEM connectors)

I can't see it taking more than a few hours to wire it up, I just need all the parts to make sure I don't leave anything out of the loop.
Another plus, the headlight also has the third wire for a highbeam. I may have to get a little creative for a highbeam indicator light, same for a signal indicator.
That's all for now

[snowborder]

just curious what you'd estimate what you got into it? I'm lookin to replace the Husky

[R7]

just curious what you'd estimate what you got into it? I'm lookin to replace the Husky

I got the bike for $6,200.
RI sales tax $420
Estimate the cost for all parts to add lighting, plus the hand guards will be about $300.
$100 +/- for extra SM parts (had the wheels so I didn't include that)
The title...well "if" I can pull it off locally, it'll be another $75
If I can't, then it get's expensive!

[Mondo]

wow awesome bike man!

[csmutty]

I really hope that you are going to do something about that front fender..

[R7]

wow awesome bike man!

Thanks

I really hope that you are going to do something about that front fender..

Been there, done that with the front fender thing. It's one of the few parts on a bike where i settle for function over looks. Even the smallest changes to the front fender end up with your face/helmet being covered in mud..no thanks

[csmutty]

Thanks



Been there, done that with the front fender thing. It's one of the few parts on a bike where i settle for function over looks. Even the smallest changes to the front fender end up with your face/helmet being covered in mud..no thanks

Yea that is just the only fashion faux pas on that bike as it sits.

[Kitt]

just curious what you'd estimate what you got into it? I'm lookin to replace the Husky

you could buy a nasty yamaha plated tard for $4500 with marchesinis...

[snowborder]

tempting and saw it, but wanting something new that only I beat on.

Really excel rims is enough for me though.

you could buy a nasty yamaha plated tard for $4500 with marchesinis...

[Kitt]

tempting and saw it, but wanting something new that only I beat on.

Really excel rims is enough for me though.

i put 25 miles on the bike! and about 15 laps around a kart track!

but as you were

Mark, I have the yamaha horn.

[snowborder]

thats you... how bouts the previous dude.

i put 25 miles on the bike! and about 15 laps around a kart track!

but as you were

Mark, I have the yamaha horn.

[PinHead]

<----Jealous
Nice ride again!

[Kitt]

thats you... how bouts the previous dude.

46 year old guy who bought it for trails and decided it was too big...

no worries man - u like going new... no harm in spending an extra few G's..

[typeone]

lookin' good! signals shipped yesterday morning, should arrive quick.

EDIT: FYI, Lockhart Philips sells an LED flasher relay that most shops carry. works great and its not too $$

[Stoneman]

Mark - set it up right and I'll buy it if you throw in the extra bits, spares, stocks, etc...

[LaRNZ]

do u have a bulkhead into the basement?

[ssg]

Mark - set it up right and I'll buy it if you throw in the extra bits, spares, stocks, etc...

Get in line focker

[R7]

Mark - set it up right and I'll buy it if you throw in the extra bits, spares, stocks, etc...

I'll know in a week or so, but you may have a deal

[R7]

do u have a bulkhead into the basement?

Stairs, but not a bulkhead. I can get a dirtbike in and out by myself with a ramp

[LaRNZ]

ook, im lookin to get my 750 into the basement via the bulkhead for this winter... dont know how it will pan out

[R7]

ook, im lookin to get my 750 into the basement via the bulkhead for this winter... dont know how it will pan out

When I lived in my parents basement, I used to bring my R7 inside through the bulkhead. The easiest way was to use a 16' plank and sea/saw the plank over the opening. 2 people ay least to get the bike down, leave it in gear and let the rear tire slide down the plank while slowing it with the front brake. It takes at least 3 people to get the bike out using the same method.

[R7]

I made some progress, what else is there to do on a rainy/snowy day

My signals were in the mailbox when I got home yesterday (thanks again Clinton) so that was one more part of the conversion I could get working on. I wasn't exactly sure how I was going to mount the front signals. I had some black plastic flat stock and was trying to figure a way to use it to make some brackets. Once i had the signals in my hands and starting looking at the bike, and holding them in a location I wanted them, it all came together
The bolts that hold the front headlight and mask on were in the exact location I wanted them. I took the bolts out, took a drill bit to the holes and slid the signals in the holes. Perfect fit IMO! I just have to be sure when I wire them, I offset the soft connectors so I can still remove the signals and headlight mask.







Next up was to mount the tail tidy to the bike. I decided rather than buy another one, I was just going to use the one off the SXV. When spring roles around and if I still have the SXV, I may buy another but for now, I'm going to install the stock unit back on that bike.
I wanted the tail tidy as far from the end of the fender as I safely could get it, to prevent "bouncy fender" while riding. It happened to the last WR I had and I added some aluminum bars to add strength...a pain in the ass and looked kinda butch.
Max suspension travel is around 12", so I pulled the linkage bolt and lower shock mount bolt so i could raise the rear wheel up at least 12". I didn't have much stock kicking around in the basement so with a combination of a small peice of 3/4" plywood, a little front fork chock I made for tying down the YZ, and a 18mm socket..I was able to prop the rear wheel up 12 1/2"



I held the tail tidy in place and marked the holes I needed to drill in the fender. I normally don't like drilling anything in the plastics, but there really is no other option in this case. I had 4 allen head bolts from the stock tail section on the R1 that were exactly what I was looking for.



Not bad? Something is a bit twisted, though I'm not sure how I'm going to correct it? It's in the rear fender and it has the exact same twist as my YZ.



Plenty of clearance at full compression, and even plenty of space to allow for future chain adjustments.





The dealer only had one mirror bracket in stock and had to order the other. For now, I just used a mirror off my SXV. I haven't decided what mirrors I want yet...they're another one of the things I go with function over looks with. I won't be using them in the woods, just dualsport rides and SM rides.



The bike as it sits now.



The parts I ordered from the dealer should be in by the middle of the week. Once I have the LED flasher relay, the brakelight switches and the signal switch, I can get the bike wired up. As of now, nothing is wired up, that's the reason the stock tail light is just hanging there.
That's it for now

[LaRNZ]

When I lived in my parents basement, I used to bring my R7 inside through the bulkhead. The easiest way was to use a 16' plank and sea/saw the plank over the opening. 2 people ay least to get the bike down, leave it in gear and let the rear tire slide down the plank while slowing it with the front brake. It takes at least 3 people to get the bike out using the same method.

good idea thanx doode

[Mondo]

i really love ur bike

[SVRACER01]

mark, will i ever get to ride this bike?