CRF450 SuMo Thread

[csmutty]

This will be a thread where I post all the progress that is being made on the 03 CRF450 as it slowly but surely becomes my race bike for this LRRS season. I might also throw some EX500 stuff in here as one of my friends, Brian, will be racing that this coming year also...and...it needs some work.

So here is how I bought the CRF at the 2nd to last race weekend.



So I finally got around to taking it apart since I don't have school. Got it down to the frame and engine. Ground the chain off after this pic was taken and sent a shattered dremel cutting disk across the garage. Didn't see any visible damage on cars...but we'll see.


So I removed all the liquids from the engine so I could bring it down into the cellar. After a little cleaning I had an area set up close to the woodstove so we wouldn't have to pay for propane to heat the garage.



First step now that I had heat was a valve adjustment since it was a new motor. I have never done a valve adjustment on a shim type engine, so this was a learning experience. I found a video on youtube to kind of guide me along. Here it is with the valve cover off.



I thought the design was pretty neat that there is a 3rd lobe on the cam that pushes on the rocker which actuates the other 2 valves. And to find TDC I had to use the timing mark on the gear that lines up with the arrow on the outside of the case.



I did not get to finish the valve adjustment yet as I am waiting on the manual to get here with the tolerances for the valve lash. I did clean up the forks and shock this afternoon though and those will be getting hand delivered to GMD tomorrow.

[lrrs428]

Wish you lived closer, I may have done valves on a crf before....lol looks good keep the posts going ill try and do the same.

[CBR929RE]

I love seeing bikes torn open...















when they aren't mine.

[seth399]

Nice, I had a thread like this when I built up my crf but then I sold it last year

Have fun

[csmutty]

Nice, I had a thread like this when I built up my crf but then I sold it last year

Have fun

http://www.nestreetriders.com/forum/...-motarded.html
I like the white!

[lrrs428]

wait till you see mine then, should be doing the plastics in the next couple of days

[KB]

Pre teen where are the new pictures?

KB

[csmutty]

Ok so since last time I shed some light on the situation...


I got the swingarm off of the bike and cleaned all of the bearings and the swingarm pivot bolt (which was rusty and pretty much unlubed). I got a bunch of storage trays (left side of the picture) to store all of the bolts and small parts that come off of the bike. By labeling them by letter and number I can keep track of what parts are in which drawer in the notebook on top of it.


Installing the slipper clutch...

Got the clutch cover off.


Took the springs and bolts out along with the pressure plate, steels, and fibers that the bolts secure.


To find that the clutch basket which the plates sit in was badly grooved.


To get the basket out required stopping the front sprocket from spinning since the engine can now not be engaged to the transmission without the fibers, steels, and pressure plate intact. So therefore I had to use the chain to lock up the front sprocket to loosen the nut that holds the clutch basket in.


Once the nut and washer was off the basket was supposed to come off, but it would not fit out the clutch cover hole. Therefore I had to take the right case off.


After looking at the basket more closely, the notches made by the fibers look out of spec, so I am going to see if the local shop that mods clutches can take a look at it for me and hopefully fix it for $50. http://www.surfnturfracing.com/Clutch%20mods.htm


I will bring it to him on Monday and see what he can do with it (if anything). It looks like it might be bad enough that I will have to buy a new basket $$$.

[seth399]

Ya dude I used to file mine down if they had little grooves but that looks pretty bad. They are decent amount of money but my CRF had Hinson internals and the basket had almost zero grooving on it when I sold it.

[lrrs313]

Ya dude I used to file mine down if they had little grooves but that looks pretty bad. They are decent amount of money but my CRF had Hinson internals and the basket had almost zero grooving on it when I sold it.

What he said. There's a reason Hinson has been around forever and most of the factory teams use their baskets. Throw one in and be done with it.

[OreoGaborio]

What kinda slipper did ya get?

[csmutty]

What kinda slipper did ya get?

STM. And I just bought a Hinson basket, so hopefully that should be in sometime this week.

[OreoGaborio]

Noice dood.

[lrrs313]

STM. And I just bought a Hinson basket, so hopefully that should be in sometime this week.

Make sure you check the clutch pack thickness when you install the slipper. The STMs are REALLY picky about it and will warp steels if its out of spec. Ask me how I know.....

[csmutty]

Slipper Contd...

New basket got here today...



Basket installed



Slipper STM Goodness...



Step by Step Install...









The awesome tool to hold the clutch in place while you tighten the nut...




And this first pic is of the clutch engaged (transmission and engine are locked together).



And here is the clutch disengaged (clutch lever is pulled in).

[lrrs428]

hmm looks very familiar, I bet you dont have parts from a ducati in yours though

[csmutty]

hmm looks very familiar, I bet you dont have parts from a ducati in yours though

Your slipper was from a Ducati??

[lrrs428]

some of it

[csmutty]

And right now the holdup is the triple clamps. I can't find anyone that makes 10mm offset clamps and the ones I have right now are 22mm and 24mm (aftermarket and stock). Just left a message with the local bike shop which also has a machine shop, so I will see what happens when he gets back in contact with me. Here are some teasers though...

Before...

After...


The goods are back from PK..


And...you can guess what this means..

[lrrs313]

Check out DH1 Racing for triple clamps. Several people on SMJ said they were working on a 13mm offset for CRF450s. Not horrible pricing either. And from the way their website reads, they can do a custom offset for you too.

[tls25rs]

Where'd you get the parts washer?

You gonna get rid of the clark 428 plug on your engine case?

[csmutty]

Where'd you get the parts washer?

You gonna get rid of the clark 428 plug on your engine case?

Parts washer was from Harbor Freight. $40 with $10 shipping.

And me and Clark are going to switch plugs the first weekend.

[tls25rs]

Cool, I might have to go invest in one of those parts washers now that Harbor Freight is open in Danvers (or whenever they do open). Cleaning parts with brake/parts cleaner sucks.

What chemical is in your parts washer? Do they sell it with the tool?

[csmutty]

Cool, I might have to go invest in one of those parts washers now that Harbor Freight is open in Danvers (or whenever they do open). Cleaning parts with brake/parts cleaner sucks.

What chemical is in your parts washer? Do they sell it with the tool?

I actually use simple green in it because it is biodegradable, which makes it easy to dispose of. These parts washers can only use water based solvents because of internals in the pump I think.

[Kurlon]

Be careful with Simple Green. If you let it sit on aluminum for too long it'll discolor it. Grease Lightning is a faster cleaner, it also discolors MUCH faster...