2006 Honda CRF-450R
An absolute monster of a bike. A carbureted behemoth that we had every intention of utilizing behind our home in Northern Colorado. Taken on trade from a good friend, this bike was working when it arrived, but there were definitely some things that were required to get this bike operational for the upcoming season. While it definitely ran, it would not start at our altitude, the front suspension was shot, and it needed some high level TLC! At the time, I wasn’t concerned about documenting the journey. In retrospect, I wish I had! I learned a lot from this motorcycle. This restoration will be generally incomplete in detail, but giving what I have to make the archive.
A great point to start from! Had the service manual in hand.
We knew that a lot needed to be done.
This was in the initial list: 1. All headset bearings 2. Rotors needed replaced 3. Drivetrain needed replaced 4. Top end engine work 5. All fluids replaced 6. Front suspension rebuilt 7. All cables replaced 8. Brake calipers rebuilt + new hoses + fluids 9. Carb rebuild (at minimum) 10. Cockpit revamp
The spark plug was richer than Bill Gates at a donor party.
Should have read the manual before taking out the spark plug.
Not liking what I see - something isn't working well.
Attempted to rebuild the carb, but it did not go well. It needed replaced.
Went with a Lectron carb because of the altitude.
Got the carb installed, an inline filter, and everything ready to kick off.
Did the valves. They were really out of spec. The exhaust valves were almost sealed shut.
Service manual - massive help.
Valves are done, got the top end cleaned up, and the valve cover reinstalled after some heavy elbow grease.
After we got the essentials done, I started on the steering Those rubber inserts needed replaced as well as most in the headset area.
Probably at its lowest point. Almost down to engine and frame.
I had the front forks rebuilt professionally.
Got the triple tree, front forks, and wheel back on as well as the rear wheel - starting to make progress.
Muffler came off, new copper crush gaskets, and a bit of clean up.
Air filter got replaced with a new pre-oiled drop in filter.
This is a look at the rebuilt cockpit with handlebars, throttle assembly & cables, kill switch, barkbusters, clutch cable, and new levers. Really looked clean.
After putting in the work, we got the bike back together and took our first kicks at the motorcycle. It’s a carbureted bike that hasn’t run in months. Combine that with the very cold weather, the brand new carb that was using baseline settings, and a noob working on the bike, and I was shocked that the bike would run.
For several weeks we couldn’t get it running. We would push start it over and over, but we stayed persistent. After working on settings, she fired off without a fuss.
