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Old 09-20-2013, 01:29 PM   #1
PBrad OP
Joined: Sep 2013
Oddometer: 85
CRF450r: My Massachusetts street titled motocross/dual sport/commuter bike

I made my 2008 CRF450R motocross bike street legal this summer. Thought I'd share:

Items I used to make it street legal:
  • Baja Designs Dual Sport Kit with LED turn signals
  • Additional pressure switch for front brake
  • 2 foldable Mirrors.
  • Trail Tech +9oz flywheel with the bigger magnet
  • Rewound stator (did this myself)
  • IP68 150CFM Radiator fan - this allows me to idle without boiling over, its also the same unit KTM uses, but I managed to get a sample from the manufacturer since I'm a mechanical engineer working on solving a thermal problem
  • Pro Moto Billet Spark Arrestor End Cap with their turn down silencer. This keeps the neighbors happy and the exhaust away from my right rear turn signal. I don't actually use the spark arrestor though, I don't want to lose any power.
  • Pirelli MT21 Dual Sport Rallycross tires (im still 95% offroad, including some motocross tracks. These tires are not that great in the sand. They look like a full knobby but ride surprisingly well on the road)
  • Chromium Nitride Coated Titanium intake valves with Beryllium Copper seats! This eliminates the need to adjust the valves every 2 effin hours. I should only need to be adjusted when I replace the piston every 100 hours or so. I've also noticed a good boost in torque from when the bike was new.

The whole project only took about a single days worth of time, most of which was paying a lot of attention to wire routing. I got a little lucky on the DMV visit. There's a form with a checklist of all the items that a state police officer needs to check off and sign which can be tricky because they make sure absolutely everything is DOT. The form is a little confusing on stating who should be checking and signing it, so I just had it signed by a dealer that does yearly state inspections, which was easy to pass. Fortunately the lady at the DMV didn't seem to know. I think showing a bit of confidence and a smile while in front of the counter helped too. Those DMV people definitely take a verbal beating every day.

I've been commuting the 12 miles a couple days a week into work for the past month or so and its been a blast. I gotta say, having a ton of power in a tiny package is awesome. Of course I don't take it on the highway, but its awesome on busy back roads. If there's traffic built up at a stop light, there's TONS of room for me to scoot to the front of the line. I know its not legal to lane split in MA but so far I've accidentally passed 2 cops sitting at red lights without them seeming to care. Maybe they thought I was on a limited use vehicle, or maybe the law only applies to multi-lane highways? The only downside is the fuel mileage. I've been averaging only about 30mpg doing light duty "city" driving.

I didn't do this for the commuting though. My buddies and I have been doing some long trail rides across the state none of which are in designated "riding areas" of which there are almost none. Of course we try to stay away from residential/busy places. There's a few portions we need to go on the road though to avoid riding through someones yard or near a storefront or something. Sometimes we'll have to be on the road for a few miles or more even. Now that my bike is legal, I go out a few minutes ahead and scout, and we communicate via bluetooth headsets. So far we've been having a blast!
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Old 02-16-2014, 09:57 AM   #2
byways's Avatar
Joined: Dec 2006
Location: Idaho
Oddometer: 1,904
Hmmm ... You commute on that "seat"?
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Old 02-17-2014, 04:41 AM   #3
Baby steps...
bobnoxious67's Avatar
Joined: Jun 2008
Location: Marion, MA
Oddometer: 2,155

Where in MA are you?
"turn it on man, turn it on-whatever, whoever you are-TURN THE FAWKER ON!" -Herbert Foster Gunnison

01 Girlie
09 TE450
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Old 02-17-2014, 06:42 AM   #4
Beastly Adventurer
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Joined: Jan 2004
Location: riding usa
Oddometer: 2,947
please keep us updated on the longevity of the motor. I am very curious Thanks
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Old 02-17-2014, 06:47 AM   #5
grand poobah
Joined: May 2011
Location: palm harbor, fla
Oddometer: 980
yeah, man.... very cool.... you're lucky you can get it inspected and tagged in your state... impossible here in florida.....
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