CRF600 Dual Sport

Discussion in 'Some Assembly Required' started by Lawman_745, Jan 28, 2018.

  1. Lawman_745

    Lawman_745 Adventurer

    Joined:
    Jan 21, 2018
    Oddometer:
    12
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    Fairmont WV
    Let me start off by saying yes, I am an idiot. I love anything absolutely off the wall. I've been racing GNCC's and any type of motorcycle racing I could since I was 6 years old.
    Recently got a very good job, but it doesn't allow time for racing anymore. This is true for for most of my old riding buddies. They have transitioned into dual sport riding and I got a chance to tag along last fall. I was instantly hooked. Traveling old back country roads, seeing unbelievable sights, and getting back to riding basics was exactly what I was looking for.
    With that, I set out scouring the local classifieds searching for some type of 650 dualsport. I wanted something that could reliably carry me anywhere I wanted to go, easy to work on, and still rip on and have that excitement factor. My search turned up only one result: a 2002 XR650R. I contacted the seller and went to check the Big Red Pig out. Everything worked as it should, but he did not have the title, MSO, or any type of paperwork I would need to get it legal. I was super bummed.
    I continued checking the local online ads trying to find something. That's when I happened on the project in question: a 95 CBR600F3. I originally planned on buying it for a song, fixing the few issues it had, and flipping for a nice little profit. That's when my father stumbled upon this:

    Holy hell! I had to have it! I bought the bike with a clean title running and riding for 300 bucks. I also just happened to have a CRF450x with a lunched motor sitting at the family farm. So brought the CBR home and started stripping it down

    Attached Files:

    #1
    Eatmore Mudd, Pezz_gs and oic like this.
  2. Lawman_745

    Lawman_745 Adventurer

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    Oddometer:
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    Now with any project, you have to have end goals or you will never accomplish what you want. I decided that I wanted it to be no more than 350 pounds, hold at least 4 gallons have gas, and be comfortable for long hall rides. Stripping the CBR down took only about 10 minutes as most of the plastic and fairing we're held together with zip ties. I decided to reuse the cbr frame and swingarm, since they were steel and easy to modify. I started with the trying to swap the CRF front end. A quick check on All Balls fork swap table showed that the steering stem bearings were completely different. I figured it would be easier to try and swap the stem from the CBR triple clamps into the crf clamps. Doing this would allow me to use the factory bearings and keep it much simpler. With a little grinding, pressing, and swearing, I got the stem pressed into the CRF clamps.

    Doing this made the front end a bolt on affair. I did have to make new steering stops and dent in the top frame rails to allow for a good turning radius. Out came the torch and BFH.

    The hardest part of the entire project will be the fuel tank. The CRF tank will not fit at all. The carbs and airbox interfere with any type of MX tank fitting. I'm going to try to cut up the stock CBR tank to move it forward more allowing for a MX type of seating position.

    Attached Files:

    #2
  3. Slytheslayer

    Slytheslayer Ride or Die!!

    Joined:
    Jan 18, 2017
    Oddometer:
    343
    Location:
    Fort Lewis, WA
    Ooh this looks like fun! I'm in! I would love to score something so cheap and build it up. I need a project bike!! Haha
    #3
    Lawman_745 likes this.
  4. Lawman_745

    Lawman_745 Adventurer

    Joined:
    Jan 21, 2018
    Oddometer:
    12
    Location:
    Fairmont WV
    Next up, I started getting the cockpit setup. The CBR had these really tacky aluminum grips on it that needed to go. The throttle side grip replaced the factory throttle tube setup and I did not have the original. Went ahead and ordered the factory style plastic one. The choke cable and throttle cables had to be rerouted for more slack to reach the higher handlebars. The clutch cable was way too short now. Luckily, the crf 450 cable was almost identical and plenty long enough! It's so nice to have a parts bike to rob and things just bolt right up. Also ordered a Trail Tech Vapor to handle my instrument panel needs.

    With the help of my old man, we set about getting more height out of the rear to match the front. We unbolted the lower shock bolt and raised the bike up on the stand. It was a compromise between getting it taller and keeping an acceptable swingarm angle for the chain. New taller shock tabs were fabbed and burned into place.

    I went ahead and took the footpegs and rear subframe from the CRF for mockup. From what I can see, it will be alot easier to cut and modify the existing CBR subframe to fit the CRF seat and plastic.

    Things left to do:

    Modify subframe
    Relocate radiator
    Adapt CRF rear wheel to fit CBR swingarm
    Relocate all foot controls
    Reroute exhaust
    Fab skidplates
    Build a new gas tank-really dreading this
    #4
    Eatmore Mudd likes this.
  5. Lawman_745

    Lawman_745 Adventurer

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    Jan 21, 2018
    Oddometer:
    12
    Location:
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    Progress

    Attached Files:

    #5
  6. Slytheslayer

    Slytheslayer Ride or Die!!

    Joined:
    Jan 18, 2017
    Oddometer:
    343
    Location:
    Fort Lewis, WA
    That thing is going to be so much fun off road!
    #6
  7. rally roo

    rally roo Total poser

    Joined:
    Apr 9, 2010
    Oddometer:
    633
    Location:
    Smuggler's Notch, VT
    Can't wait to see how this turns out! I used to have a '94 CBR600F2; those motors are a lot of fun. Hope the ergonomics don't pose too big of a problem!
    #7
  8. Lawman_745

    Lawman_745 Adventurer

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    Jan 21, 2018
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    Thanks guys! Yeah the ergos will be difficult for sure. The way the motor and carbs sit in the frame make it a challenge.
    #8
  9. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    4,523
    Location:
    Sydney Skunkworks
    Really enjoying your build and watching with interest. Steel frame makes it a lot easier too.

    I had thought about building a DRZ600RR with a Gixxer 600 into a DRZ400E frame.

    I did build a CB400F into an XR460/4. It was a great bike to ride the dirt.

    [​IMG]
    #9
  10. Lawman_745

    Lawman_745 Adventurer

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    Hasnt been very much progress lately. Working 7 days a week will do that I suppose. I keep going back and forth on making a tank or just using the factory one for now. Riding season is fast approaching and I'm going to run out of time. I did manage to get the CRF pegs to fit the CBR brackets for now if I decide to kept the original tank.
    #10
  11. Lawman_745

    Lawman_745 Adventurer

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    Decided I can't do all this work and cop out towards the end. Started mockup on the CrF tank. Had to cut out the bottom bulge and a little bit of the airbox. Going to use the giant CBR overflow bottle as a secondary fuel tank and use the CRF overflow tank. Up next is subframe surgery.
    #11
  12. Lawman_745

    Lawman_745 Adventurer

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    IMG_20180212_142246568.jpg IMG_20180212_142226220.jpg
    #12
  13. Lawman_745

    Lawman_745 Adventurer

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    Jan 21, 2018
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    No going back now.... Need to trim the tank some more to get it to fit inside the frame. That should allow the seat to move forward and get a better riding position.
    IMG_20180215_140328416.jpg
    #13
  14. dwdantzler

    dwdantzler Been here awhile

    Joined:
    Jan 8, 2015
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    192
    Location:
    Brunswick, GA
    thats begging for an underseat gas tank
    #14
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  15. Lawman_745

    Lawman_745 Adventurer

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    I'm going to try and make it fit inside the frame tomorrow, it needs to be down and forward.
    #15
  16. pennswoodsed

    pennswoodsed lizards,bugs and me

    Joined:
    Jan 20, 2007
    Oddometer:
    979
    Location:
    Reading,Pa
    Probably something wrong with me,but these are the most fun threads anywhere !
    #16
    Lawman_745 likes this.
  17. Lawman_745

    Lawman_745 Adventurer

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    Jan 21, 2018
    Oddometer:
    12
    Location:
    Fairmont WV
    #17