CRF 450X rally/adventure build (Pic heavy)

Discussion in 'Some Assembly Required' started by Small bore adv, Feb 20, 2019.

  1. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

    Joined:
    Feb 11, 2005
    Oddometer:
    96,729
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    Alexandria, VA
    Beautiful paintwork! :thumb
    #61
    Small bore adv likes this.
  2. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    So how did I manage to get the starter in without pulling the motor? Let me first describe the issue.

    The starter motor is located directly behind the cylinder. The head of the starter motor (gear side) fits snug into a machined hole in the right side cover, an o-ring keeps this a water tight seal.

    Because of the tight tolerance between the OD of the starter head and the ID of the machined hole, the starter has to slide perfectly linear into the side cover. This wouldn’t be an issue except that the casting for the cam chain tensioner is directly behind the starter motor.

    Seen in the first picture below. The starter does not have enough room to miss the cam chain tensioner, more specifically the bolt holding the starter together is the point of contact.

    If the starter bolt is removed the starter slides into place, however the bolt can not be re installed because the cam chain tensioner blocks the path.


    255A6934-CA23-443A-983A-ACAD5CB2E1A7.jpeg

    51B68FCF-C467-44F1-9487-55913B539A63.jpeg

    Solution:

    Spotface (Grind down) the face of the starter head (opposite side of the gear) so that the head of the bolt is 1/8” recessed. This allows the head of the bolt to “just” miss the casting for the cam chain tensioner.

    BFDEA45F-94D2-4D4C-A212-F92E96DA183B.jpeg

    Here you can see how the left side sits deeper compared to the right side. Just enough to allow it to miss the CCT.
    #62
    DiggerD, xr-nut and BergDonk like this.
  3. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
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    E7110474-02B7-471D-989A-E154B0AFE422.jpeg Final product.

    I had the same issue when I was removing the starter, however it is possible take part of the starter apart in place to remove it. Obviously that’s not possibld when re-installing it.
    #63
    villageidiot likes this.
  4. Small bore adv

    Small bore adv Adventurer

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    Apr 3, 2018
    Oddometer:
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    Thanks! It’s very satisfying.
    #64
    AcorsG and villageidiot like this.
  5. Paul466

    Paul466 Been here awhile

    Joined:
    May 28, 2013
    Oddometer:
    110
    Location:
    Colorado
    Just noticed the oil tank in front of the motor, I wonder if that would work on the 450r also.
    #65
    Small bore adv likes this.
  6. Small bore adv

    Small bore adv Adventurer

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    Apr 3, 2018
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    99
    Location:
    Michigan
    That’s for coolant, there is no external oil tank, this bike has a wet sump system.
    #66
    Paul466 likes this.
  7. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    13D609EF-8994-44FC-B868-381ADBB3542B.jpeg
    Here you can see the OD of the starter head where the it fits into the side cover.
    #67
  8. Stinky

    Stinky Team Hematoma

    Joined:
    Mar 12, 2006
    Oddometer:
    576
    Location:
    NW WA
    Great work Small Bore! I’ll be following your build closely.
    #68
    Small bore adv likes this.
  9. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
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    Thanks! It’s been a fun build so far.
    #69
  10. Small bore adv

    Small bore adv Adventurer

    Joined:
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    ED0D6A07-158D-4D88-85FB-65A90FC9DEE5.jpeg 0A88C1D7-178B-45A5-BCB7-96FA9785AFFA.jpeg 0A88C1D7-178B-45A5-BCB7-96FA9785AFFA.jpeg

    Hello all,

    Things have slowed down lately (currently finishing up winter semester) haven’t had as much time to work on the bike.
    Yesterday I made all the brackets to properly attach the rear tank. I also routed all the fuel lines, added a few heat insulators too. Might wrap the fmf slip on to prevent heat going into the rear fuel tank. Tested all the electrical, everything seems to work good. I need to weld the skid plate and weld a bracket to hold the gps stuff up front. After that it should be all systems go for testing!
    #70
    joenuclear and Snapper33 like this.
  11. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    D7A47E58-C9C1-4E14-91B8-98E19578A9D7.jpeg Bike is struggling to run, idle is rough, popping and backfiring through the intake. Double checked the timing, valve lash, compression. All are in spec. Possible carb issue or maybe the CDI is taking a slow death? It has a fat blue spark, however it could be firing at the wrong time or inconsistently?
    Changing the jetting now from:

    148 main , 70 leak , 45 pilot

    To

    160 main, 55 leak, 48 pilot
    #71
  12. Wildebeest90210

    Wildebeest90210 Long timer Supporter

    Joined:
    May 24, 2013
    Oddometer:
    5,694
    New to this thread but have you checked your accelerator pump ? I had problems on a KTM and setting up the pump proper sorted it.
    May not be the fix but this may be of use anyway
    https://www.instructables.com/id/Fixing-the-dreaded-lean-bog-on-Keihin-FCR-MX-carbu/
    #72
    Small bore adv likes this.
  13. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
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    Michigan
    Welcome,

    Yes I checked the acc pump diaphragm for any rips or signs of wear.. everything looks good, if it was the acc pump tho I would expect the bike to still idle. Right now it doesn’t even want to start, sometimes it fires up right away and dies, after that it refuses to restart.. I’m going to see how the new jets work. If I stil have an issue I am going to swap CDI box with a friend.
    #73
  14. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
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    Update:

    Bike has a little over 500 miles on it so far, mostly riding in Canada. Navi tower needs some design changes. Going to redo some of the wiring and simplify things.

    Attached Files:

    #74
  15. Small bore adv

    Small bore adv Adventurer

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    117353D9-9C10-4DA1-92C5-6E1204BA2AA3.jpeg 81CA4754-716D-458E-8283-03E0FF0416BE.jpeg 04D53EF9-08D2-4841-8476-9246D7DE80EB.jpeg
    #75
    No-Fret, JagLite, NoelJ and 2 others like this.
  16. Small bore adv

    Small bore adv Adventurer

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    CAECA7DB-9659-4208-9510-C6E2AB004C34.jpeg

    Thank you seatconcepts !

    Really want to get the navi tower sorted out soon. Unfortunately it will probably be a project for the off season. Going into my final year of college, so time and money are at an all time low
    #76
    OzCRU likes this.
  17. Small bore adv

    Small bore adv Adventurer

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    Apr 3, 2018
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  18. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
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    Location:
    Michigan
    12C39E84-7207-4832-B013-AD4D0A4F136D.jpeg

    200 more miles this past week.
    #78
    OzCRU and JagLite like this.
  19. h0lger

    h0lger Adventurer

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    Oct 5, 2016
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    Location:
    Tallinn, Estonia
    Why did you remove the nav tower and the fairing?
    #79
  20. Small bore adv

    Small bore adv Adventurer

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    Apr 3, 2018
    Oddometer:
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    Michigan
    Got a few kinks to work out yet. I’ll get it all dialed in soon.
    #80