CRF 450X rally/adventure build (Pic heavy)

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

  1. h0lger

    h0lger Adventurer

    Joined:
    Oct 5, 2016
    Oddometer:
    48
    Location:
    Tallinn, Estonia
    Alright.
    I'm planning on building something similar for my 690 so I might have some questions soon :)
    #81
    Small bore adv likes this.
  2. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    Sounds good
    #82
  3. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
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    Location:
    Michigan
    Hello all,

    It’s been a while since I have updated the 450x rally bike progress.
    First of all, I am going into my last semester of engineering and I have been working full time as a design engineer for over a year now. On top of that I am also getting married in August . So time has been limited, but I am now going to school and working from home, which leaves me more time for hobbies.
    Last year (2020) I did around 1800 miles on the bike, however the navigation tower was always “so so”. Not quite as rigid and solid as I had hoped for. I could make some modifications to it, however I decided to go in a new direction.

    Attached Files:

    #83
  4. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    Amazon box mock-ups have been replaced with Solid-Works models, something I picked up while working in my internship.

    Next, the wiring / rats nest on the last step was driving me crazy. I have scrapped it all and have designed a completely new rally / street legal setup. The new setup will use a fuse block on the tower to help organize things.

    The bike itself is holding up very well, over 2k miles since I purchased it in 2019 and the oem valves are still in spec. It needs to have a suspension rebuild bad.. needs a few other little things such as a fresh clutch, BD 150 watt stator, wheel bearings etc. All in all I am very happy with my bike choice.

    Attached Files:

    #84
  5. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    So it begins,

    I found this gem in “Moto rally kit builders” Facebook page for $100. It is an MST kit designed for some kind of orange bike.. anyways, it will be going on a Honda now.

    Attached Files:

    #85
    dwdantzler and LJC like this.
  6. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
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    Location:
    Michigan
    To make sure I knew exactly how this tower would work on my bike i did the painstaking process of measuring, recording, and modeling of each component. I am very glad I did because it helped tremendously when designing the brackets that would attach the tower to the head tube. I also realized that the forks would touch the tower no matter what I did. ( I will post pictures of the brackets later).

    Attached Files:

    #86
    Pezz_gs likes this.
  7. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    Above:

    For this very complex part I wouldn’t be able to measure and record the shape, too many sweeping radiuses and other geometry. I found that a carefully taken photo from a bird’s eye view would allow me to trace geometry on cad. The final product was within millimeters of the real part, good enough!
    #87
    DiggerD and sruss67 like this.
  8. remy1080

    remy1080 n00b

    Joined:
    Jan 7, 2021
    Oddometer:
    9
    Location:
    Amsterdam
    Nice one! Keep up the good work. Subbedd
    #88
  9. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
    Oddometer:
    99
    Location:
    Michigan
    New (non-welded) navi tower bracket. 3 M6 bolts drilled and tapped into the head tube. The two lower bolts are exactly where the optional factory dampener is bolted. The third hole is at the very top, over 0.5” thread engagement should be plenty.

    Attached Files:

    #89
    remy1080 likes this.
  10. Small bore adv

    Small bore adv Adventurer

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    0C923979-40AE-43DD-A94A-4BAF630071A9.jpeg A864327B-1CCA-4C97-AA52-55D1FBBBAFCB.jpeg 7C23ABF2-3051-4754-8498-884EF601C552.jpeg 0C923979-40AE-43DD-A94A-4BAF630071A9.jpeg A864327B-1CCA-4C97-AA52-55D1FBBBAFCB.jpeg
    #90
  11. dwdantzler

    dwdantzler Been here awhile

    Joined:
    Jan 8, 2015
    Oddometer:
    425
    Location:
    Brunswick, GA
    wow, great score there!
    #91
  12. Small bore adv

    Small bore adv Adventurer

    Joined:
    Apr 3, 2018
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    Getting some wiring done, using a hella fuse block and piggybacking the hot wire to each output. This is a cheap/ easy way to get AUX power without a million wires. The navi tower brackets are welded up, some slight adjustment side to side is needed. 288297E5-2FBD-4EF9-B9D7-5E8EC5C1C460.jpeg 8D7251B3-2EB5-4776-A8E6-817CEB120F8D.jpeg DDD4AD51-8C97-4FF9-AF92-2BF15D40010B.jpeg EC7D9B5F-A704-42AA-AB72-444294DACF31.jpeg 7ECB4620-A735-4B80-BDAC-2904B3F16208.jpeg
    #92
    greasyfatman likes this.
  13. Small bore adv

    Small bore adv Adventurer

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    Oddometer:
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    Michigan
    Somehow I need to get some graphics on this bike. Does anyone have a source for good perforated graphics that will survive gas fumes? And maybe some tank templates.
    #93
  14. Small bore adv

    Small bore adv Adventurer

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    EDF75EA4-0C93-4837-A61C-C8239BAACA25.jpeg F7D4BEAC-D78F-4865-908E-20C931C1B5F8.jpeg
    #94
  15. Small bore adv

    Small bore adv Adventurer

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    Top picture:

    I had an old Tusk lighting kit laying around, I decided to pull it apart and map out the circuit. I wanted to adapt this into my AUX power on the navi tower. I will add a relay for the main power supply that will be triggered by the rear tail light on the bike. This will allow me to remove the tusk on/off switch.

    the lower picture:

    this is a fuse block type setup from Blue Sea. Unfortunately after finding some cad files online I discovered the fuse block is way too big. I ended up using a Hella 8 port fuse block, which does not have a common power feed. This means I will have to run power to the fuse block and piggy back to each port.
    #95
  16. Small bore adv

    Small bore adv Adventurer

    Joined:
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    upload_2021-1-19_19-14-30.png
    #96
  17. Small bore adv

    Small bore adv Adventurer

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    Here is the final design
    upload_2021-1-19_19-16-6.png
    At most I will see around 4 amps at typical use. 11 amps if everything was all on at once, which will never happen. Also, my stator has been sent to Baja Designs for a 150 watt rewind.
    #97
  18. Small bore adv

    Small bore adv Adventurer

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    Apr 3, 2018
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    Michigan
    Last few rides I felt a lot of vibrations in the clutch. Decided to take it apart and check it out, found that all the steel plates were warped. Not bad for being 16 years old, I bought a OEM replacement steel plate set.

    Attached Files:

    #98
    No-Fret likes this.
  19. Small bore adv

    Small bore adv Adventurer

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    #99
    scot_douglas, OzCRU, nostep and 2 others like this.
  20. Small bore adv

    Small bore adv Adventurer

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    scot_douglas, OzCRU, Bt10 and 8 others like this.