I swapped a tricked out '06 Husky WR250 for this bike.
Drained the engine oil, and found the oil filter cover o-ring was knackered, and it was siliconed in place. This is the crap I cleaned out of the stainless filter. Ugh.
The air filter was so worn out that the sealing flange had crumbled, and the bottom of the filter wasn't even sealed against the airbox. Seeing this, I decided the motor was going to come apart for inspection.
Mild or wild on the rebuild?
Nice air filter, eh?
The wheels and spokes were trashed. Vice grips were used to try to unseize the spokes from the nipples some where along the line. The bike must have been ridden quite a bit with broken spokes to wallow out the rim dimple like this.
The hubs were worn out too. The spoke holes were blown out. New hubs and wheels will be required.
Shock seal blown too. And the shock linkage was totally fragged. Had to buy a new one.
Fork seals were blown.
The clutch didn't work too well. So I took the cover off, and pulled the plates. I've never seen a more worn out clutch basket.
At this point, I decided the hell with it, time for a full strip to the frame rebuild. This bike was too knackered to go far from the garage as it was.
Nice mirror, eh?
Hated the graphics, so I peeled 'em off. To reveal pretty torn up plastics.
Rear disc was bent, and the plastic guard broken off. I changed the rotor to a wave type, and added an MSR guard.
The damper was worn out, so I sent it to Scott's for a rebuild. They updated the internals, too.
Both radiators were bent, and had pinhole leaks in the core. Rather than fooling with it, i have some plans to up grade the cooling system, and add an oil cooler/reservoir. Into the trash these go.
Suspension, triple clamps and swingarm come off next for rebuilding. The suspension is going to Bruce's Suspension for rehabilitation. New bearings and seals will go into the linkage and swingarm pivots. Lots of work.
Lots of cool parts. Litespeed frame guards, Hammerhead controls, etc. Many changes to come.
Subframe, fender and airbox removed.
Time to put it on the lift, and remove the wheels, shock, forks and swingarm. Suspension compnents will head to Bruce Triplett for revalving and service.
Big, braced radiators and an oil cooler.
'06 CRF450R camshaft.
This rekluse billet clutch basket takes over for the worn out OE basket. If I kill this, I'll get a steel Hinson.
Oversize clutch cover. More oil.
New steering head bearings. Packed with aluminum based (waterproof) grease.
New upper steering bearing, packed with waterproof grease.
Honda's steering heads seal better than anyone elses, IMHO. Frame bracket for the Scott's steering damper was the wrong one for the underbar mount.
I like to use allen bolts as much as possible. Trick materials are even more fun. It makes it easier to work on the bike in the field, and I can carry less tools. The lower pinch bolts are allens too.
Anti seize is your friend. It doesn't take much.
Bruce Triplett redid the suspension - both the forks and shock were leaking and very worn. New springs, bushings and valving too. Fork Tube Savers and Seal Savers round out the package.
The big radiators and oil cooler setup.
This was the last thing that eliminated the white from Red Four.