My 2008 Honda CRF450R project

Hi all, just wanted to share some emotions of my last winter project bike. It had several neat features but was in pretty bad shape though - the piston ended it's life cracking. This was a call to rebuild the bike starting with the engine.

So this was what we did:

We stripped the engine down to install new bearings

014crf450reclbearings.jpg

015crf450reclbearings.jpg

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017crf450recl.jpg

013crf450reclbearings.jpg

then the seals

020crf450reclseals.jpg

018crf450recsealsjpg.jpg

019crf450reclseals.jpg

followed by a new oil pump

021crf450recloilpump.jpg

and transmission which had broken down (had a broken fifth gear)

022crf450recgearbox.jpg

023crf450recgearbox.jpg

024crf450recgearbox.jpg

025crf450recgearbox.jpg

026crf450recgearbox.jpg

I will post more pics of the project soon. Cheers.

Edited by kba-pro

Great project, keep it coming!

Friggin jigsaw puzzle

Nice project and photos.

jeff

Friggin jigsaw puzzle

I wish it was as easy as a jigsaw puzzle then I could do it! Nice job very clean :thumbsup:

any pics of the bike ?

That is how you do it kids, a clean organized work area... Keep up the good work and keep us posted.

any pics of the bike ?

Be patient, the picture will start coming together very soon!

And to others - thank you for the good words :thumbsup:

So there we go - the crankshaft taken out and ready to recieve a new HOT ROD.

027crf450reccranckshaft.jpg

028crf450recconnectingr.jpg

029crf450reccranckshaft.jpg

and into the engine block it goes

030crf450r0eclcrancksha.jpg

it's time for fresh gaskets

031crf450recgaskets.jpg

032crf450reclgasket.jpg

so the internals are all in place - it's time to take care of the engines' right side starting with brand new bearings

033crf450recrbearings.jpg

034crf450recrbearings.jpg

035crf450recrbearings.jpg

036crf450recrbearings.jpg

037crf450recrbearings.jpg

038crf450recrbearings.jpg

the bearings are now installed and ready to get covered by fresh seals

039crf450recrseals.jpg

so here is our rebuilt CRF450R block closed up and bolted together

040crf450r27eclr.jpg

041crf450reclr.jpg

I will post more pics soon enough (:

Oooh, that's my bike! I can see this thread being an all time favorite. Good stuff enjoy the rebuild.

Dan

Now for the oil pickup pipe and sprocket gear -

042crf450recloilpumpspr.jpg

043crf450recloilpumpspr.jpg

Once they are in place it's time to install the gear-shift mechanism

044crf450recorgearshift.jpg

045crf450recorgearshift.jpg

046crf450recorgearshift.jpg

In order to keep the engine well balanced a balancer shaft is necessary. This is how it's beeing installed:

047crf450recbalancersha.jpg

048crf450recbalancersha.jpg

049crf450recbalancersha.jpg

Now for the kick-starter

050crf450recorkickstart.jpg

051crf450recorkickstart.jpg

It is now time to install the Rekluse Z-start pro clutch starting with Hinson basket

054crf450recorclutch.jpg

055crf450recorclutch.jpg

056crf450recorclutch.jpg

057crf450recorclutch.jpg

058crf450recorclutch.jpg

the clutch plates

059crf450recorclutch.jpg

060crf450recorclutch.jpg

and the Rekluse top

061crf450recorclutch.jpg

062crf450recorclutch.jpg

063crf450recorclutch.jpg

064crf450recorclutch.jpg

065crf450recorclutch.jpg

066crf450recorclutch.jpg

067crf450recorclutch.jpg

bolt it together

068crf450recorclutch.jpg

069crf450recorclutch.jpg

and there is the complete clutch mounted on the engine!!

I was so impressed until the second to last pic where you're torquing the clutch cover. I had visions of you wearing a white smock with surgical gloves. jk.

This is a great thread and very nice work. Next time I need an engine rebuild can I send it your way?

Keep the pics coming. :thumbsup:

I was so impressed until the second to last pic where you're torquing the clutch cover. I had visions of you wearing a white smock with surgical gloves. jk.

This is a great thread and very nice work. Next time I need an engine rebuild can I send it your way?

Keep the pics coming. :thumbsup:

Absolutely! My home page will be ready very soon where you will be able to find whatever you are interested in and just order it whether as a product or a service! Keep in touch!

cheers, kba-pro.

i dont see how you take so many pictures! when i rebuild motors my hands get so greasy that it would drown a camera!

any reason u went with the z start pro and not the EXP or EXP CORE?

any reason u went with the z start pro and not the EXP or EXP CORE?

We liked the Z-start pro better because it suits our riding skills more than EXP Core. We didn't do that much of choosing.

Starting next: Prox camchain

070crf450retecamchain.jpg

071crf450retecamchain.jpg

Followed by the flywheel

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The right engine cover is ready to be installed so now to take care of its' sealing

073crf450recorseals.jpg

074crf450recorseals.jpg

075crf450recorseals.jpg

and bearings

076crf450recorbearing.jpg

077crf450recorseals.jpg

and the gasket of course

078crf450recorgasket.jpg

Only the clutch cover remains

079crf450recor.jpg

And here it is!

080crf450recorclutchcov.jpg

So now it's time to install the Boyesen waterpump

081crf450recorcoolerpum.jpg

082crf450recorcoolerpum.jpg

083crf450recorcoolerpum.jpg

taking care of the seals...

084crf450r70ecolseals.jpg

085crf450recolseals.jpg

Here is the ignition module installed

086crf450recol.jpg

and the gasket

087crf450recolgasket.jpg

The FLO reusable oil filter. It's good because it can be washed after every oil change.

088crf450recoloilfilter.jpg

089crf450recoloilfilter.jpg

090crf450recol.jpg

Coming up: the piston and everything..

So awesome, such a great way to learn about the internals of a motocross engine (japanese). Could you email me a rar/zip file of all your pictures. I'd like to have them for when I take on an engine rebuild. mitchthegreat@g*ail.com Thanks!

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