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It’s a simple fact: machines are getting more fun to ride. We can’t be the only ones that have noticed this, right? With each passing year and each improvement to power, handling, and performance, the machines have gotten faster and sleeker. The Can-Am Maverick X3 Max RS Turbo R certainly has. When it came out a few years ago, the machine was a class leader. Now, it’s a class dominator, combining cutting-edge technology with pure speed. That’s why Can-Ams swept the 2020 King of the Hammers podium, and that’s why we were so eager to get our hands on one and start retrofitting it from top to bottom.

Comfort

Off the showroom floor, the Can-Am Maverick X3 Max RS Turbo R didn’t need any adjustments to its handling or power. For us, this build was all about finding the right parts to fine-tune the machine for our particular riding style. So, we went straight to comfort - those are some of the most fun accessories to add, anyway. Luckily, we had a huge selection of Can-Am aftermarket parts and Can-Am OEM parts to choose from.

The first accessory we would’ve added was a UTV roof, but the Can-Am already came with a high-quality plastic roof. This is a big thing – a roof offers shade, protection from the elements, and protection in the event of a crash, and it’s nice to see that Can-Am worked to include one on their new machine. So, we moved onto the next accessory, a half windshield. With the half design, we’ve found that we get the air flow we want in the warmer temperatures, plus some coverage and wind-blocking during the colder season. Plus, the windshield can help deflect branches or other trail hazards on those tight, technical, and tough trails.

To continue enclosing in our cab, we moved on to a rear window. Tusk’s Polycarbonate Rear Window did the trick, most noticeably eliminating the dust that all too often swirls around the cab during a ride. The doors were the final feature we needed to completely close in the cab, and we decided to go with the Can-Am Aluminum Half Doors on the front and rear doors. Like the front windshield, the half design on the doors allows for airflow while still providing protection and security by keeping debris out and limbs in. We also chose these doors for their aluminum construction. Durable, lightweight, and easy to install, the doors were the ideal addition to our machine. As an added bonus, the doors come with latches that are easier to use than the strap handles that came stock.

The last of our comfort items was another must have for us: a side mirror. A rear-view mirror is important, too – keeping an eye on everyone and everything in a four-seater is no small task – but having a side mirror is a game changer. Not only can you see some of what’s behind you, but you can gain a useful perspective of the terrain around you. The Tusk Pivot UTV Mirror accomplishes this, in a way better than most. Wrapped in a cast aluminum housing, built strong, and designed with a little modern flair, the Tusk side mirrors are the perfect addition to any machine. Their key feature, though, is their breakaway design. That, coupled with their ability to mount on any machine’s stock location, round out the powerhouse product’s features.

Function

With comfort taken care of, we decided to squeeze a little more function out of the Can-Am. For us, that meant installing parts of Tusk’s three-piece rear cargo system. It’s a three-piece system not because the parts come together but because they can all be attached to one another. Not all three are required for installation, though – the modular system has the options for just about every riding style and need.

Our system started with the Tusk Impact Rear Bumper. Powder coated heavy-duty aluminum, the bumper mounts directly to the frame without any modification. The Tusk Cargo rack was mounted next. The Maverick X3 Max RS Turbo R has a bed, but it’s not very big, so the cargo rack helped give additional space and provided multiple tie-down points for even more cargo options. A different way we could’ve gone was to install the Can-Am LinQ 12 Gallon Trunk Box - it fits the look of the machine and mounts easily – but we opted for the rack that was a little more open with extra tie-down points. Last was the Tusk Spare Tire Carrier that connected the full system together. It’s important to bring a spare on the trail, and also important to have something to help you install it. So, a scissor jack was mounted to the side of the machine, along with a fire extinguisher for extra safety.

Tires and Wheels

The tires the Maverick X3 Max RS Turbo R came with weren’t bad per se, but their tread pattern was dated and they were only 30” tall. For a machine that’s already pretty low to the ground, we knew we needed to make some changes. Off the stock tires and wheels went, and on the Tusk Terrabite Radial tires and Tusk Nebo Beadlock wheels went. It was an easy switch to make for both the tires and wheels. With an additional 2” in height and a much more aggressive tread pattern, the Terrabites were well-suited to our preferred style of riding. Truth be told, they’re our favorite all-terrain tire on the market right now. The wheels are favorites, too, especially because of their beadlock design. The difference between standard wheels and this beadlock design is the beadlock ring. When the tires get mounted on the beadlock rim, the ring gets installed over the lip of the tire, pinching it to the wheel and keeping it mounted even at low PSIs or through aggressive rock crawling. The peace of mind that your tire isn’t going to get knocked off the rim on your ride is worth every cent of the upgrade.

Interior

The final stage of our build focused on the interior of the UTV. We already mentioned that the rear bed was light on storage, so we decided to fit our machine with a little more and install a few Can-Am bags. Can-Am brand, the bags look right at home in the machine, and their molded design keeps them firm even when they’re not packed full. With upper door bags, a bag between the seats, and the overhead bags, our Can-Am's storage capacity increased greatly. We still had one more trick up our sleeve, though: The Tusk Rear Cargo Rack. If you have a four-seater but don’t ride with passengers that often, the Tusk system converts the entire back of your machine into a cargo space with racks. With the rear seats gone and rack in, you have a flat surface with multiple tie-down points to maximize the storage capacity of your machine.

One accessory we would’ve added had our machine not come with it was a 4- or 5-point harness. If you have a machine that doesn’t have harnesses, you should consider investing now. With several protection points, they’ll help keep passengers in the vehicle in the event of a crash.

A Few Extras

With comfort, function, the tires and wheels, and the interior of our machine retrofitted to perfection, just a few more extras were needed to finish off the build. First was the Tusk 12” light bar. Mounted on a shock tower, the lightbar has a sleek, seamless look and adds extra visibility on the trail. Second, we rigged up the Tusk Lighted Whips. They add some style to your flags if you have them, and some personality to your machine if you don’t. Plus, the lighted whips have hundreds of color combos, making it one of the most customizable accessories on your machine. Third, we made a customized graphics kit with Attack Graphics to tie all of the other parts and accessories together. It was the cherry on top of one good looking machine.

All Wrapped Up

The Can-Am Maverick X3 Max RS Turbo R didn’t need many changes from the showroom floor, but the changes we did make really took the machine to the next level. We now have an aggressive rock crawling machine, and we couldn’t be happier with how its performing. Check out the parts list below for everything that we added, and head to our YouTube channel to see all of the other cool builds we’ve been working on.

Tell Us What You Think

What do you think of Can-Am's new UTV? What parts would you have added to it? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Tusk Impact Rear Bumper	Tusk Seat Cargo Rack Kit Rear	Tusk Modular Spare Tire Carrier
Tusk UTV Scissor Jack Kit	Tusk Removable Half Windshield Clear - Scratch Resistant	Tusk UTV Polycarb Rear Window Clear - Scratch Resistant
Tusk Shock Tower LED Light Bar Kit	Tusk UTV Horn & Signal Kit - Without Mirrors	Tusk Terrabite® Radial Tire
Tusk Nebo Beadlock Wheel	Tusk LED Dual Lighted Whip Kit	Tusk Heavy Duty Adjustable Flag Mount
Tusk Pivot Folding UTV Mirror Kit w/A-pillar Mounts	Can-Am Front Aluminum Half Doors	Can-Am Rear Aluminum Half Doors
Can-Am Overhead Storage Bag	Can-Am Shoulder Storage Bag	Can-Am Quarter Door Storage Bags
Can-Am LinQ Trunk Box	Tusk UTV Fire Extinguisher Kit	Attack Graphics Pheonix Complete UTV Graphics Kit
Yeti Tundra 35 Cooler

We’ve been interested in the CRF450X since it first came out in 2005 but became even more interested when Honda announced a new 2019 model. We’d had the chance to ride a ‘17 CRF450RX and had really gelled with it, so we were hoping we’d have the same experience with the new 450X. We were looking for a bike with a wider gear ratio and more flywheel effect, and that was just what the 2019 CRF450X was on paper. So, we pounced on the opportunity to ride and outfit the newest version. We bought our ‘19 brand new and took our time with it, resulting in this long-term test and build.

A Weighty Issue

The first thing we noticed about our new CRF450X was that it just looked heavy. Part of that could be because it shares so many components with the CRF450L, but we were curious enough to put the 450X on a scale. For fun, we put our new 450XCF on the scale, too – not the same bikes, but both brand new 450s. Coming in at 270 lbs., the CRF was 35 lbs. heavier than the KTM. With that comparison fresh in our mind, we got to thinking on how to make the bike lighter. We started with the normal things like removing the plastic case covers and then moved onto calculations to slim down the weight. It didn’t take much of that to realize we were headed down a rabbit hole. So, we scraped the original plan and focused the build on how we wanted the bike to handle, what the power characteristics were, how the suspension felt, and everything we could do to set up the bike for our preferred riding.

Set-Up

Setting up a bike means setting it up for how you like to ride and what type of riding you like to do. A top priority for us was making sure the CRF450X could handle itself on difficult single track. More than that, though, we wanted the bike to be versatile and generally high performing across varied terrain, including desert racing. That versatility started with the suspension. Stock, the suspension – springs, valving– was just too soft for our liking, so we shipped it off to Dicks Racing. What we got back was a dialed-in suspension with spot on settings. In fact, we didn’t get the new suspension bolted on until the night before a desert race, and it still felt great during the race. We might’ve changed one clicker here or there, but overall, the suspension was right where we wanted it. It's critical to get your suspension dialed in, especially on a heavier bike like the CRF450X. Throw a bigger rider on an already heavy bike and you’re going to need to go up in spring rates. The higher spring rates will hold the bike up high in the stroke, making it more plush because it lets the suspension move freely in the plush area of travel.

With the suspension taken care of, we shifted our focus to the handlebars. We knew from the beginning that we wanted this bike to be raced, so a steering stabilizer was a necessity for us. We opted for the Scotts Steering Stabilizer for this bike. In the high speeds, the stabilizer brings a lot of peace, along with being more comfortable during the longer rides. Since the Scott stabilizer mounts under the bars, you have to account for an extra inch in height on your handlebars. We used to like having our bars up a little higher, but we’ve come to realize we can corner better and the bike handles better if the bars can stay a little lower. That’s why we installed the Pro Taper Evo Steering Dampened Low Bend handlebars. Putting those bars on there with the stabilizer ended up putting us back at the stock bar’s lower height that we had liked. We also made sure to wrap our new bars with the Tusk D-Flex Pro handguards. An update to the already popular handguards has given them a bigger shield, and we’ve loved having them on our bike – we never run our bikes without them.

Protection

Taking a bike on races, through gnarly single track, and over logs and rocks is going to beat it up, which is why taking a few protective measures can go a long way. The stock skid plate was ok, but we were looking for just a little more protection. We opted to install to the Works Connection Aluminum Skid Plate with rubber isolators. A common complaint about skid plates is that you bolt on a rigid one and you lose some of your frame flex, but that’s not the case with the Works Connection due to its rubber isolators. Their skid plate is bulletproof, too. There are some gouges, nicks, and scrapes here and there, but the frame and cases are in good shape, so the skid plate has definitely been doing its job.

We moved on to the chain guide next. Our Hondas in the past have struggled with guides coming off of the swingarm, bending, or breaking altogether, so we installed the T.M. Designworks chain guide. It's by far and away the strongest guide on the market right now, and we’ve had no problems running it on our bike. We also made sure to install a Tusk Disc Guard to keep our rotor nice and straight with no wobble.

Performance

At a 3-gallon capacity, the IMS tank is the first thing anyone sees when they look at the bike. Though it looks big, it doesn't feel big while you’re riding – your knees fit underneath it, the tank fits well, and it doesn’t bulge out. What’s more, having 3 gallons of fuel is extremely convenient – you can go over 100 miles a tank without having to worry about how much fuel you have. The size isn’t necessary for desert racing per se, but it’s well worth it for the trail rides.

Next, we turned our attention to the exhaust. The stock system was quiet and felt a little choked up, so we decided to invest in something that was freer flowing. For us, that was the FMF Quiet Core IV. The system comes with a quiet insert that’s a spark arrestor, and if you run it in that configuration, it isn’t much louder than stock and flows much better. Remember, though, that changing the exhaust means you have to richen the fuel. JD Jetting has their fuel controller called the Power Surge 6X Fuel Injection Tuner. It allows the rider to increase the fuel to match the freer flowing exhaust. It also has a small air filter cover that we replaced to make it even more open. The combination of those things gave the bike so much more power and just made it feel so much better.

One thing that we considered doing was installing the FMF Power Bomb Header. While we didn’t end up doing it, we’ve heard good things about the Power Bomb with several riders saying it’s smooth down low with a nice, linear feel. And, if you want to get a little rowdy, you can take out the quiet core insert if you’re on a track or in an area that isn’t sound controlled. It really makes the bike bark off the bottom, albeit a little flatter. When we get tired, though, we like to ride with the insert in so that we can hang onto the bike a little longer! Either way, we’re happy with the power the 450X puts out. We’ve heard of people doing some crazy things like making it a 6-speed transmission, but we just can’t imagine getting to the point where this bike needs that.

Tires and Wheels

Moving on to the wheels and tires, we chose the Tusk Recon Hybrid tires for the front and rear. Hybrid tires are something that have come out more recently and are a combination of MX tread and a trials-tire carcass. When we were designing the Tusk tires, we were trying to hit more towards an MX tire, so it has a stiffer carcass than a full-on trials tire but still has plenty of bump-absorption and the ability to flex around and make traction. The result was a tire that hooks up like you wouldn’t believe. It’s definitely better suited for slick rock, up the canyon, boulders, and loose stuff than high speed desert racing, but for trail riding and the extreme stuff, the hybrid tire is the way to go.

And since we hate getting flats, we paired the tires with the Michelin Bib Mousse tubes. We’ve run the Bridgestone Ultra Heavy Duty Tubes in the past and in other bikes, but we wanted extra protection for our CRF450X. The Bib Mousses have been around for a while, and we’ve always had great luck with them. They’re our go-to foam insert because we know exactly what to expect with them.

For the wheels, we installed a shiny new set of the Tusk Impact Wheels. Strong, durable, and reliable, these wheels are an undeniable bang-for-your-buck. Plus, they add great color to your bike with several options for customization.

Fresh Look

Attack Graphics took care of our nearly finished CRF450X with a set of personalized graphics. With those graphics and their Rocky Mountain Seat cover, our bike had a distinct and fresh look (not to mention the seat cover is ultra grippy and comfortable).

Looks and performance wise, the stock headlight was the next thing that needed updating. We’re using the title “headlight” loosely here – what came on the bike was more of a daytime running light that we would not be confident using at night. So, we switched it out for the Baja Designs Squadron Sport LED light. The Baja Designs light fits right into the stock light’s spot and runs off of AC power with an AC to DC converter right on the light. It's a 5-minute install time at the most, and the Squadron is one of the brightest lights we’ve seen on the market.

Of course, the bike wouldn't be complete without a few extras, so we added a few bling parts here and there, a new shifter, some new levers, all new engine plugs, and the Primary Drive chain and sprocket. These parts really tied the bike together and finished it off nicely.

How’d it Do?

In the year we spent testing and working on this bike, we were able to really finetune its handling, performance, and looks to our exact riding needs. We had a lot of fun doing it, too, and now we’re just enjoying having a bike that’s not only everything we need, but everything we could want from a bike. We think we’ll be riding this one for several years to come.

Tell Us What You Think

What do you think of our bike build? What are your must-have additions, and do they match any of our recommendations? Let’s talk about it in the comments below.

Parts Available at Rocky Mountain ATV/MC
Scotts Performance SUB Mount Complete Stabilizer Kit	ProTaper EVO 1 1/8" Handlebar Steering Damper Low Bend Black	Clean Speed Steering Stabilizer Scotts Submount Cable Guide
Odi V2 Emig MX Lock-On Grips Black/Red	Tusk D-Flex Pro Handguards Black 1 1/8" Bars	Tusk Grip Donuts
Tusk Impact Complete Front and Rear Wheel Kit	Primary Drive Sprocket Bolt and Nut Kit	Primary Drive Rear Aluminum Sprocket 51 Tooth Black
Renthal Front Sprocket 13 Tooth	Primary Drive 520 ORH Gold X-Ring Chain 520x116	T.M. Designworks Factory Edition 2 Rear Chain Guide Red
Attack Graphics Custom Race Team Complete Bike Graphics Kit CR Red	Rocky Mountain ATV/MC Pro Series Seat Cover Black/White	Michelin Bib Mousse Foam Tube 90/100x21 (M16)
Tusk Recon Hybrid™ Tire	Tusk Billet Race Foot Pegs	Works Connection Extended Coverage Skid Plate with RIMS
JD Jetting Power Surge 6X Fuel Injection Tuner (NO CA)	Tusk Billet Rear Disc Brake Guard Red	Tusk Aluminum Brake Pedal Red Tip
Twin Air - Air Filter	FMF Hex Q4 S/A Silencer	Baja Designs Squadron Sport LED Light Kit
IMS Fuel Tank (NO CA) 3.0 Gallon Natural

If you work at Rocky Mountain ATV/MC, chances are you have a machine you’re working on or one you’re saving your paychecks for. Most everyone here has the itch to ride and an even bigger itch to keep up with the latest and greatest machines the industry has to offer. That said and with the rotation of so many new models and bikes coming out every year, we get our fair share of chances to ride, test-fit parts on, and just get experience with most new machines. So, when one of our team members picked up the new 2020 YZ250FX, we couldn’t wait to start personalizing the bike. We needed the bike to be versatile enough to tackle single track, desert races, technical terrain, and the occasional motocross track. With the bike’s performance, controls, and protection as our main focuses, we got to work.

Performance

Our build first focused on various areas of performance. No doubt the bike is a performer, but there were a few areas we wanted to make better. After nailing down our first impressions of the bike and getting some significant seat time in, we realized one persistent problem: often times the bike didn’t want to start. The bike wouldn’t even click - we’d have to shift into neutral and rock it back and forth to get it firing back up. With a little research, we realized we weren’t the only ones having this problem and the bike’s stock battery was likely the culprit. Some customers have had the stock battery perform flawless, but ours had an issue. Installing the Tusk Lithium Pro Battery was the first improvement we made to the stock 250FX.

With the main (and really only) issue with the bike taken care of, we moved on to the more personalized upgrades we needed to make. That started with a spark arrestor – one is required for the areas we ride. FMF’s 4.1 Anodized Exhaust System with a Carbon End Cap gets the job done and looks good doing it. The spark arrestor has a great sound and doesn’t cut out performance – on the contrary, we noticed a slight increase.

Another important factor in steep hill climbs and technical trails is cooling. Like most other riders, we like a little peace of mind when riding, and the Tusk Universal Radiator Fan Kit gives us just that. By setting a starting temperature on the fan kit, we can trust that it will kick on and give our engine some relief during those slow, technical climbs where airflow may be infrequent or inconsistent. And just to keep the coolant flowing well, we switched the stock radiator hoses for those in the Tusk Radiator Hose Kit. We’ve found the Tusk offering to be more durable than stock, and their color options give every bike a factory look well below the factory price.

Controls

Our focus then shifted to the YZ’s controls. The first modification we made here was to the handlebars. Everyone’s riding style and level of comfort is different which means the stock handlebars should always be assessed at the very least. After riding on ours, we decided to install some Fasst Flexx handlebars. We’ve been more than satisfied running the Fasst Flexx bars on other bikes and have found that they absorb vibration well, so it was an easy choice for us. We’ve even noticed that we have less soreness, reduced arm pump, and minimal fatigue after just a few rides on the new bars.

Working our way out from the bars, we decided to install all new levers as well. Plus, if you have a hard time keeping your bike on two wheels like we sometimes do, you’ll have the opportunity to invest in breakaway levers like we did. We opted for the ASV C6 levers. They perform as well as we could want and have a 6-year warranty as a bonus. Plus, they look great on the bike and feel great while riding.

Capping off our bars are the ODI V2 Emig Pro Lock-On Grips. In our opinion, these are some of the best grips you can get. Their lock-on design makes them easy to install by eliminating the need for grip glue. Every ride without fail, the grips absorb vibration and keep our hands comfortable.

With all of our new controls installed, specifically the handlebars, we realized that we didn’t have much space left up front. Since we still needed a spot for our start and kill switch, we opted for a mounted perch switch. It gave us a spot for our switches and space for the levers and handguards we wanted to install.

Moving down the bike, new foot pegs were in order. The Fasst Impact Moto Pegs fit perfectly. Not only are they wider than stock, but the Fasst Impacts are replaceable as far as the cleats go. Their design also helps them absorb vibration and impacts, making them especially useful on the rough, technical, and hard terrain we frequent.

Along with the new foot pegs, the inexpensive yet effective Tusk Aluminum Brake Pedal and Shift Lever were both installed. They are consistently high-quality and even come in cool colors. Speaking of cool colors, a Dirt Tricks Zirconium Rear Sprocket was a must-have for our YZ. You’d be hard-pressed to find anyone who doesn’t think the Dirt Tricks sprocket looks amazing. The sprocket is also a high-performer – Dirt Tricks designed it to last 6x longer than a traditional aluminum sprocket. Paired with the Primary Drive Gold X-Ring Chain and Steel Front Sprocket, our build was really coming together.

Keeping our momentum, we made an adjustment to the last point of contact: the stock seat. Going from a stock seat to a new seat with a seat cover is a night and day difference. With our new seat and an Attack Graphics Seat Cover, we felt completely at home on our bike. A customized setup like this, especially with a gripper seat cover, can even help reduce arm pump as you don’t have to grip the bike as tightly.

Some new tires, the Tusk Hybrid Recons, were a quick performance part we couldn’t resist adding. The tires are highly-rated and highly sought after for their versatile capability in varied terrains and exceptional handling in the tricky rocky parts.

Protection

Heat shields were the first protection pieces we needed to add. Yamaha’s stock shields were weak and too easy to bend, and we knew we needed something more reliable and durable. P3’s Exhaust Heat Shields were the easy choice as they’re lightweight and offer maximum coverage. Next on the list, radiator guards were installed. To keep our radiators protected from front and side impacts alike, the Bullet Proof Designs Radiator Guards offered optimal protection while still allowing us to use our radiator fan kit.

It’s a known fact that Acerbis does a great job making plastics and protection pieces, and that's why we trusted their X-Ultimate Handguards, X-Grip Frame Guards, and Chain Guide and Slider Kit to round out the protection features on our YZ250FX.

Finishing Touches

With the essentials taken care of, we had just a few extra finishing touches to add to the bike. A custom Attack Graphics graphics kit topped our plastics off for looks and protection, and a few Tusk bling parts like Front and Rear Brake Reservoir caps and Billet Brake Disc Guard added some factory-freshness on a budget.

The Finished Bike

With everything installed on our YZ250FX, we knew we’d taken an already great bike to the next level of performance, protection, and handling. We couldn’t be happier with the results and plan on ripping the bike for many years to come.

Tell Us What You Think

Do you have a new 2020 bike? What are your must-have additions, and do they match any of our recommendations? Let’s talk about it in the comments below.

Parts Available at Rocky Mountain ATV/MC
Acerbis Chain Guide and Slider Kit 2.0	Acerbis Plastics Kit	Acerbis X-Brake Front Disc Cover with Mounting Kit Blue
Acerbis X-Ultimate Handguards	ASV C6 Series Pro Clutch Lever	Attack Graphics Custom Roost Complete Bike Graphics Kit
Attack Graphics Factory Seat Cover	Bullet Proof Designs Radiator Guards	Dirt Tricks Zirconium Rear Sprocket
Fasst Flexx 1 1/8" Handlebar	Fasst Impact Moto Pegs	Fasst Rear Brake Return Spring Kit
FMF Factory-4.1 RCT Anodized System With Carbon End Cap	Odi V2 Emig Pro MX Lock-On Grips	P3 Exhaust Heat Shields
Primary Drive 520 ORH Gold X-Ring Chain	Tusk Aluminum Brake Pedal	Tusk Anodized Front Brake Reservoir Cap
Tusk Anodized Rear Brake Reservoir Cap	Tusk Billet Aluminum Engine Plug Kit	Tusk Billet Rear Disc Brake Guard
Tusk Billet Start/Kill Switch	Tusk Digital Radiator Fan Kit Universal	Tusk Folding Shift Lever
Tusk High Pressure Radiator Cap with Temperature Gauge 1.8 Bar	Tusk Radiator Hose Kit	Tusk Recon Hybrid Tire

When FMF Racing reached out to us asking to collaborate on a 2020 KTM 500 EXC-F build, we couldn’t say yes fast enough. The 500 EXC-F is already an exciting platform, but FMF had some killer ideas on how to take the bike to the next level. With their vision, our parts, and some help from a few other sponsors, we built the 500 EXC-F into an enviable off-road machine.

A Brief Look at the KTM 500 EXC-F

The 500 EXC-F has been around in some form since the late ‘80s, but has seen some serious innovation and upgrades over the last 30-something years. For 2020, the bike actually got a complete overhaul, something that hasn’t happened since 2012. Redesigned and refreshed, the 2020 500 EXC-F is equal parts competitive and innovative with a host of new features:

• Reworked chassis
• Updated camshafts, exhaust systems, and electronic fuel injection (EFI)
• Computational Fluid Dynamics (CDF) technology and a smarter coolant circuit routing to ensure optimum engine temperature in all riding conditions
• A new two-piece header pipe which can be disassembled much more easily for better access to the shock
• New high-tech lightweight chromoly steel frames

That list just scratches the surface of this exciting bike in KTM’s celebrated range of 4-strokes. Check out the table below for the full specs of the 2020 KTM 500 EXC-F to see what we were working with on this build.

2020 KTM 500 EXC-F Specs
Engine
Displacement	510.9 cm3
Design	1-cylinder, 4-stroke engine
Bore	95 mm
Stroke	72 mm
Starter	Electric Starter
Transmission	6-speed
Clutch	Wet, DDS multi-disc clutch, Brembo hydraulics
EMS	Keihin EMS
Chassis
Frame Design	Central-tube frame with double-cradle
Rear Suspension	WP Xplor PDS shock absorber
Front Brake	Brembo twin-piston floating calliper, brake disc
Rear Brake	Brembo single-piston floating calliper, brake disc
Front Brake Disc Diameter	260 mm
Rear Brake Disc Diameter	220 mm
Chain	X-Ring 5/8 x 1/4"
Steering Head Angle	63.5°

The Build

Like we said, FMF already had a few parts in mind to fine-tune the performance of their 500 EXC-F.

Engine

It’s hard to beat Rekluse’s Radius CX Clutch when it comes to off-road riding. An auto clutch, the Radius CX automatically engages and disengages, meaning all you have to do is shift and twist. When you’re navigating through rocks, roots, and rough terrain, it’s nice to have one less thing to worry about.

To go along with the new clutch, the bike was, of course, outfitted with an FMF Factory 4.1 RCT Exhaust. The full system enhanced the performance, sound, and overall look of the bike.

Chassis and Drive

Next on the list were some new wheels, so we set the bike up with a set of the Tusk Impact Wheels – black rims, silver spokes, and orange hubs. The Tusk wheels are lightweight, durable, and can even be a few lbs. lighter than most stock wheels. Plus, the wheels can be bought fully assembled or as separates, which means they can be as plug-and-play or customized as you want them to be.

Mounted on the new wheels are Dunlop Geomax EN91 Enduro tires. When it comes to off-road handling and reliability, the EN91s are tough to beat. Their tread pattern offers traction in the loose stuff and high speeds alike, and their tread compound is made to be both strong and durable. Dunlop’s Tilt Crown Blocks (TCB) can be found through the tire as well, working to improve handling, especially on rocky and stone surfaces.

We also equipped the bike with some of our in-house Tusk Typhoon Brake Rotors. Minimalistic and sleek, the rotors are the ideal blend of performance and style.

Off-Road Accessories

If it’s riding off-road, it needs a set of Tusk D-Flex Pro Handguards – it's as simple as that. Shielding your hands from roost, debris, and even a little bit of the elements, the D-Flex handguards are a great way to up your bike’s protection and give it some color.

Another necessity for FMF’s KTM was an upgraded fuel tank. They opted for the IMS 3.0 Gallon Tank. The natural color looks great, the capacity allows for longer rides, and the increase in size doesn’t look or feel bulky on the bike.

The Baja Designs XL80 LED Light Kit was another a natural fit for the 500 EXC-F. The setup offers more than the average headlight, boasting 9,500 lumens, a waterproof construction with MoistureBlock ™, and an LED life expectancy of 49,930 hours. Designed to be the optimal mix of power and performance, the XL80 is one of the best headlights on the market for off-road riding.

The apex of FMF’s off-road accessories, though, was the Voyager Pro from Trail Tech. There’s little the Voyager Pro can’t do. From mapping new routes to uploading existing GPX trails and riding areas, you’re not getting lost and you’re not missing out on anything with the Voyager handy. The premium GPS even has a “Buddy Tracking” system that uses localized radio signals to see up to 20 riders in a single group at a time. See where your friends are riding, communicate via Bluetooth, or send an emergency beacon – all possible without even a hint of cell reception.

Finishing Touches

Fitted with just a few more accessories, the bike was ready to rip. An orange-accented Tusk Folding Shift Lever, Tusk Aluminum Brake Pedal, and Tusk Billet Bling Kit tied together the look of the bike, along with a fresh graphics kit from Attack Graphics. A lesser thought of accessory, the Tusk Grab Handle was also installed, adding a major convenience factor to the bike.

The Wrap-Up

We had a blast working with FMF and the other sponsors on this 2020 KTM 500 EXC-F. After they got the bike dialed-in and personalized, FMF came down to our neck of the woods, Southern Utah, to put the bike through some real off-roading.

As you can see, it passed the test.

Check out the parts list below or visit the bike build sales page for even more suggestions for your 2020 KTM 500 EXC-F.

Tell Us What You Think

Be honest – how badly do you want a 500 EXC-F now? Did we leave any of your favorite parts off? Let us know in the comments below!

KTM OEM Parts Available at Rocky Mountain ATV/MC
Tusk D-Flex Pro Handguards	Odi V2 Emig Pro MX Lock-On Grips	Tusk Folding Shift Lever
Tusk Aluminum Brake Pedal Orange Tip	Primary Drive Front Sprocket	Primary Drive Rear Aluminum Sprocket
Primary Drive 520 ORH Gold X-Ring Chain	Tusk Racing Axle Block	KTM Front Axle Puller
Baja Designs XL80 LED Light Kit	IMS Fuel Tank	Rekluse RadiusCX Clutch
Tusk Stainless Steel Typhoon Front Brake Rotor	Tusk Stainless Steel Typhoon Rear Brake Rotor	Tusk Brake Rotor Bolt Kit Front/Rear
Tusk Billet Bling Kit	Tusk Grab Handle	Trail Tech Voyager Pro GPS/Computer
Tusk Impact Complete Front and Rear Wheel	Dunlop Geomax EN91 Enduro Tire

How can you beef-up an already beefy machine like the 2019 Can-Am Maverick Sport XR-C? Each of Can-Am’s Maverick line is exciting in its own right, but we fitted out this rock-crawler to perfection.

Most of the protection we like to add to machines like this - bumpers, a-arm guards, and a skid plate - come stock with the XR-C. With this machine already trimmed for rock-crawling, we went to work to see what we could add to increase the comfort, durability, and driving experience. Further, the parts we chose will improve not only the XR-C, but any of Can-Am’s versatile Mavericks.

Safety

The first items we added increase the safety of the machine and its passengers. The most important is the Tusk Fire Extinguisher with Quick-Release Mount. It’s quickly accessible, and is a great addition for protecting your investment. You’ll be glad it’s there, even if you never have to use it.

The next addition was a spare tire carrier. Having a spare tire in case of a flat is the fastest and surest way to make the trip back home. The Tusk Spare Tire Carrier holds the tire above the cargo space, allowing free access to coolers and other items you take with you when you wander. The tire is mounted no higher than the profile of the machine, so you can drive through your toy haulers or other enclosures with it in place. To lift our XR-C in the event we needed to replace a tire, we added the Tusk Scissor Jack and Mount. The mount can be easily attached to the spare tire carrier frame for easy accessibility.

Moving to the inside of the cab, our next safety upgrade was seat harnesses. The Tusk 4-Point Safety Harness provides an additional level of protection without compromising your vision or ability to drive the machine. The straps are easy to use and adjust, with padded shoulders for comfort, and pockets for tools, phones, and so forth. They keep you in place when the going gets rough, and safely in your seats inside the roll cage in the event of roll-over. They retain the stock seatbelt on installation, so you can fold the harness away and revert to the seatbelts whenever you want.

We next installed a horn and turn signal kit for street use. Check with the laws in your area to know whether the Tusk UTV Horn and Signal Kit will allow your machine on the streets.

We also added a Zumo GPS with Ram Mount to help with navigation. Find the trails and parks you want to see, and then return to base camp without getting lost.

Comfort

It’s crucial to be aware of your surroundings on the trail, so we added side mirrors to keep track of where we’ve been and keep us safe. We chose the Tusk Alloy UTV Mirror Kit with A-Pillar Mounts. To complement the side mirrors, we put a Can-Am Panoramic Center Mirror inside the cab. Having a clear view of what’s behind you is not only beneficial on the trails and dunes, but may also help with getting your Maverick licensed for streets in your state.

The next aspect of improved comfort is handy storage. Our favorites are the Can-Am Shoulder Storage Bag, and the Can-Am Quarter Door Storage Bags. These bags hold generous amounts of what you need handy but won’t compete with you for space. Plus, the bags come padded, keeping your knees protected and comfortable should they ever knock against the door.

A little protection from the elements goes a long way in making the ride more enjoyable. Moving to the outside, we installed an automotive-grade glass windshield. Sturdy, easy to clean, and durable, the Tusk UTV Folding Glass Windshield sports a forward air vent in the frame to let fresh air in and push dust out. For even more fresh air, simply unscrew two knobs at the top of the windshield frame to lower it onto a bracket mounted on the front bumper. Use the knobs again to hold it in place.

The windshield frame also has room for a manual windshield wiper. A natural complement to the front windshield was the Tusk UTV Polycarb Rear Window, which will keep dirt and sand off as you ride.

In addition to securing the windshield while down, the front-mounted bracket can also hold the Tusk LED Light Bar. We mounted a larger 30” Curved Light Bar Kit on the top as well. The bright LED beam lights the trail up for a double benefit of comfort and safety after the sun goes down.

Protection

The machine came stock with a skid plate underneath, but we chose to replace it with the Tusk UHMW Quiet Glide Skid Plate. The Tusk skid plate is larger, providing more coverage, and glides the machine smoothly over trail hazards. It fits the stock rock sliders and is a necessity for those Maverick trims that have no protection underneath.

Next, we added the Tusk Teton Beadlock wheels and mounted some Tusk Terrabite tires. The beadlock rims of the Teton wheels grip the tires to ensure they stay mounted, while the durable Terrabite tires resist puncture and tearing on the roughest terrain.

They make an especially effective combination for the terrain the 2019 Can-Am Maverick Sport XR-C was made for.

The Wrap-Up

In adding some comfort and safety to the 2019 Can-Am Maverick Sport XR-C, we feel we have the complete package. We have the ruggedness of a King of the Hammers rock-crawler and the security we want for a family ride.

Tell Us What You Think

Did you like this build? Did we leave anything out? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Tusk Quiet-Glide Skid Plate	Tusk 4-Point 3-inch H-Style Safety Harness	Tusk Spare Tire Carrier
Tusk UTV Scissor Jack Kit	Tusk UTV Fire Extinguisher Kit	Ram Mounts U-Bolt with Arm and Adapter for Garmin Zumo
Tusk Alloy UTV Mirror Kit with A-Pillar Mounts	Can-Am Panoramic Center Mirror	Tusk UTV Folding Glass Windshield
Tusk LED Light Bar	Tusk UTV Polycarb Rear Window	Tusk UTV Force Aluminum Roof with Spoiler
Tusk Curved LED Light Bar Kit 30"	Tusk UTV Horn and Signal Kit	Can-Am Quarter Door Storage Bags
Can-Am Shoulder Storage Bag	Tusk Aramid Terrabite Tire	Tusk Teton Beadlock Wheel

In 2019, Honda released the CRF250RX, a brand new machine tailored to off-road riders and racers.

With designs rooted in the CRF250R and aspirations set to Yamaha’s YZ250FX and KTM’s 250 XC-F, the CRF250RX is a high-performer with great handling, awesome suspension, and good power. After a few months of putting it to the test, we came up with a few accessories that we feel the CRF250RX really needed to give it better performance, keep it protected, and fine-tune it to our riding style.

In this video and article, we’ll give you our take on the bike and go over a few of the essential parts we added to really take this bike to the next level.

Let’s get to it.

Engine

The 2019 CRF250RX’s engine requires a short introduction.

In 2018, Honda overhauled their CRF250R’s engine. It was generally well received, riders citing that it pulled really hard on top, but needed a little more bottom end. Honda took that feedback into consideration and made some refinements to their 2019 engine, i.e. the engine in the 2019 CRF250RX.

With that history in mind, we were excited to ride the stock 2019 CRF250RX to see how Honda's new engine measured up. Our verdict? It didn’t disappoint – the bottom end was noticeably improved from 2018, it was decent in the mid, and was a screamer on the top. The bike seemed comparable to the KTM 250 XC-F, but didn’t quite reach the grunt of the YZ250FX. So, we set out to improve on the bottom end even more and add a few performance mods along the way.

First, we switched out the stock exhaust for dual FMF 4.1 RCT Anodized Titanium Silencers with Carbon End Caps. The FMFs are a top-of-the-line addition for the CRF250RX, helping the bike breathe better and just improving its all-around performance. Another bonus is that the silencers have the option for spark arrestors should any off road riders or racers need them. With off road riding and racing in mind, though, it’s worth noting that the FMFs are significantly louder than the stock exhaust – an expected tradeoff for the increase in performance, but a fact to be made aware of nonetheless. So, for anyone riding in sensitive areas, be sure to check that the FMF pipes don’t violate any sound restrictions.

With our exhaust breathing better, we moved onto our intake system and revamped it with the Twin Air Power Flow Intake System. This system completely replaces the stock cage, and even comes with an air filter with fire retardant foam. The new intake system, paired with the new silencers, made a noticeable difference, greatly improving the overall performance of the machine from top to bottom.

After the exhaust and intake were sorted out, we realized we were still running into a problem: In tedious and technical terrain, our bike was still flaming out and stalling. The solution? There were two things we did to remedy this:

• Turn up the idle. This may seem like a no-brainer, but even the most experienced riders sometimes forget that something so simple can make a big difference.
• Install the Hinson Momentum Clutch Basket. This is a more significant change, and therefore made a more significant impact. Coming in at 3 lbs. 4 oz., Hinson’s steel basket is almost double the weight of the stock basket. That weight gain may seem excessive to some, but it’s actually what makes the Hinson so effective. The extra weight acts similar to (if not the same as) a flywheel weight. As the motor is going, the weight provides more rotating mass on the driven gear, keeping the crank and piston moving and helping the motor chug through the slower, more technical stuff with ease.

Off-Road Accessories

Once we got our engine dialed in, we looked for some accessories to make our bike more off-road worthy.

The first accessory we added was the Honda Showa Steering Stabilizer. It’s a natural fit for this Honda – the frame and triple clamp come compatible with it, and the front number plate perfectly hides it. With the reduced head shake, resistance in uneven terrain, and easy installation, the damper is a must on all of our off-road machines. This specific damper can be purchased via OE diagrams, but we also sell it as a kit containing all necessary bolts and hardware. We opted for the kit, mostly for the bolts and hardware – the damper works with an uncommon 7mm bolt, so be wary of that if you’re purchasing the stabilizer separately.

After installing the stabilizer, we added some Steg Pegz from Stegz. This bolt-on accessory may not seem like a necessity, but it truly revolutionizes the ride. Steg Pegz work with a lightweight yet strong bracket and a small rubber disc. Positioned right behind the calf of your boot, the pegs grip your boot when you stand up on your foot pegs, supporting your weight and alleviating stress on your arms. They’re a life saver in any technical and gnarly riding situations – we've even used them in desert races. It doesn’t take more than one ride to get used to them, and we’re likely to have them on all of our off-road bikes going forward.

Protection

Next up were some extra protection items for our new-and-improved CRF250RX. We started with the Cycra Full Armor Skid Plate. Out of all the skid plates we’ve tried, Cycra’s is one of the toughest. It’s thick, gives the best coverage, and has withstood every beating we’ve given it.

That being said, there is one qualm we have: the plate’s drain hole doesn’t line up with the bike’s drain bolt. This is a minor inconvenience, but it’s worth mentioning. For us though, the Cycra was well worth it, and we opt to just take off the skid plate when it’s time for an oil change rather than drill a hole (which is still something that could easily be done).

The second protection upgrade we made was the Tusk D-Flex Pro Handguards. These handguards are a staple for us, and we run them on just about all of our bikes. There’s just something about the durability, reliability, toughness, and coverage that keep us coming back every time – the D-Flex handguards are truly unmatched.

Another safety measure we took was adding the Baja Designs Squadron Pro Single LED Light. Since we like riding through summer nights and in the dark, this light is a great feature to have. Mounting right in the corner of the front number plate and with an LED life expectancy of 49,930 hours, the light gives us the peace of mind we need to ride long past the sunset.

Performance

To give our bike even more of an off-road edge, we freshened it up with the Tusk Recon Hybrid tire. While this tire hit our site not too long ago, it’s nothing new to us – a bona fide “tried and true” product, we’ve put thousands of miles on these tires, optimizing their design and performance. In the end, we couldn’t be happier with or prouder of the results. Any off-road or technical rider knows what a game-changer hybrid tires can be, and the Tusk offering is no exception.

The tires are super gummy, giving riders confidence in all of that rough, rocky, and rooty stuff and keeping the bike from getting kicked around. That said, the tires still hold up well in aggressive corners and hard accelerations and don’t feel squirrely or unreliable in the slightest.

With the Tusk tires hooking up so well and holding it down at high speeds, we decided to add the Tusk Radiator Fan Kit as a safeguard. Just because our tires can go all day doesn’t mean our engine can - at least not on its own. Tusk’s fan kit reads your engine’s temperature and kicks on at the degree you set, cooling the bike down to a safe running temperature. For us, we set our fan to kick on at 190°F and turn off once the engine reaches 185°F. What’s more, this all comes in a high-quality, reliable Panasonic motor, making the Tusk fan comparable to most factory kits.

A fan kit really is a must for technical, tough, aggressive riders as it gives you confidence that you won’t overheat or overwork your bike. That’s why we made the Tusk kit so affordable – it's a necessity for hard working weekend warriors like us, and one that can be purchased without breaking the bank or breaking after the first use.

The Wrap-Up

With those engine upgrades, off-road accessories, protection additions, and performance enhancements, our 2019 CRF250RX is refined and ready to rip. We liked the bike before, but now we’re in love and are already looking forward to where Honda will take this bike in future years.

Remember – the parts we discussed were just the necessities. For all of the parts we added to the bike, check out the table below or head to the sales page. You can also browse our full selection of 2019 CRF250RX OEM parts and aftermarket accessories.

Tell Us What You Think

Do you like what we did with this build? Are there any parts we should’ve added? What about parts that we shouldn’t have? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Tusk Chub 1 1/8" Big Bar	Tusk Billet Rotating Bar Clamp	Honda Progressive Steering Damper Kit
Odi V2 Emig Pro MX Lock-On Grips	Tusk D-Flex Pro Adventure Handguards	Tusk Brake Lever
Tusk Anodized Front Brake Reservoir Cap	Tusk Anodized Rear Brake Reservoir Cap	Cycra Full Armor Skid Plate
Rocky Mountain ATV/MC Pro Series Seat Cover	Tusk Billet Aluminum Steering Stem Nut	Tusk Aluminum Oil Filter Cover
Tusk Stainless Steel Typhoon Front Brake Rotor	Tusk Stainless Steel Typhoon Rear Brake Rotor	Tusk Rear Brake Clevis
Hinson Momentum Clutch Basket With Cushions	Hinson Billetproof Clutch Cover Black	FMF Factory-4.1 RCT Dual Anodized Titanium Silencers with Carbon End Cap
Primary Drive Front Sprocket	Primary Drive Rear Aluminum Sprocket	Primary Drive 520 ORH X-Ring Chain
Twin Air Power Flow Intake System	Tusk Folding Shift Lever	Stegz Steg Pegz
Tusk Billet Race Foot Pegs	Tusk Nyloc Axle Nut	Tusk Racing Axle Block
Tusk Digital Radiator Fan Kit	Tusk Impact Complete Front/Rear Wheel Package	Tusk Recon Hybrid Tire
Tusk Rubber Valve Support/Seal	Tusk Rim Lock Nut/Spacer Kit	Baja Designs Squadron Sport Single LED Light

Last year we picked up a CRF250L and did a full build on it to fit our needs. We liked the bike, but we really felt like Honda could do better to fulfill riders’ needs in the mid-sized adventure market. So, when we heard about the CRF450L, we truly felt this just might be the bike we were looking for from Honda.

The CRF450L is the first performance dual sport from the Japanese manufacturers that is street legal and can be plated straight from the showroom floor. Once we got our hands on one, we immediately started planning out a build to make the CRF450L a top-of-the-line adventure bike. With the right additions, it became even more versatile: a gritty performer on the trails, a smooth runner on the pavement, and a comfortable ride for long excursions. Watch the video below to checkout all of the mods we made to this bike and keep on reading to get an even more in-depth look at the parts and accessories in this build.

Luggage

Our first addition to the bike was luggage. We wanted to keep the bike light, but adventure trips require gear. To carry it, we started with the Tusk Pannier Rack system and top rack. This system fits the bike particularly well because of Honda’s strong extended sub-frame, which also provides the perfect foundation for a solid luggage setup.

Our choice of bags was the light and durable Wolfman Rocky Mountain saddle bags, and the Wolfman 303 Duffel bag. They have plenty of room to hold what you need without adding too much more weight. Wolfman offers a wide range of luggage making selecting just the right bags for your adventure easy. The Wolfman Enduro tank bag, for example, is an excellent choice for all of those items you need quick access to when out on the trail. Our bags are secured to the pannier system with the Tusk Soft Baggage mounts to make adding and removing them a snap.

Protection

The first addition in this category was the Tusk D-Flex Pro hand guards. Small, effective, and sturdy, these were our first choice, and a necessity for any off-road riding.

To protect the underside of the bike, we installed the Flatland aluminum skid plate. While the stock plastic skid plate was adequate, it can’t compare to the tough, thick, welded metal that Flatland offers. We took the worry out of any bumps and scrapes by installing the Flatland.

Comfort

An important aspect of longer rides or rougher trails is your comfort level. The first and most important addition for comfort was the Seat Concepts Comfort XL. The CRF450L’s stock seat is the same one used on the CRF450R, and is completely inadequate for longer adventure rides. The design of the Comfort XL provides a soft, wide section at the back for sitting flat on long, smooth roads, but narrows at the front for squeezing the bike when you work through trails. For a little luxury, we added the Tusk seat heater.

The next addition was the Tusk Accessory Dash Panel. It provides three spots for switches to control things such as the seat heater, lights, and anything else you might need. It also comes with a cut-out for a 12-volt power source to keep electronics charged while out on the trails.

Next, we swapped out the handlebars for some over-sized Tusk Chub Big Bars and Big Bar Clamp Kit. We liked the stronger feel and more ergonomic bend of the bigger bars. We also added Tusk grips and grip heaters. Warm hands are a must when the air gets cool at higher altitudes, and will make all the difference in cold-weather riding. We added another favorite, the Double-Take Adventure mirrors, to finish off the handlebars. These mirrors fold in to clear tight trails, but can be extended again for more open spaces.

To finish our comfort category, we replaced the stock foot pegs with the wider shape and better grip of the Tusk Billet Race pegs. The Tusk Folding shifter offers a more forgiving (and longer lasting) option to the rigid stock shifter.

Performance

The next category to cover is performance. The stock engine works perfectly for us: it powers us through all types of riding conditions, so we left it as is. Fuel range, on the other hand, was far too short to enjoy an extended adventure ride. We replaced the stock tank with the IMS 3 Gallon Fuel Tank (not available in California) to increase our range to over 100 miles.

The Dunlop D606 tires are the standard for our adventure bikes. These DOT-rated tires offer an aggressive tread and outstanding grip on-road and off. Filling the tires out are Bridgestone Ultra-Heavy Duty tubes. Ultra-tough and ultra-thick, these tubes are far less likely to pinch than their competitors, and are another staple for our adventure bikes.

Despite a nice-looking and effective stock headlight, we installed the Baja Designs Headlight, Squadron Pro/S2 Kit. To take our illumination to the next level, we use the S2 light for normal lighting, and Squadron Pro (mounted just below the S2) as the high-beam. The Baja Designs lets us push the bike even on the darkest trails.

We added the Tusk Radiator Cap with Temperature Gauge to monitor engine temperature during the more aggressive parts of our ride.

Like the engine, the suspension was excellent, and we chose not to change it. We adjusted the preload and the clickers to compensate for our luggage, but the components are all still stock.

Cosmetics

You have to look good while going fast. To enhance the bike’s cosmetics, we ordered a set of Attack Graphics to complement this already good-looking bike.

Just for fun, we also included a Tusk Billet Bling Kit to give this performer some added sparkle.

End Result

We’re very impressed with the versatility of this bike, and are pleased with the ease in which it became an extended adventurer. If you’d like to watch this motorcycle perform stock, watch our VERSUS video in which we match the CRF450L with the Husqvarna FE 501 to see how the bike stacks up against one of the top contenders in its class. If that still isn't enough, check out our newest VERSUS video comparing the CRF450L to the KTM 500 EXC-F.

Parts Available at Rocky Mountain ATV/MC
Tusk Pannier Rack System	Tusk Soft Luggage Mounts	Wolfman Rocky Mountain Saddle Bags
Wolfman 303 Duffel	Wolfman Enduro Tank Bag	Tusk D-flex Pro Hand Guards
Flatland Racing Skid Plate	Seat Concepts XL Comfort Seat	Tusk Seat Heater
Tusk Accessory Dash Panel	Tusk Chub Bars and Big Bar Adaptor Clamps	Tusk Grips
Tusk Grip Heaters	Double-Take Adventure Mirrors	Tusk Billet Race Pegs
IMS 3 Gallon Tank	Dunlop D606 Dual Sport Tires	Bridgestone Ultra-Heavy Tubes
Baja Designs Headlight Kit	Tusk Shifter	Tusk Radiator Cap with Temperature Gauge
Attack Graphics Kit	Tusk Billet Bling Kit

Ju

The CR250R needs no introduction, but we’re going to give it one anyway.

An iconic two stroke, the CR250R is well known and well loved. It’s won just about every trophy it ever could, earning accolades for pro racers like Jeremy McGrath and Ricky Carmichael. But, like all good things must come to an end, the CR250R met its end in 2007 after R&D and production on the two stroke was discontinued. Now, all that riders like us can do is scoop up used models and fix them to suit our varying needs.

That was the story for our used 2004 CR250R. The full-fledged MX bike was on sale for a screaming deal, so we pounced on it and got straight to work. Wanting to do something a little different, though, we got to work on turning the already set up MX bike into an aggressive, off-road riding, trail-railing beast. Looking at the parts and accessories we’ve added, we think it was a total success, but we’ll let you be the judge of that. Watch the video to check out the mods, and keep reading to get a more in-depth explanation of the parts and process.

Engine

When it comes to used dirt bikes, it always helps to pick one up that’s running and (mostly) working; Trust us – we’ve been down the roached road before. Luckily, our ’04 was running and working pretty well, actually, and the engine was only suffering from the common problems that most older CR models do.

Our engine upgrades started with the air boot intake system. There were some sealing issues with the air boot and the air filter, so we combated them with a new, aftermarket filter, and by siliconing the air boot to the air box.

With those issues taken care of, we moved on to the carburetor. We purchased our bike knowing that CR250Rs are notorious for having a finicky carburetor, and that we really didn’t want to have to deal with it. From the start, CRs are difficult to jet and get running perfectly – without even a major change in elevation or temperature. That wasn’t something we wanted to worry about or mess with, so we went straight for the Lectron High Velocity Adjustable Power Jet Carburetor Kit. These kits are hot on the market right now, and for good reason. Using a metering rod instead of jets, the Lectron kit self-adjusts for elevation and temperature, eliminating the need to play around with jetting. That alone was a huge benefit for us, not to mention the confidence we gained in our ’04 as we rode it through deserts and up mountains in the same day.

As we continued working through the engine, we realized that our bike was already equipped with the V-Force 3 Reed Valve. The V-Force setup is a no-brainer for two stokes, especially the CR250R. Helping throughout the power range, the system not only provides more power, but also more bottom end and more top end. We would’ve added one to our CR if it wasn’t already on there - it’s something we wouldn’t want to ride a two-stroke without.

Though the V-Force system definitely helped our bikes bottom end, we still felt like it was lacking. This is a common issue for late model CRs, but our solution was adding the Boyesen Exhaust Flange in conjunction with a new, complete FMF system. Another no-brainer, the Gnarly Toque Pipe was the best suited for our type of riding. Built to be tough, the pipe offers more bottom end bark that carries well through the mid-range. We capped it all off with the Turbine Core II Silencer - the popular, forest service approved, spark arrested addition that keeps us able to ride our favorite single-track trails here in Utah.

Trail Setup

Along with our engine upgrades, another huge facet of this built was getting our bike set up for trail riding. As we mentioned before, the CR250R is a full blown MX bike, so it needed some serious modifications to be able to manage the tighter, more technical parts of the trail. Those modifications started with the 12 oz. Heavy Flywheel Weight coming from Steahly. A weight that attaches to the flywheel, the kit helps with transition through the powerband, giving more grunt down low and more rear wheel tractability.

To work with the new flywheel weight, we set our CR up with the Rekluse Radius CX Clutch. A full auto clutch with the best components that Rekluse has to offer - this is an upgrade we cannot rave about enough. After installing it on our ’04, we noticed a laundry list of benefits, notably eliminated stalling, increased power delivery for no slipping, and longer-lasting parts that outlast stock components. The clutch cover that comes with the kit is just an added bonus, featuring a deeper cover for more oil capacity, and a billet-aluminum composition for durability and toughness in those gnarly, off-road riding conditions. And it’s worth mentioning - with the Rekluse, you really do get what you pay for; it’s a huge investment, but when you’re likely going to have to replace those worn out parts on your used bike anyway, it’s worth it to replace them with an enduring, high-quality system like Rekluse’s.

We had just a few more improvements to make, starting with the 3.1 Gallon Tank from IMS for more range on the trails and through the desert. Next, we added a shiny new set of radiators along with some flashy red radiator hoses. With just those few more additions, our CR’s trail specifications were rounded out, and we finally started feeling confident in its off-road capabilities.

Chassis and Drive

The first thing we tackled in the chassis and drive category was the wheelset. For looks and performance, we went straight to Tusk. Their Impact wheels are second to none, and their 18” rear wheel gave us the setup and forgiveness we needed for our type of off-road riding. Tires were the next step, and we opted for Michelin’s Starcross 5 Medium Terrain Tires. A personal favorite, these tires are long lasting with the same, dependable traction throughout their whole lifespan, even in a variety of terrains. With some Bridgestone Heavy Duty Tubes installed in between, our wheelset was complete.

Driving our fresh new wheelset is the Primary Drive Chain and Sprocket Kit, complete with a steel front sprocket, alloy rear, and gold X-ring chain. Not only do they look trick, the Primary Drive kits are long lasting, low maintenance, and definitely a bang for your buck.

One of the favorite chassis upgrades we made was a kickstand from Trail Tech. If there’s one thing on the trail that gets annoying, it’s holding our bike every time we stop. With the easy-to-install, easier-to-use kickstand, that nuisance was eliminated, and we couldn’t be happier.

Next, we mounted the GPR V4 Stabilizer under our bars. The stabilizer may be out of sight under there, but it definitely isn’t out of mind; GPR’s kit makes a huge difference not only on a single track where we nail rocks and roots, but also just typical off-road riding, helping to keep higher, more consistent speeds. Inspiring confidence, the setup reduces headshake and makes us feel more comfortable, and therefore more stable, wherever we ride.

It’s also important to mention the brake system on our CR. As with any other bike this age, the brake system was not up to snuff with the power and performance of new bikes. So, we wanted to get our CR’s brakes up to par and, since the brakes that came with it were worn out anyway, we replaced everything with our go-to brand for brake components – Tusk. With steel braided brake lines for the front and rear, along with some new brake rotors, our stopping power and leverage were drastically improved. Altogether, the new brake parts really brought our bike to the level of newer models.

Protection

To protect all of our shiny new upgrades, we added a slew of accessories. Starting with our new brake components, we added a Tusk Billet Rear Disc Brake Guard and a Works Connection Caliper Guard. Moving forward, we installed the super tough, nearly indestructible Ricochet Off-Road Skid Plate to protect our engine. From there, Devol’s Aluminum Radiator Guards were the best option for our new radiators. Not only do the guards brace the radiators and keep them straight, they also protect the fins and keep the radiator working like it should. The last protective measure we took was the Tusk D-Flex Handguards. Another personal favorite, the handguards offer the durability, quality, and everything else we need in a set of full wrap around handguards.

Rider Triangle

With our CR250R running well and well protected, it was time to fine-tune its performance, starting with the rider triangle. The rider triangle refers to the rider’s three points of contact on the bike – the bars, the pegs, and the seat. For the bars, we opted for an oversized set of Pro Taper EVOs. The bars give good flex for trail riding and, with some Pro Taper Pillow Top Grips on top, the bars were that much more comfortable. Grippy and sturdy, the pillow tops helped to cut down on the vibration of our older two stroke.

Another thing that helped on our bars was the Magura Hydraulic Clutch. Your bike doesn’t even need to have the Rekluse clutch for the Magura system to be a huge improvement over the stock clutch setup. With an unbelievably easy clutch pull, Magura’s hydraulic clutch consistently enhances our comfort on longer rides and keeps us from getting fatigued as easily.

Moving down to the feet, we swapped out the foot pegs that came on the bike for the Tusk Billet Race Foot Pegs. Switching out the worn – or maybe even stock – foot pegs on these older bikes for an aftermarket offering is a great way to enhance control and feeling every ride. The wide foot bed and super grippy feel on the Tusk pegs made them the best fit for us. And, since we were already down there, we also added a new shift lever and brake pedal from Tusk as well, just to round out our foot upgrades.

The seat cover was last, and it was an easy choice. We’ve run the Rocky Mountain ATV/MC Pro Series Seat Cover before, so we already knew that it was perfect for the type of riding we wanted to do. The cover’s grip helps keep us in place on the seat, and the colorway really played into the look we wanted for our CR.

Suspension

Some other fine-tuning we had to do was with the suspension. Fortunately, the setup our ’04 came with was actually pretty good. All that we did was freshen everything up – setting the sag and giving the clickers a few small adjustments. That quick touch up worked great for us, and has been working well with everything we’ve thrown at our bike.

Aesthetics

Last but not least, we had to add some bling to our new and improved CR. It wasn’t running like an ’04 anymore, so we didn’t want it to look like one. With the MX Restyle Kit from Polisport, our bike’s plastics were updated to this decade, and it made a huge difference. With a custom set of matte Attack Graphics on there, our color scheme was completed, and it really turned out fresh.

The bike was finished off with some red anodized parts – just the cherry on top – giving our CR that bling factor we were after.

In the End

After finishing our bike and taking it on some grueling rides, we were impressed with its handling, performance, and overall feel. This ’04 has never run better, and it’s well on its way to becoming our go-to trail riding machine. Check out the table below for a better look at the parts we used in this build, and be sure to like and subscribe to our YouTube channel to never miss a build like this, plus tons of other cool content.

Tell Us What You Think

Do you like how our CR250R turned out? Would you have done anything differently? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Pro Taper Evo Bars	Pro Taper Pillow Top Grips	Tusk Billet Bar Clamp
Tusk D-Flex Pro Handguards	Tusk Aluminum Throttle Tube	GPR V4 Fat Bar Stabilizer Kit
Tusk Front Brake Line	Tusk Rear Brake Line	Magura Hydraulic Clutch
Tusk Brake Lever	Ricochet Offroad Skid Plate	Tusk Skid Plate Foam
Polisport Lower Fork Guards	Polisport MX Restyling Kit	Works Connection Rear Caliper Guard
Boyesen Clutch Cover	Boyesen Ignition Cover	Polisport Mud Flap
Tusk Billet Rear Disc Brake Guard	Tusk Linkage Guard	Tusk Oversized Front Brake Rotor
Tusk Rear Brake Rotor	Tusk Brake Rotor Bolt Kit	Tusk Rear Brake Clevis
Steahly Heavy Flywheel Weight 12 oz.	Rekluse RadiusX Clutch	FMF Gnarly Torque Pipe
FMF Turbine Core II Silencer	Boyesen Exhaust Flange	Primary Drive XTS Front Sprocket
Primary Drive Rear Sprocket	Primary Drive Gold X Ring Chain	Primary Drive Sprocket Bolt Kit
Primary Drive Rear Chain Guide	Tusk Air Filter Bolt	Trail Tech Kickstand
Tusk Billet Foot Pegs	Tusk Folding Shift Lever	Devol Extreme Radiator Guards
Trail Tech Vapor Speedometer/Tachometer	Lectron High Velocity Adjustable Power Jet Carburetor Kit with 3 Inch Cable	IMS Fuel Tank
Tusk Gas Cap for IMS tank	Attack Graphics Custom Alloy Kit	Tusk Billet Bling Kit
Rocky Mountain Seat Cover	Devol Lowering Linkage Arm	Tusk Impact Wheel Kit
Michelin StarCross 5 Medium Terrain Tire	Bridgestone Heavy Duty Motorcycle Tube	Tusk Rim Lock