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

We picked up the 2019 450 XC-F at the beginning of 2019, and instantly knew the bike was something special. After the first ride, we were stunned by how lightweight, sleek, and stable KTM’s newest offering was. It certainly lived up to manufacturer’s reputation of producing podium-level bikes for racers, but we wanted this to be more than just a racing bike. We wanted to take KTM’s dependability with us, whether it was slick rock riding in Moab, local single track mountain trails, endurocross races, or even trail cleaning. So, we took KTM’s beast of a 450 and broadened its uses to make it a jack-of-all-trades for any everyday rider.

Motor

One of the main talking points of the new 450 XC-F was the changes that were made to the motor. While the lower profile cylinder was definitely a plus, many consumers weren’t fans of the new power characteristics. For those that were seeking snappy power, the 450 XC-F didn’t deliver those instantly-high horsepower numbers like models in the past did. We took this into consideration and, after putting some hours on our KTM, we realized we were really having to lean on the throttle. In other words, we were doing everything we could to eek as much power out of the machine as possible. We just weren’t accessing the bike’s power fast enough, so we decided to make some changes.

The most impactful change to the bike’s power came from something fairly small: swapping out the throttle cam. Stock, the 450 XC-F comes with what KTM calls their “gray” throttle cam. It offers a longer pull, one that’s too long for our liking. So, we switched out the gray cam for KTM’s black cam. The black cam has a shorter pull, and helped us jump out of corners and accelerate more quickly without sacrificing our comfort or riding position.

Exhaust

With our motor fine-tuned, we turned our attention to the exhaust. Higher power output usually necessitates a new exhaust, but we found ourselves needing a new system for other reasons, too. After taking a spill in some hard-pack gravel, and another across some ice, we ended up damaging the stock setup. For our replacement, we went with the best and installed the FMF Full System.

Unbelievably lightweight and durable, the new system gave us the peace of mind the stock exhaust did not. It also performed better, giving us reliable power through the rev range.

Playing it Cool

Our new motor and exhaust system were all set up, but we decided that we needed one more thing: a radiator fan kit. These kits are a lifesaver on slow and technical terrain, allowing us to ride for longer without worrying about overheating our engine. We opted to install the Tusk Digital Radiator Fan Kit.

Easy to install and easier to use, the Tusk kit helped us feel more confident and secure about our motor’s performance.

Protection

Next up, we had to decide how we wanted to protect our new engine upgrades. The first addition we made was the AXP Racing Xtrem HDPE Skid Plate. The high density polyethylene (HDPE) plastic construction is 8mm thick, offering unmatched coverage. The biggest plus of this product, however, is its built-in linkage guard that is convenient and boasts a quality that’s second to none.

For more protection components, we looked to Bullet Proof Designs. Their Radiator Guard, Chain Guide Guard, and Disc Guard are all strong, billet aluminum pieces made in a variety of colorways. This helped give our bike a customized look, all while safeguarding the investments we had made.

We rounded out our safety features with the Tusk D-Flex Handguards. This bike is going to take us on a lot of adventures, so we wanted to make sure we could be ready for whatever terrain we might encounter. Plus, the guards protected our levers nicely, making them an inexpensive and effective addition.

Drive

When it came to the drive system, we already knew that Primary Drive products were what we wanted. Their chain and sprocket kits are as strong as they are lightweight, and are able to withstand the rigors of adventure riding. With their Gold X-Ring Chain and Front Steel and Rear Aluminum Sprockets, our bike was looking blinged out.

We also opted to swap out the stock dome spring washer for the Primary Drive model. This is a huge upgrade from stock as the OE washer loses its spring faster than it should. The Primary Drive counterpart is made of higher quality steel, helping it retain its spring longer.

There was only one more upgrade we needed to make to our drive system: tires and wheels. To fit our bike’s color scheme and personality, the Tusk Impact Wheels were a no-brainer. Rather than getting the complete wheel kit, we purchased the rim, hub, and spokes separately to maximize our customization opportunities. Laced with a black rim, orange hub, and black spokes, our wheels were looking fresh and ready to take on some new tires.

Our KTM needed tires as versatile as it was, and the Michelin Star Cross 5 Medium Tires did the trick. Their all-around tread is capable from slick rock to sandy trails, and their Comfort Casing Technology (CCT) provide shock absorption to reduce rider fatigue. Though these tires are already strong and lasting, we also decided to add Bridgestone Ultra Heavy Duty Tubes in the front and rear. These tubes help prevent pinch flats, keeping our tires secure no matter where we’re riding.

Handling

With the motor, exhaust, protection, and drive features figured out, our bike was finally looking the part. Now, we just needed to make sure it was riding as good as it looked. We started with the AER air forks. Don’t get us wrong, these forks are some of the best of their kind that we’ve ever seen, but there are always some downsides to air forks and their characteristics. For one thing, they tend to run high in stroke. It’s harder to get the tires to stay down in a rut or corner, and in the slower stuff like rocks or logs, the riding is just too harsh. To get us more comfortable on the bike, the forks were shipped off to Kreft Moto. Kreft specializes in WP suspension, and boy, have they found their niche. They’ve honed in their suspension skills, and have developed proprietary technology to help. In this case, we were after their Revalve Control. This feature is an external piece at the bottom of the fork that allows the rider to control or change valving without having to break anything down. That means that we can go from moto in the morning, change the suspension, and be cruising trails in the afternoon. It’s awesome technology that only Kreft is using, so we took full advantage of that as well as their attentive micro-finishing to the lower fork tubes and shock shaft. Once we got everything back, our suspension was set up to our weight, riding skill, and style, and we couldn’t be more thrilled.

Our suspension was down pat, but there was still more to do to optimize our 450’s handling. First up was the Ride Engineering Show Steering Damper. This was a great option for us. The damper is not bulky, which means we don’t have to sacrifice our bar height or comfort to accommodate for the product. When riding, the damper offers resistance when the wheel gets pulled in uneven terrain, and keeps the bike straight when it’s hard for the rider to hold on.

Ride Engineering also hooked us up with a One Piece Bar Mount. In the case of a crash, the mount helps to keep the handlebars rigid and unmoving, preventing injuries and tweaking of the bars. This is a good thing, because we want to make sure our sleek Fasst Flexx handlebars stay in prime condition for as long as possible. The Fasst bars are super strong, so they help absorb the impacts and jolts of the ride, letting us ride longer without feeling the effects.

To connect our Tusk D-Flex Handguards to the bike, we used the Tusk Flexx Bar Handguard Mounts. This allowed us to mount the warp around handguard while maintained the flexibility of the bars. We topped the bars off with the ODI Emig Lock-On Grips. The grips are the whole package: they’re comfortable, look great, and are easy to install.

Our focus on handling wrapped up with the Stegz Steg Pegz. A good pair of foot pegs should do a lot of things, and the Stegz offering checks all the boxes. Designed to grab onto the back of riders’ boots, the foot pegs keep riders in a good, forward riding position, keeping them on the bike and reliving arm pressure and fatigue. They were an awesome final addition to round out the capabilities of our KTM.

Body

With the internals of the machine taken care of, it was time to focus on the body. There were a lot of things we changed, but one thing we decided to keep the same was the gas tank. The stock tank is already slim, not to mention it already gives us the range that we need.

For the changes, we decked out our machine with Acerbis products. Their X-Brake Disc Guards, X-Brake Frame Guards, X-Power Crank Case and Clutch Cover and Plastics Kit played to the factory look of our bike. Their colorways were the perfect complement and, with a full matte graphics kit and seat cover from Attack Graphics, our bike was finished off and easily the best looking bike on the trail (it will be, too, until you do this build for yourself).

The Wrap-Up

And just like that, our build was complete. Our KTM’s power was restored with a little spunk and spirit to take us from trail, to track, to rock, to race with enough ease for most everyday users. In the end, our 450 XC-F build is only the beginning of many adventures to come.

Tell Us What You Think

What do you think about our build? Did we leave anything out? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Fasst Flexx 1 1/8 Handlebar	KTM Lock-On Throttle Tube	Ride Engineering Handlebar Mount
Ride Engineering Bar Mount Bushing Kit	Ride Engineering Showa Steering Damper and Steering Head Stabilizer Bracket Kit	Tusk D-Flex Pro Handguards
Tusk Flexx Bar Handguard Mounts	ODI Emig Lock-On Grips	Tusk Front Brake Reservoir Cap
Tusk Rear Brake Reservoir Cap	AXP Racing Xtrem HDPE Skid Plate	Acerbis Plastic Kit Orange/Black
Acerbis X-Grip Frame Guards	Attack Graphics Graphic Kit	Attack Graphics Factory Seat Cover
Tusk Billet Steering Stem Nut	Tusk Oil Filter Cover	Tusk Front Brake Rotor
Tusk Rear Brake Rotor	Tusk Oil Filler Plug	KTM FMF Factory 4.1 RCT Titanium Silencer with Carbon End Cap
KTM FMF Titanium Megabomb Plus Header	Primary Drive Alloy Sprocket & Chain	Acerbis Chain Guide/Slider Kit Black
Bullet Proof Designs Chain Guide Guard	Primary Drive Dome Spring Washer	Tusk Folding Shift Lever
Tusk Aluminum Brake Pedal	Stegz Steg Pegz	Tusk Kickstand
Tusk Nyloc Axle Nut	Tusk Axle Blocks	Bullet Proof Designs Radiator Guards
Tusk Digital Radiator Fan Kit	Trail Tech Stator Kit (80 Watt)	Tusk Billet Fork Adjuster Knobs
Tusk Impact Wheel Set	Bridgestone Ultra Heavy Duty Motorcycle Tube	Michelin StarCross 5 Medium Terrain Tire
Acerbis X-Brake Vented Front Disc Cover with Mounting Kit	Bullet Proof Designs Rear Disc Guard	Tusk Rubber Valve Support/Seal
Tusk Rim Lock Nut/Spacer

The Honda CRF450R is an iconic bike not only in Honda’s lineup, but also in the history of four-strokes. In 2002, Honda dropped the first ever 450cc race bike – the CRF450R – and the model completely changed the game as far as competitive 4-stroke race bikes go. After a few years’ worth of refinements and upgrades, the model quickly became the cream of the crop, with 2005-2008 standing as the golden years for Honda’s 450 race bike.

So, when we saw a totally roached ’05 CRF450R go up for sale, we got an idea: What if we restored this revolutionary bike to its former, golden-era-racing glory? We knew it would take a lot of blood, sweat, and TLC, but we were determined to have a reliable, competitive race bike by the time we were done. So that’s what we did, and we even filmed it all in an in-depth, totally comprehensive video series called Roached2Racing. Here, we’ll just go over the parts and accessories we added, but you can use this article and that video series as a resource and fun way to look at restoring an old four-stoke. Check out the stand-alone build video below, and keep reading for an explanation of all of the mods we made!

Engine

The first thing we tackled on our roached-out Honda was the engine. We picked up the 14 year old bike knowing it didn’t run, so we were prepared to go through the engine from top to bottom. Starting with the top end, we replaced the worn out piston, bearings, crank, seals, and gaskets with the Wrench Rabbit Engine Rebuild Kit. Next, we made sure our head got some fresh valves, then moved down to the bottom end to replace those bearings, too. With some all-new transmission components added, our Honda was officially running again. There were still a few more engine issues we wanted to address, though – starting with the clutch.

With how worn the other engine components were, we weren’t surprised to find a trashed clutch basket and fried clutch plates in our Honda. We decided to go with all aftermarket replacements, first adding the Hinson Momentum Clutch Basket. A common problem with older 450 four-stokes is stalling and flaming out, but the Hinson clutch is an effective solution. Essentially the same as a flywheel weight, the weighted basket adds rotating mass to the engine, addressing the problem and adding some extra performance in the off-road, technical, gnarly conditions we want to ride our CRF in. With the Tusk Competition Clutch Kit and Billet Proof Hinson Clutch Cover added, our clutch was like new, refreshing the look of our engine while toughening it up a bit.

The final clutch upgrade we made was further up the bike with the Magura Hydraulic Clutch. Older 450s are notorious for having a hard clutch pull, and that can really take a toll on you after you after a few hours of riding or racing. To combat that fatigue, we made the switch to a Magura system. The easy installation (the system is essentially plug-and-play) provided a night-and-day difference in clutch-pull. Magura’s consistent, one finger pull is such an improvement from the stock setup and was easily one of the top upgrades we made to our CRF.

Continuing up the bike, we noticed that our stock radiator hoses were leaking. This was an easy fix to make, and we replaced the old hoses with Mylers Radiator Hose Kit. It was a must-have adjustment to make, while still serving as a nice accent to our engine. We also decided to add an hour meter. With our fresh engine upgrades, we’re not taking any chances with maintenance. An hour meter helps keep us on a regular maintenance schedule so that we can keep our new bike in top condition.

To round out our engine upgrades, we made some final adjustments to the intake and exhaust. The old air filter was replaced with a Tusk First Line Air Filter, and the carburetor was rebuilt with the Tusk Carburetor Repair Kit. With our new and improved intake, it made sense for our exhaust to follow suit. The stock header was munched, anyway, so we installed a full FMF system, including the spark-arrested Q4 silencer. Lightweight, durable, and dang good looking, the full system was the perfect addition to our refreshed engine.

Altogether, the engine upgrades all stayed within stock specs, keeping the bike reliable and still really fun to ride.

Chassis and Drive

As with any bike this age, parts are likely going to be worn out, loose, and ready for replacement. That was true for all of the bearings on our 2005 CRF. We kicked off our chassis and drive upgrades with a whole set of new bearings from Pivot Works. New steering stem, swing arm, shock, linkage, and wheel bearings revolutionized our bike’s feel and helped get everything working and moving properly again.

Once the new bearings were added, the next moving part we had to tackle was the wheels. The front wheel that came on the bike was cracked, giving way to seized spokes and nipples. Repairing them wasn’t worth the manpower, not to mention the safety concerns, so we opted for a full wheel replacement. We knew that we wanted our bike to have a red and black color scheme, so we decided to build a custom Tusk Impact wheel set with black rims, black spokes, and red hubs. The new wheels provided just what our bike needed – long-lasting performance with some extra flash.

When it came to the tires, we didn’t hesitate. A personal favorite of ours is the Dunlop MX52, so that’s what we mounted on the front and rear. They looked great on our new wheels and are an awesome option for desert racing - something we plan on doing with our rebuilt CRF450R. That’s why we also added some Bridgestone Ultra Heavy Duty Tubes. Sure, they add a little extra weight, but it’s well worth the protection from flats during a race or typical off-road riding.

Next up, our bike was in desperate need of a new chain and sprockets. Adding the Primary Drive Chain and Sprocket Kit with an X-ring chain and stock gearing was the best option for us. The kit even came with a counter shaft spacer, giving us just enough to safely run the X-ring chain without rubbing the case.

The brakes on our Honda needed a little TLC, too. All of the brake components were still stock – old fluid, squishy brake lines, worn rotors, and shot brake pads. It all needed to go, and it all got replaced with top-of-the-line Tusk parts. With steel braided brake lines, stainless steel brake rotors, and sintered metal brake pads, our bike had improved stopping power comparable to even that of newer bikes.

Protection

Protecting our engine upgrades was the next obvious step for us. We’ve found that investing a little money in protection items at the start saves headaches and more costly repairs down the road, so we didn’t hold back on our upgrades. First up was a skid plate. Acerbis has a plastic option that offers great coverage for both the undercarriage and the side of the engine, along with quick installation and removal for easy maintenance.

When we bought the bike, the radiators were bent and mangled. We did our best to straighten them without doing more damage, and were ultimately able to salvage them. To prevent them from going back to their old crooked ways though, we added some Works Connection Radiator Braces. The braces are a great preventive measure, one that we think is well worth the investment as they will save us the time and money of trying to straighten bent radiators, or purchase new ones, down the road. An extra preventative measure we took with the radiators was swapping out the original radiator cap for the Tusk unit with a built-in temperature gauge.

To further protect our bike, we also added the Rear Billet Disc Guard from Tusk. It’s a huge upgrade from the stock plastic (if your bike still has it), and it nicely covers all of your bike’s brake components.

Last but not least, we wanted a way to protect our hands and our levers. We opted to install our favorite wrap-around style handguards, the Tusk D-Flex Pro Handguards. Designed to be sturdy and durable with a safe, close fit, the handguards are a must-have for any form of off-road riding and racing.

Rider Triangle

Once the bike was consistently running and well protected, we started fine-tuning the performance. The process began with the rider triangle, or the three parts of the bike the rider touches: the handlebars, the pegs, and the seat. Now, Hondas have always been known for having spot-on ergonomics right off the showroom floor, and this 2005 model is no different. That being said, small, personalized adjustments to the triangle can make noticeable improvements to your bike’s feel and performance.

Starting with the handlebars, we installed a set of ODI CFT Podium Handlebars in the Country Boy Bend. This bend measures up closely to the Renthal 927 bars that came stock on the CRF450R in 2005, and it’s a bend that is the perfect blend of comfort and forgiveness for our riding style. To further trick-out the bars, we added some fresh ODI V2 lock-on grips. Easy to install, easy to remove, and extra comfy, the grips were a flashy accessory for our new bars.

Next, we shifted our focus to the foot pegs. On our bike, everything by the feet was stock, including the foot pegs, shift lever, and brake lever. We decided to replace everything. The stock pegs were ditched for the Tusk Billet Race Foot Pegs, and, trust us, the wider foot bed and extra grip were well worth it. Along with the new shift lever and brake pedal, our bike had noticeably improved feel and control.

To complete the triangle, our bike’s seat got some refinements. Under the old seat cover was the stock foam, still soft and in decent condition. So, with the original foam, we installed a new Factory Seat Cover from Attack Graphics. It grips when you’re on the gas, is consistently comfortable, and had an option that played right into our red and black color scheme – it was the perfect fit for our bike.

Suspension

Though Hondas are also known for having great stock suspension, our stock setup needed some freshening up. We decided that, before just sending the suspension off to be professionally tuned, we wanted to see what we could do on our own with the stock components. So, we went through the forks and shocks, added all new Pivot Works components, and replaced the oil. After spending some time adjusting the sag and clickers, we were pleasantly surprised with how well-sprung the bike felt and how well it rode in our preferred off-road conditions.

Bling Bling

With the bike fully functional and thoroughly fine-tuned, it was time to focus on the aesthetics. You’ve got to look good while you’re going fast, so we went all-out with the blingy accessories. For style and function, we added the Acerbis Oversized 3.2 Gallon Tank in Natural. 3.2 gallons is the standard size for desert racing, and the natural color gave our bike a nice accent.

For plastics and graphics, we put together an Acerbis full plastic kit in red and black with a full-custom set of Attack Graphics in their new matte finish on top. To go along with that, we powder coated the frame, triple clamps, swingarm, and sub frame. The black finish fit in nicely with our plastics and graphics, and really brought the color scheme full circle. Some anodized components were the final accessories to get installed, serving as an easy and cheap way to completely customize our bike and give it a little more personality.

The Wrap-Up

By the end, our bike was everything we hoped it would be – reliable, competitive, and super fresh. We had a blast building on our CRF450R, but it’s been even more fun ripping it through rides and races. If you have an older four-stroke, or are just interested in what it takes to do this type of build, be sure to check out the Roached2Racing series to get an in-depth look at how we did it!

Tell Us What You Think

Do you think our 2005 CRF450R can compete with the new 2020 models? Are you dying to invest in an old four-stroke now? Let us know in the comments below!

Parts Available at Rocky Mountain ATV/MC
Tusk Competition Clutch Kit with Heavy Duty Springs	Wrench Rabbit Engine Rebuild Kit	FMF Q4 S/A Silencer
FMF Power Bomb Header Pipe	Hinson Billetproof Clutch Cover Black	Hinson Momentum Clutch Basket w/ Cushions
Tusk 4-Stroke Oil Change Kit Pro-Honda HP4M Synthetic Blend 10W-40	Tusk First Line Air Filter	Tusk Carburetor Rebuild Kit
Tusk Fuel Mixture Screw	Tusk Radiator Hose Kit Red	Acerbis Skid Plate
Tusk Impact Universal Linkage Guard	Tusk Billet Rear Disc Brake Guard	Tusk High Pressure Radiator Cap with Temperature Gauge 1.8 Bar
Works Connection Aluminum Radiator Braces	Tusk D-Flex Pro Handguards	Tusk Impact Rim - Front
Tusk Impact Rim - Rear	Tusk Motorcycle Spoke Kit - Front	Tusk Motorcycle Spoke Kit - Rear
Tusk Impact Motorcycle Hub - Front	Tusk Impact Motorcycle Hub - Rear	Tusk Aluminum Front Wheel Spacers Kit
Tusk Aluminum Rear Wheel Spacers Kit	Tusk Motorcycle Rim Lock	Pivot Works Swing Arm Bearing Kit
Pivot Works Steering Stem Bearing Kit	Pivot Works Shock Bearing Kit	Pivot Works Linkage Rebuild Kit
Primary Drive Sprocket Bolt and Nut Kit	Primary Drive Alloy Kit & Gold X-Ring Chain Rear Sprocket	Primary Drive Rear Chain Guide
Primary Drive Chain Roller	Acerbis Chain Slider	WPS Rim Strip
Bridgestone Ultra Heavy Duty Motorcycle Tube	Bridgestone Battlecross X30 Intermediate Terrain Tire	Tusk Brake Rotor Bolt Kit
Tusk Aluminum Brake Pedal Red Tip	Tusk Brake Pad - Sintered Metal	Tusk Brake Pad - Sintered Metal
Tusk Oversized Floating Typhoon Brake Rotor Kit, Front	Tusk Stainless Steel Typhoon Brake Rotor, Rear	Tusk Front Motorcycle Steel Braided Brake Line Standard Length
Tusk Rear Motorcycle Steel Braided Brake Line Standard Length	NGK Iridium Sparkplug	Tusk Billet Start/Kill Switch
Tusk Multi-Function Tach/Hour Meter	Tusk Nyloc Axle Nut	Tusk Rear Brake Clevis
Tusk Aluminum Oil Filter Cover	Tusk Billet Bling Kit	Tusk Billet Aluminum Steering Stem Nut
Acerbis Replica Plastic Kit	Acerbis Lower Fork Protectors White	Acerbis Air Box Mud Flap Black/td>
Attack Graphics Factory Seat Cover	Attack Graphics Custom Blitz Complete Bike Graphics Kit	Acerbis Fuel Tank 3.2 Gallon
Acerbis Front Number Plate	Pivot Works Fork Kit	Bel-Ray High Performance Fork Oil
Pivot Works Shock Rebuild Kit	Bel-Ray HVI Racing Shock Fluid	Tusk Brake Lever
Tusk Clutch Lever	Tusk Folding Shift Lever	Tusk Kick Starter
Tusk Billet Race Foot Pegs	Tusk Universal Rubber Mounted Handlebar Clamp Kit	Tusk Throttle Cable
Odi V2 Half Waffle MX Lock-On Grips	ODI CFT Podium Handlebars Country Boy Bend	ODI Grip Donuts
Magura Hydraulic Clutch