2019 CRF450L Mod and Farkle Fest

Discussion in 'Mechanics Garage' started by NorcalBoy, May 29, 2020.

  1. NorcalBoy

    NorcalBoy Member

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    Got a message from the shipper today, the information I sent to them to substantiate the claim was enough to justify a full refund of the retail price of the forks and the shipping from UPS. Not sure if they will fork over the cost of the mods that had been done, but I don't really give a shit about that. At this point, I don't even want them back and hope that they DON'T find them hiding somewhere in LA.....All I want is the check to help cover my new forks :Eyebrows:

    I ordered some new Zeta Racing fork caps for the forks. Zeta is a supplier of parts to Team Honda Japan. Once installed, the caps have dials so that the compression can be adjusted without tools and also come with integrated, flush mount, pressure bleed valves. Gonna drop them off to AHM on Friday so they can be installed when the new forks get assembled.

    [​IMG]

    Hoping to be off for a month or so, following the completion of the current project I'm working on. Can't wait to put this thing together, so
    I can make room for the RVF assembly and also have something to actually ride for a change.
     
  2. NorcalBoy

    NorcalBoy Member

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    After work and UPS got in the way of the project, this weekend I'm going to get a chance to get back at it and get some stuff done.

    Worked on the wheelset a little this evening. Installed the Motion Pro Armor Strip tape to cover the spoke nipples and make the inside of the wheel nice and smooth for the tubes. This stuff really helps with pinched tubes when running lower tire pressures off road. It's kind of a bitch to get it down in the valley of the rim, but it's worth it. Also installed some Warp 9 Racing bead locks to prevent the tires from spinning the valve stems out of the tubes off road. These are the lightest and best made locks I've come across, the lock shoe is CNC'd alloy with a titanium thread, capped by machined alloy bead lock nuts and spacers. Got them in black to match the rims.

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    Tomorrow the rims are going to Musselman's Honda to get the tubes and tires installed. Went with Motoz Tractionator ADV for the front, with a Motoz Hybrid Extreme for the rear. Using Bridgestone 3mm HD tubes to help prevent flats.

    [​IMG]

    I have quite a few things to get done, unfortunately the suspension will not be completed until next week, so I will try to get as much done as I can without it.
     
    Last edited: Sep 2, 2020
  3. NorcalBoy

    NorcalBoy Member

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    Got an early start and tried to get a few things done yesterday.

    Started by replacing all of the steel case bolts on the right side of the engine with ti stuff from Mettec.

    [​IMG]

    Once that was done, I got busy installing the Champion Adventures Thermo/Smog delete kit. This kit is clean way to clean up the OEM setup. They modify your OEM four way fitting off the water pump. You have to send this part to them, they modify it, and then send it back with the rest of the kit parts.

    OEM

    [​IMG]
    The small hose fitting on the right gets eliminated by machining it off, threading the interior, and installing a drain bolt and copper sealing washer.

    Modified four way installed

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    The OEM thermo housing gets completely eliminated and a CNC'd fitting is added to hold the temp sensor. When it's all installed, it looks like this:

    [​IMG]

    I refilled the coolant and checked everything for leaks, all was good. Got started installing the Works Chassis Lab flex tuned engine mounts. This is something HRC has been doing for a long time to their factory bikes. They tune the flex of the engine mounts by using mounts of different stiffness to make the chassis work better. I ended up going with the soft upper mounts and the medium front mounts. Works Chassis Labs has done a lot testing and this setup is what they recommended for me.

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    This is a comparison of one of the OEM upper frame to head mount and the WCL parts. The upper frame to head mounts are CNC'd aluminum with hard anodizing, while the front frame to case mounts are titanium. I sourced some ti bolts from Racetech Titanium to mount them up. I'm going to install these this morning. I ran out of time yesterday, as I had to drop off the wheels, tires, and tubes to get the tires mounted, a conference call for work, and I had a 1:00 pm tattoo appointment. :Boink:
     
  4. NorcalBoy

    NorcalBoy Member

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    Did a couple steps forward and one step back kinda thing the last two days. I'm all good with it, as this is the first time a lot of this stuff has been fit together and sometimes things need an adjustment or twelve. I'm trying to work through all of the bugs this weekend, so when the suspension comes back next week, it will just be a matter of bolting it all together.

    The first issue was with the Works Chassis Lab engine mounts. The front engine to frame plates were a little thicker than the OEM stamped steel plates, sooooo, the OEM bolts weren't long enough to have the nut fully engaged on the threads. Not a problem, as I was planning to replace these bolts and nuts with ti stuff, so I just went ahead and ordered a big ol' order of ti from Mettec so that all of the hardware was titanium. These are long bolts, 121 (2), 123, 134mm and this is where the most weight savings can be made. They were changed to 125 (3) and 135 mm. I also ordered up the two oddball sizes for the upper mount to head locations from ProBolt. Done.

    The mounts look pretty nice and with ti hardware they should look decent. I also replaced all of the engine case bolts and some others with ti stuff and ordered up an additional 7 or 8 to finish off the left side of the engine. With aftermarket parts...as noted earlier, sometimes they are a different thickness and require each bolt to be measured, to make sure they fit. Otherwise you can waste a lot of money in a hurry.

    Left Side Engine

    [​IMG]

    I have a new Works Connection oil filter cover, but I need to lean the moto on it's side to install it without draining the oil, so that's gonna have to wait a bit.

    I got the Vortex ECU/FI programmable controller mounted up and ready to go

    [​IMG]

    It has 10 preinstalled maps and one map that can be modified by dyno tuning....if Vortex will ever restock the tuning kit with the cables and software. I also bought the bar switch so I can toggle between two maps on the fly. The ECU also has fuel trims that can be adjusted with a basic flat blade screwdriver. Tokyo Mods set it for 5-5-5 to match the exhaust and airbox mods and I selected Map 9 as the main map, which is the best power dyno map, when running an FMF full system, an aftermarket air filter, and the airbox with the lid removed. I'll have to get it on the dyno for a test run and see where it's at.

    Next I retrofitted the front and rear calipers with full titanium kits from Titan classics in the UK. These kits come with Ti Nitride coated pistons, ti pins, etc. I added Pro Bolt blue ti banjo bolts, was gonna use aluminum ones from MotoStuff, but decided against aluminum. I also added a DLC coated ti pad pin from Racetech Titanium and mounting bolts from Mettec.

    Rear Caliper Parts

    [​IMG]

    Assembled with TM Designworks disc guard and Galfer HH pads

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    Moved to the front...this is where it kinda got weird, or at least I saw something I had never seen before....

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    The front pistons were PLASTIC with attached metal caps where they contact the pad...no thanks. Replaced them with castlellated ti nitride coated ti pistons.

    The parts

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    Assembled with all hardware in ti and Galfer HH pads

    [​IMG]

    With the calipers now done, the brake systems should be pretty solid when it goes back together.

    I got the tires mounted on the wheels by Musselman's Honda, while I hung out in parts with my buddies and watched a couple live motos of the AMA outdoor nationals from Red Bud.

    I went with MOTOZ Tracionator ADV front, and their Hybrid Extreme rear and all the other nice bits I posted from before. The wheels turned out pretty decent.

    Today I mounted up the Dirt Tricks ultra lightweight steel sprocket with Ti sprocket hardware from Mettec. I couldn't mount the Galfer Tsunami wave rotor, because I spaced out ordering the special bolts that Talon hubs require, so I placed an order for those from Mettec today. The OEM bolts are through bolts with nuts on the backside, but the Talons use a short bolt, with a very short 2mm shoulder and thread directly into the hub. No worries, on the way.

    [​IMG]

    I did have the correct length ti bolts to do the Galfer Tsunami wave rotor, so I got the front wheel finished.

    [​IMG]

    The Galfer rotor is pretty nice, as it's full floating, predrilled, and tapped to accept the speedo sensor ring. Makes the install painless. I think I'm really going to like the Galfer system that the moto is getting, fluid, lines, pads, and rotors.

    Well that's it for today..going out to drink a couple michelada's with my sis and her BF, one of my gal pals is bartending today at Bison Witches, so it should be a fun afternoon. Tomorrow is graphics day....
     
    Last edited: Sep 5, 2020
  5. NorcalBoy

    NorcalBoy Member

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    Well after having a couple michelada's and some chili con queso, I felt I had the necessary fuel to tackle my second favorite moto thing (after mounting tires)..... applying graphics. It's a very time consuming process that takes a ton o' patience and a lot of heat gun to get them right.

    I got these graphics from Decal Works. They are semi custom, which means, you get to pick whether they are glossy or matte finish, the base design, select the colors, and then add product logo's (if you choose to). I went with the T1 design in matte finish. I didn't want to overwhelm the OEM graphics, because I actually like the design, and I just wanted to enhance the look and add a little race flavor to it.

    Right side fork guard

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    Left side fork guard

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    Rear fender

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    Front fender

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    The package deal

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    I'm glad this is done and I'm pretty happy with how it all worked out. This pretty much completed all of the tasks I needed to finish this weekend, hopefully my suspension will be ready next week and I can pick it up. Headed back to work Monday, so it will be a bit before I can get going with finishing this project off. Need to get it done, the RVF engine is shipping this coming week and I really want to get the project done.
     
  6. Diving Pete

    Diving Pete Member

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    My NC24's come as standard with the plastic brake pistons.. I also thought it was strange.
     
  7. NorcalBoy

    NorcalBoy Member

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    I've seen a lot of things, but I had not seen that. Learn something new all the time. I was just glad that I was replacing them anyway. Not a fan of plastic in such a critical location.
     
  8. Jim McCulloch

    Jim McCulloch New Member

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    Top Notch brother!

    And WOW on the plastic pistons. Seems like a strange one to me also. I have never seen it.
     
  9. lsc86

    lsc86 New Member

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    Those wheels are darn sexy indeed! Have never seen a rear sprocket that thin and minimalist before, pretty impressive tech.
     
  10. NorcalBoy

    NorcalBoy Member

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    Thanks! The Dirt Tricks sprockets are lighter than the equivalent sprocket in aluminum, and they come with a 1 year warranty that even covers excessive wear. They are a bit pricey, but worth it IMO.
     
  11. Terry Smith

    Terry Smith Member

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    IIRC Brembo had a recall in the last year replacing plastic master cylinder pistons that could crack, might have been on high end Aprilias or Ducatis.

    http://www.safebraking.com/tech-why-are-some-brake-caliper-pistons-phenolic-plastic/

    https://motorbikewriter.com/update-brembo-brake-safety-recalls/
     
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  12. NorcalBoy

    NorcalBoy Member

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    The ti bolts from Mettec for the engine mounts and a few other things were delivered today and the ti hardware for the radiator braces and the rear disc shipped out today.

    The Baja Designs Squadron/Pro S2 headlight was delivered last Saturday, I just didn't have the time to go get it, before I headed back out for work.
    https://www.crfsonly.com/catalog/product_info.php/cPath/355_358_381_413/products_id/7042

    The P3 carbon heat shield for the FMF Megabomb header shipped out today. It's a nice piece that they just released to the public in the last week. Jason from P3 hooked me up big time and gave me a 20% discount.
    https://p3carbon.com/shop/heat-shie...omb-honda-maxcoverage-crf450l-450x-2019-2021/

    Tomorrow, I'm headed to Specialized Coatings in Huntington Beach to drop off a few pieces that I'm having done in black chrome ceramic. Exchanged a couple messages with former Honda HRC rider Cole Seely about the coatings he's been doing on his project moto's and he recommended these guys. Can't wait to see the final product. Cole retired after last year, due to injury at the Tampa Supercross, but he has taken up a new gig building trick offroad moto's and vlogging about it on YouTube.

    Really hoping to get a call from Brandon at AHM Factory Services this week, telling me that my suspension is ready to get picked up. I'm stoked to see how it turns out. As long as the last few orders arrive safely, those are the last pieces of the puzzle I need to get this thing done. Just need to find the time to do it, after that.

    UPS confirmed that they cannot find the forks that went AWOL at their LA facility, so now I'm waiting for the claim to be settled to see how much they are actually going to pay out for the loss...anything would be good at this point, but I'm hoping for a decent check from them. Anything will help offset the $2400 it is costing to replace them.

    More news as I get it. Thanks for following along on this.
     
  13. Jim McCulloch

    Jim McCulloch New Member

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    Wow just like Christmas! That headlight looks like it could light up a Stadium. Can never have too much light offroad.
     
  14. NorcalBoy

    NorcalBoy Member

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    It is a simple drop in replacement for the OEM headlight and maintains the Hi/Lo function of the stocker. Only the top 2 LED's are lit on lo, on high you get all 6. It is road legal, otherwise I wouldn't have done it.

    I got all the parts dropped off at Specialty Coatings today, after looking at the black chrome appearance ceramic, I decided to go more matte finish and went with their ceramic in cobra black. I thought the black chrome would show too many scratches and look too out of place. It's more for wheels, I think. Anywho, they worked with me to get the finish I was looking for, and I wanted ceramic, especially for the exhaust. Great people, excellent customer service, and they told me they'd have it all done in a week. Things are moving right along....
     
  15. Diving Pete

    Diving Pete Member

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    Great news on the update......
     
  16. NorcalBoy

    NorcalBoy Member

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    Parts came back from ceramic coating. Turned out really decent, the finish is absolutely perfect, not a single flaw anywhere. Stoked with the results and the speed they were able to turn them around. I will use these folks again.

    [​IMG]

    Spoke with my suspension guy and the fork stanchions and shock shaft came back from DLC coating and the upper fork tubes are back from stripping and hard anodizing. The machinist also finished up the necessary internal spacers for the lowering. Brandon is going to start assembling everything this week and the only thing that we are still waiting on is the custom length shock spring which is supposed to be done this week. Hoping to pick it all up next week. This guy has his shit together and I'm hearing nothing but great things about his work from folks that have his kit. The suspension should finish up at about the same time as my current project, so I'll have a bunch of time to finish the build and test it.
     
  17. Jim McCulloch

    Jim McCulloch New Member

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    Sweet! What will you do for an encore?
     
  18. NorcalBoy

    NorcalBoy Member

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    Hopefully start working on the RVF, the engine was done weeks ago and now it's gone radio silent with the engine builder......
     
  19. NorcalBoy

    NorcalBoy Member

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    Good day today, went and met up with Brandon Peterson at AHM Factory Services to take delivery of my forks and shock. After all the trials and tribulations, it's finally over. Had to grab them today, as Brandon and his guys are on their way to San Felipe for the Baja 500 tomorrow to support Colton Udall's 2020 race effort, as well as a couple of other folks. Had to have them, couldn't wait another week, lol.

    Fork Mods
    Lowered 30 mm by machining the cartridge. This makes the lowering fully and easily reversible and utilizes stock length springs
    New springs adjusted for my weight
    Revalved
    Vapor blasted axle carriers
    DLC coated stanchions
    Stripped and hard anodized upper tubes
    Zeta Racing fork caps with integrated air bleed and tool less compression adjustment

    [​IMG]

    [​IMG]

    [​IMG]

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    Shock Mods
    Lowered 30 mm internally, fully reversible
    Custom shock spring
    Shortened bump stop to allow full travel after being shortened
    Revalved to match forks - valved for 145 pound rider, vet intermediate desert
    Superfinished shock shaft
    Billet anodized spring seat and retainer
    Billet anodized reservoir cap
    Billet anodized shock body cap

    [​IMG]

    [​IMG]

    [​IMG]

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    Brandon did an amazing job on this setup. Can't say enough good things about him. He snatched a brilliant victory from defeat, as I still don't have a resolution with UPS and the other company. He charged me an unbelievably great price on the new set of forks, the mods, and the shock work. I highly recommend Brandon to anyone with an offroad moto.

    Just need to get my current work project done to buy myself the time to finish bolting this thing together. Still waiting on a Red Moto oversize water pump kit and the carbon upper fork protectors from Lightspeed...other than that I do believe I have everything to finish. Snuck in a handful of other mods that need to get done while I'm reassembling this beast. This thing is going up on AHM's website, so I wanna get it done soon! I'm starting to feel the need for some authentic street taco's, some JJ's Cantina, and some riding in Mexico.
     
  20. Jim McCulloch

    Jim McCulloch New Member

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    Y..Y..Y..You aren't actually going to get that dirty are you? WOW what a work of art! I like the part about it being reversible. I have seen too many parts that were totalled due to irreversible shoddy mods. And you never know how shoddy they are until after you own the bike.

    GOOD JOB!
     
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