Intro

[SAWR450BOY]

Just joined TT,  My names Dylan, I stay in East London, South Africa. The East London Area is part of the wild cost which has many great routes to ride on. Bought a 2005 WR450F which the previous owners has neglected.

 

Decided to tear down the bike and give it some much needed TLC. Bought for little cash, but gonna  build her like it should of been built.

 

How I bought her

 

Tear Down

Edited January 4, 2014 by SAWR450BOY

[SAWR450BOY]

Bad picture, but the rim was cracked and welded then cracked on the weld again.

3 bolts stuck in tank inserts - tank inserts just turning - any ideas to get them out or do I replace with IMS long range tank?

blown seal

 

 

 

Edited January 4, 2014 by SAWR450BOY

[SAWR450BOY]

They even tried to weld Ti header

Anyone know from what bike this exhaust came from?

 

[SAWR450BOY]

Frame is rusted in areas but can still be fixed. Powder Coat or Paint?

[FORMA MOTO]

That's a YZ exhaust

Spin the stuck fasteners with a cordless drill until the plastic melts,then remove. Reinstall new fasteners with JB Weld or similar. 

[comp123]

_{God Bless America!}

[woods-rider]

📎IMG-20140104-00142.jpg

Bad picture, but the rim was cracked and welded then cracked on the weld again.

📎IMG-20140104-00144.jpg

3 bolts stuck in tank inserts - tank inserts just turning - any ideas to get them out or do I replace with IMS long range tank?

📎IMG-20140104-00145.jpg

blown seal

📎IMG-20140104-00147.jpg

 

In this first pic, where you show wear on the swingarm from the kickstand spring, it shows that your swingarm bearings are way shot. I had the same thing on my 2006. By the time I tried to service them it was too late. I had to cut the swingarm pivot bolt in three peices to get it out and the swingarm was very worn in many places including where the bearings went. It had to be replaced.

 

You should get a larger tank. That stock tank is only good for about 45 miles. Every off road 450 should come with a 3 gal tank minimum IMO. These MX size tanks are just a joke.

Edited January 5, 2014 by woods-rider

[SAWR450BOY]

Well, stripped the rest of the bike today, all wheel bearings, swing arm and linkage bearings are all shot. The swing arm is toast due to poor maintenance, removed chain guide, to find the chain had worn the swing arm paper thin. Pictures to follow later. The frame is bare and I whipped out high pressure cleaner to clean all the components.

Next is to send out frame for media blast, then for chemical clean for inner frame tubes before going for powder coat. Forks and shock to be sent out for complete rebuild from top to bottom. Need to just find a good clean used swing arm.

[D-rek07]

I really hope you got that thing cheap.

[SAWR450BOY]

some pics of swing arm and linkage damage

[Krimble]

Can't wait to see what happens to this bike. They do have a lot of potential if given general maintenance. How is the motor condition? I would at the very least check valve clearance.

Here is my recent build. I have an 03, which is really similar to the 05. You might find some good info in it. 

https://www.thumpertalk.com/topic/1003047-my-first-wr450f-build/

 

Welcome to the forum. Most likely the best spot for WR info.

Edited January 19, 2014 by Krimble

[SAWR450BOY]

Can't wait to see what happens to this bike. They do have a lot of potential if given general maintenance. How is the motor condition? I would at the very least check valve clearance.

Here is my recent build. I have an 03, which is really similar to the 05. You might find some good info in it. 

https://www.thumpertalk.com/topic/1003047-my-first-wr450f-build/

 

Welcome to the forum. Most likely the best spot for WR info.

The engine sounds good and previous owner said he had clearances checked 2 months before I bought it, but if the bike is anything to go by, going to check the motor as well. I have checked you build earlier, really love how it turned out. ?

 

I want to fit a trail tech voyager GPS kit, anyone had any bad experiences with this?

[woods-rider]

I want to fit a trail tech voyager GPS kit, anyone had any bad experiences with this?

 

I have one. I originally had it on an '06 which is really similar to your '05. Get yourself an odometer eliminator wheel spacer from flatland racing since you won't need the stock speedo cable or sensor.

 

http://www.flatlandracing.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=FR&Product_Code=21-08&Category_Code=Odometer+Eliminators

 

The Voyagers are great for what they are, but are nowhere near as powerful as a modern hand held GPS unit as far as loading maps etc. But it has a bunch of features that a typical GPS doesn't so it just depends on what's important to you.

[SAWR450BOY]

I have one. I originally had it on an '06 which is really similar to your '05. Get yourself an odometer eliminator wheel spacer from flatland racing since you won't need the stock speedo cable or sensor.

 

http://www.flatlandracing.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=FR&Product_Code=21-08&Category_Code=Odometer+Eliminators

 

The Voyagers are great for what they are, but are nowhere near as powerful as a modern hand held GPS unit as far as loading maps etc. But it has a bunch of features that a typical GPS doesn't so it just depends on what's important to you.

Thanks for the advice on the Trailtech, will get one of the speedo eliminators.

[SAWR450BOY]

Kinda figured out why the front brakes were so spongy ? . Seeing that you can't buy this part new, going to repair it. Will post a pic once repaired. ?

[SAWR450BOY]

So got the frame back from painting yesterday. Took the time to use a syringe and inject rust convertor/deactivator into the frame and swirled it around to coat as much as possible of the interior of the frame ( expect for the oil chamber of course. Let it drain out and once dry, sprayed on wax coating to all the seams, holes and joints on the frame just as an added precaution.

Now to slowly start to piece her back together.

[SAWR450BOY]

So its been a while since I last posted, got a good used swingarm from the States for a good price in very good condition, so I thought while I am about it, I would upgrade front forks and rear shock to better 2006 units, plus got a good 2006 ECU for better. Next is to upgrade brakes and have to decide when I get new outer rims if to keep it silver or change to black.

Edited August 2, 2014 by SAWR450BOY

[GuyGraham]

some pics of swing arm and linkage damage

 

 

Its not the chain that has worn the top of the swingarm, but the chain slider itself, and your replacement will do the same unless you prevent it

 

Heres the fix

https://www.thumpertalk.com/topic/1087114-chain-slider-has-worn-a-hole-in-the-swingarm/#entry11623557

Edited August 3, 2014 by GuyGraham

[SAWR450BOY]

Its not the chain that has worn the top of the swingarm, but the chain slider itself, and your replacement will do the same unless you prevent it

 

Heres the fix

https://www.thumpertalk.com/topic/1087114-chain-slider-has-worn-a-hole-in-the-swingarm/#entry11623557

Thanks will keep this in mind

[W R]

Dang that is a bike that has been severely neglected. Nice to see you bringing her back to life.