2004 WR450F bringin' her back from the dead project
Posted April 13, 2011 - 07:14 PM
Immediately after getting home, I power washed off the parts, and then carried all the parts into the basement to start the inspection/cleaning/assembly part of the project. Well, with the parts that I had, this is what either A: needed replacement or B: needed attention.
-Motor, well if you were to assemble all the parts that I got, it would look like a engine, except there really wouldn't be anything inside. It was missing every thru shaft, crank, piston, transmission gear, shift linkage, clutch, flywheel.... so.. yeah.. motor is done.. so I found a replacement 2006 WR450 engine in Texas with a spun bearing and it's in the mail now.
-Frame obviously got refinished to rid the rust and check all threaded holes. I had to completely remove both lower anchor nuts for the rear subframe because the threads were gone from the previous owner installing standard course bolts into a metric fine hole..
-Rear suspension linkage and swingarm bushings were 100% dry of grease and seized solid. All bolts/bushings had to be pressed out using a 20t press.. one bolt actually required almost 15,000 psi to break it free.. lol. While the others needed close to 8,000 psi each. So new bushing/bolts had to be ordered. Rear shock was in excellent shape (probably cause the rear links weren't moving) which was good a fairly pleasant surprise.
-Front suspension/Triple.. Upper triple needed replacing because again I found some standard bolts installed for the bar clamps. When I removed the steering head, some ball bearing fell on the floor so new bearing were needed. Fork seals were good, but the dust boots needed replacing.
-Controls.. hotstart/clutch perch and levers needed replacing, the only thing holding them together were the rubber boots.. roflmao. Throttle tube was cracked in multiple pieces. Throttle cable was pooched. Bars were bent. Front brake lever was broken under the boot (but master cylinder is good).
-Brakes.. front and rear brake pads were well past their expiry date... he must've been running using the backing plates on rotors for quite some time. So, new pads were in order, but surprisingly the rotors were in decent shape. Front and rear calipers/lines were in good shape after some cleaning and they showed no signs of wear.
-Body plastics.. everything was broken. period. But, the seat, tank and airbox were in decent/useable shape.
-Cooling. RH rad was bent and failed a leak check. LH rad was slightly bent, so I got some of our metal bashers to straighten it a little, and to my surprise it passed the leak test. Coolant lines also were in good shape, they're starting to get hard, but they're still useable for now until I get leak.
-Drive.. front sproket was missing teeth, rear steel sproket looked like a saw blade, and chain was garbage. Tires were off the bead but holding air. Once I removed the tires to inspect the rims, I found that both front and rear tire beads were done and both rear rim locks were damaged. I also had to true the rear wheel, I used a buddies truing rig to remove some lateral runnout which was out of spec.
Sooo.. as you can tell, the bike was a wreck. I found on ebay a rad from a 03 YZF, the motor I found on SMJ, all the plastics are coming from UFO plati, body hardware is coming from cheapcycleparts, and tires/tubes/chain/sprokets/exhaust I picked up while I was in Edmonton.
Here's how she sits right now
here's some of the parts unuseable parts along with the ever so growing pile of serviceable parts
and the motor..
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Posted April 13, 2011 - 09:07 PM
Keep us posted....I am currently do a 2005 WR450F myself. It might need a motor soon, It does run very stong, But is pretty noisy.
But all in all my project bike is looking great, New plastic on,just gotta put on new rubber-got them today, Decal kit was shipped.
Just wondering what u paid for the motor....I'm thinking it'd be easier to got that was than a rebuild.
Posted April 17, 2011 - 10:06 PM
But, another devellopment, seem the motor that's in the mail has... ummm... stopped moving. The person I bought the motor from packed up the motor into two boxes, supplied two tracking numbers. Both boxes arrived at the same time in Chicago, one box has cleared customs, the other is "arrived at International Dispatch ISC Chicago" and it hasn't moved since.. I think I'm gonna have to call USPS tomorrow to find out what's going on. Last time something like this happened, one of the employees decided to help themselves to the item I ordered in shipping and is now facing theft charges.
Also I ordered a new skid plate, and a front light assembly. Also, I finally found a graphic kit that works with my theme for the bike. I wanted a graphic that could have been supplied from factory, but on second look you realize that it isn't factory. It'll be custom made by bikegraphix but it'll look similar to this but with a few changes :
Posted April 18, 2011 - 09:40 AM
Posted April 18, 2011 - 10:36 AM
tagging along, I just picked up a 04 WR450F with a blown crank/cylinder, the bike locked up last weekend, cylinder already off so I know i've gotta do one bent valve, and a new cylinder/piston and a new rod or whole crank depends on the cam gear
Do you have a machine shop willing to do the rod? I believe the rod/crankpin/lower rod bearing are on backorder thru Yamaha.. but things might have changed.
Posted April 18, 2011 - 10:44 AM
rebuild crank 129 $
new wiseco 225 $ includes main bearings
cylinder works big bore kit with piston/gaskets 478cc 395 $
honestly I'll probably just do wiseco, I think they are US made again, the rebuild + mains is almost as much as the wiseco, and then I know the cam chains gear is good
Posted April 20, 2011 - 05:25 PM
I have no idea what you have to do to this to get a piston to lock up like this, it wrecked the rod and cylinder
all 3 intake valves touched the piston, I'm not sure if i wanna try doing the head myself yet, I usually have someone else do it
Posted April 20, 2011 - 05:48 PM
I would hazzard a guess that probably it was wrist pin bearing which seized, which then started putting excess strain on the piston side skirts.. which then work hardened it until it broke.. which then took out both the cylinder and the head... HOLY FAUK... wow.. just wow. Other than that, the bike looks really good.. doesn't even look like it's been riden at all.
Well here's some updates for mine.. it was like Christmas for me today. Received the rest of my order from UFO, and the radiator I won on ebay, and also 3/4 the engine came in the mail.. which is awesome because it'll provide something for me to do over the Easter long weekend.. disassemble, inspect, and order the replacement parts for the engine But, I did manage to get the body fit testing done already, and I have to admit, I really like this UFO LED taillight assembly.. especially because UFO managed to order me in the version for my bike in White...
Here's some pictures... I'm starting to get excited, finally the bike is starting to look like a bike and not some random pile of parts on my basement floor. The "motor" in the chassis is the cases which came with the bike, and the motor on the floor is what I picked up in Texas
But on a side note.. I think I've gotta try to find a kickstand for this machine.. I'm not really diggin the motoX axle stand.. the bike doesn't feel secure resting on it
Posted April 20, 2011 - 06:02 PM
all 3 intake valves hit the piston, 1 is bent badly, the other 2 probably are but I cant see it visibly
I've heard of getting the cam journals welded and machined, now idea how much it costs, I am not sure if I will repair this engine or part it out, this place does it, http://enginedynamics.com/index.html
Posted April 20, 2011 - 06:12 PM
The head pictured is a 04, and the head in the mail is a 06. I'll probably only be using the 06 stuff on the bike. On my 04 head, all the valves are removed, the seals look good, valve journals are good, and all 5 valves look like their straight. But the camshaft bearings are slightly notchy feeling (ie.. worn beyond limits). Also the 04 cylinder looks great, not a scratch on it, cross hatch is still visible.
I won't be able to officially sell anything off the motor right now until I receive all the rest of the parts in the mail to inspect them in depth. But, if you're interested, lmk.
Posted April 21, 2011 - 04:22 AM
I'm going to polish the cam journals and measure clearance before I do anything, yamaha runs tight, .001-.0015, most other brands run .003-004, the cam journal problem is common
I'm gonna split the cases too, I dont like to order any parts until I have a complete list of what's needed
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