Frequently asked 450R questions/thread!s

[rollie]

Maybe we could get a mod to sticky this for a while? theres been like 4 threads in the past 5 days about the same subject so i thought this might be easier for people, feel free to add!!! This should serve as a GUIDE to modifications/info while i do my best to get everything right, do not blame me for messing anything up! That being said, i hope this helps some people!

Main differences between the different years

2004 - . first year the 450R was made.only available in Red, gearing is 14/38

2005-Stayed basically the same, with the addition of Black plastic. Gearing is 14/38

2006- Came in electric start and kickstart models; came in Red and Black. received updated/different:
-Hood
-Headlight
-Brake light
-Subframe
-air box
-Carb
-Transmisson
-Head
-removal of oil cooler
-rear plastic is slightly different
-Air Filter
-Different bore/stroke
-Gearing is 13/38

2007- Unchanged from 2006, Also came in White.

2008- Received new Tires, Smaller gas tank, and gas tank cover. Came in Red, Black/Blue, and White.

2009- Unchanged from 2008, came in Red, Black, and White/orange/black.


What is the bolt pattern?
Front:4/144 Rear:4/110

What other rims will fit on my 450r?
Kawasaki Sport models, Suzuki Sport models, Arctic cat(DVX400), Can-am sport models. All Cannondale model's anymore?

Will an 04-05 exhaust fit on my 06+?
Generally, no. Some people have gotten certain brands to fit but the exhaust comes out of the header at a slightly different angle and the sub frame mounting points are not the same.


Will a 08+ Tank cover fit on my 04-07?
With some trimming, yes but there will be about a 1/2 gap on the bottom of the gas tank. It will also scratch your tank in some spots so it would be a good idea to put some sort of graphic or clear sticker under the cover to prevent it. If you don't plan on taking the cover off, you can also use double sided tape to get the cover to stick to the tank more and it will reduce the amount of space not covered by the tank on the bottom, Most agree that the 1/2 gap isn't enough to notice unless you know that it's an 04-07 tank underneath.


I want to add a kickstart to my 06+ ER, What do i need?
Complete list and part #'s:

1. 2 Pinion (28T) 28211-HP1-670 1
3 Plate, Kick Stopper 28215-HP1-670 1
4 Ratchet 28221-HP1-670 1
5 Spring 28223-HP1-670 1
6 Gear (31T) 28231-HP1-670 1
7 Collar 28232-HP1-840 1
8 Plate 28233-HP1-840 1
10 Spindle 28251-HP1-840 1
11 Spring 28261-HP1-840 1
12 Collar 28282-HP1-840 1
13 Bolt, Flange (6x14) 90004-GHB-620 1
14 Washer (14mm) 90451-PC9-000 1
15 Washer B (22mm) 90455-ML7-000 1
16 Washer (27x20x1) 90554-728-940 2
17 Bearing (22x29x10) 91007-HP1-671 1
18 Bearing, Needle 91105-KN7-671 1
19 Bolt, Hex (6x16) 93301-06016-0A 2
20 Circlip (19mm) 94510-19000 1
22 Gear (25T/13T) 28240-HP1-840 1
23 Arm, Kick Starter 28300-HP1-840 1
19 Bolt, Kick Joint 28306-MEN-670 1
seal 91204-KF0-003 1
gasket 11394-HP1-600 1
optional 05 kickstart arm 28300-HP1-000 it's $60 cheaper and works the same
(30MM) 11333-HP1-841


I want to put an 08+ tank on my 04-09, what do i need?
Complete parts list and #'s.

1 08+ Gas Tank 17510-HP1-A00
2 8+ Tank Cover 83700-HP1-A00ZB (Red) ( 83700-HP1-A00ZA (White)
83700-HP1-A00ZD (Black)
3 08+ Pet Cock 16950-HP1-A01
4 Left Front Gas Tank Mount 17522-HP1-A00
5 Right Front Gas Tank Mount 17521-HP1-A00
6 08+ Rear Stay Plate 17525-HP1-A00
7 (2) 08+ Bands 95012-11001

Green wire mod(06+)
On the 06+ 450R's, underneath the hood, if you look at the CDI box, there are three plug in type boxes with multiple wires going into each one. If you are facing the CDI, The plug in box all the way to the left, There should be a green wire, if you cut that wire and heat shrink/grease the ends, You will get 1000extra RPM's and it will change the power curve slightly. THIS WILL ONLY WORK ON THE 06+ TRX'S.

Will an 06+ swing arm fit on my 04/05? Are there any benefits?
The 06+ swing arms stock, are .75 of an inch longer than the 04/05's. So it will add some more stability. In order for the swing arm to work properly you will need linkage and a rear shock off of a 06+ as well as the swing arm, everything else bolts up.

Whats the best exhaust for my 450R?
Most will say: Sparks, Dasa, or Rossier. These exhausts are some of the loudest available though so keep that in mind when buying them!, the DASA is available in a 99Db version though.

What is the best cam for me/my quad?
A lot of this depends on the rider and riding style, for example Hotcams stage II is a great all around cam, where as the 04/05 HRC cam is more for top end type riding. Do a search in this section! there is TONS of information on this topic but it's hard to narrow it down to justa few good cams!

Cams:
Hotcams
Webcam
Curtis Sparks and most big engine builders have there own.


04/05 spindles are they better?
http://www.exriders.com/vbb/showthread.php?s=&threadid=417166

What Mods Should I Start With?
http://www.exriders.com/vbb/showthread.php?s=&threadid=417591

Lowering Subframe (pics)
http://www.exriders.com/vbb/showthread.php?s=&threadid=416728

Show Off your 450R
http://www.exriders.com/vbb/showthread.php?s=&threadid=232071

lets see some xc r's
http://www.exriders.com/vbb/showthread.php?s=&threadid=416229

Show off your MX 450R !
http://www.exriders.com/vbb/showthread.php?s=&threadid=406195

Post up those TT Bikes!!!
http://www.exriders.com/vbb/showthread.php?s=&threadid=409094

450R graphics
http://www.exriders.com/vbb/showthread.php?s=&threadid=207828

Will an 04/05 motor fit in an 06+ frame?
http://www.exriders.com/vbb/showthread.php?s=&threadid=417972

Parts needed for starter clutch replacement
http://www.exriders.com/vbb/showthread.php?s=&threadid=448092

Race wire harness diagrams
http://www.exriders.com/vbb/showthread.php?s=&threadid=461586


Valve adjustment : HOW TO w/
pic's
http://www.exriders.com/vbb/showthread.php?threadid=284416

08+ Tank and over on 04-07
http://exriders.com/vbb/showthread.php?s=&threadid=483843

[troybilt]

don't forget the '08/'09 tank cover on '04-'07... been asked quite a bit lately.

Good post, I'm sure there will still be the same questions asked on a regular basis... but worth a try right. :macho

[BadinBlack]

good post for sure!

[rollie]

Im updating it as i think of questions, if anyone has other questions/answers or corrections let me know! even if this falls back onto the back pages, atleast when people search they can find the info!

[veenser2000]

there seems to be many threads on the differences from 04-05, to 06-07, and 08-09 machines if anyone has a good informative thread im sure rollie would appreciate it.

[spanky101]

Doing a great job rollie, you have alot covered, and hopefull itll cut down on the stupid repetative questions

[IRISH-RACER-14]

post how the 06 swingarm is longer than an 04-05 and that it will work

[Dave400ex]

I always see a ton of questions about different Cams

[BlaineKaiser450]

Dasa + Sparks + Rossier

Cant forget that one

[airmobile101]

Originally posted by Dave400ex
I always see a ton of questions about different Cams
Yep! True that!

[fastredrider44]

Looking good rollie! Also how bout the 04-05 crank bearing mod. Lots still ask that one. The 450R graphics thread used to get sticked too.

[KEVIN132]

also congrats to rollie for finishing 2nd!! overall in neatv open c!!!
good thread tho rollie!
RPR to the rescue!!

[rollie]

Allright i updated what i could! I don't know everything but im trying my best to get everything i've learnt about these bikes down!

[airmobile101]

Originally posted by rollie
Allright i updated what i could! I don't know everything but im trying my best to get everything i've learnt about these bikes down!
I salute you! At least your putting an effort into it. Im learning myself!

[warr72]

The 08 and up ER's have a new cam design and you can't use any of the older cams in them. There is alot of horsepower locked up in those 08 and up ER heads. Up sizing the leak jets or getting an adjustable leak jet on the 06 and up ER's will help with starting and the infamous bog. A 24 volt system to the starter will give the ability to start on the go, awesome for xc racers. Meaning the quad will start with the clutch out and in gear. ;)

[sameltoe]

[QUOTE]Originally posted by fastredrider44
[B]Looking good rollie! Also how bout the 04-05 crank bearing mod. Lots still ask that one. Ok whats this?? Do tell...

[Clement222]

hi i was wondering what is the stock tooth count for both front and rear sprockets on a 2005 TRX450R thnaks.

[miles Machine]

04-05=14/38

06-up=13/38

[Clement222]

thanks for your help man

[400exrider707]

04/05 vs. 06+ bikes have different bore/strokes.

Definitely need a link to the 04/05 crank bearing mod, with part numbers.

Also dont forget the 04/05 spindles on to the 06+ bikes.

[Scro]

If you buy a complete 04/05 kickstart assembly, there are several parts that will need to be updated with the 07 counterparts to add the kicker to the 06+ electric start. These parts are:

28233-HP1-840 - Gear retainer plate
28251-HP1-840 - Kickstart spindle
28261-HP1-840 - Spring
28232-HP1-840 - Spring collar
15201-HP1-600 - Oil guide plate

The rest of the gears and parts from the 04/05 kickstart assembly will work.

More than likely, if you buy a used 04/05 kicker assembly it's not going include the bearings for the cases. These part numbers are:

91105-KN7-671
91007-HP1-671

The actual kick lever from an 04/05 will work on 06+, but the lever will scrub the plastic a little. You will need to buy the 06+ kick lever if you want it to fit correctly in the plastic: 28300-HP1-840

[racer 557]

What about like maintence most to do like where everything is located and say like a before riding check list for some of the newer guys??

[Lquad71]

what about the 05 to 06 front ends

are all the a arms interchangeable?
what about spindles?
I just need to know what will happen if i try to put some 06 a arms on my 04?

[racer 557]

i believe a arms might be same its just they might be a little diffrent because of the spindles i do know 04-05 spindles are diffrent than 06+

[KEVIN132]

arms will work but 04-05 spindles are dif and better!!

[sameltoe]

I'm positive the lowers are the same between years. I believe the uppers are a litl shorter on 06+

[mxslevnik69]

do you guys know what parts would be needed to make a 450r into a 450er?

[Scro]

Originally posted by mxslevnik69
do you guys know what parts would be needed to make a 450r into a 450er?

You're going to need alot of things. An ER wiring harness, starter, starter clutch, starter reduction gears and bracket, battery, solenoid, fuse wiring, wiring for the battery, start button cluster, and quite a few extra nuts and bolts. You will also have to make your own battery box somewhere. I'll try to sit down one night and make a complete list with part numbers.

[arTuReX]

SCRO that list would be great!, I always wanted to convert my 450r to 450er!

[Scro]

Originally posted by arTuReX
SCRO that list would be great!, I always wanted to convert my 450r to 450er!

The 04/05 models can not be converted to use the 06+ electric start components. The only way to get e-start on them is the Goki system.

[arTuReX]

Well in this economy is gonna be a while till i get the Goki, thanks SCRO!

[Scro]

I was looking at the new OEM prices for all the e-start components. It looks like it would be cheaper to add the Goki e-start to the 04/05, that it would be to add the OEM stuff to the 06+.:eek:

[DEVINF450R]

Will a Vortex ignition from my 05 fit my 08?

[KEVIN132]

id rather push start my bike than add that ugly goki thing!!!:huh :eek2:

[Dirtjunkie85]

thats a good thing to post, very helpful!! Thanks!

[notsolow400ex]

I have an 08 trx 450er i have 4 years of warrenty on it I was wondering if i do the green wire trick if that would void my warrenty?

[hrc450er]

at the right dealer it wont matter, i dont know why they care because they just bill honda for the labor anyways. so y wouldnt they look past it to get the work. i have my bike fully built and my honda dealer will warranty anything. they even let me get aftermarket parts instead of oem when i replace something i just have to pay the difference in cost of the two so go talk to your dealer and see if they will easiest way to know if not then go to other dealers

[bean2080]

i thought this might be helpfull for this thread. its a very detailed step by step on how to adjust your valves.

http://webpages.shepherd.edu/ghott01/valveadjustment/valveadjustment.html

[muddzilla94]

this would be helpful, what you need to rebuild your bottom end.
91003-HP1-671 1 BEARING (25X56X15) $ 25.44 $ 18.61
90004-GHB-680 3 BOLT, FLANGE (6X28) $ 6.48 $ 4.92
11394-HP1-670 1 GASKET, R. COVER $ 19.14 $ 12.54
91256-383-721 1 O-RING (17.8X2.4) $ 1.65 $ 1.26
91022-MT7-003 1 BEARING (30X35X26) $ 17.62 $ 13.37
15433-HP1-671 1 SEAL, RING $ 1.76 $ 1.34
11395-HP1-670 1 GASKET, L. COVER $ 9.77 $ 6.4
91203-HP1-671 1 OIL SEAL (12X22X5) $ 3.49 $ 2.65
11191-HP1-670 1 GASKET, CRANKCASE $ 14.91 $ 11.32
18601-MBW-003 1 VALVE, REED $ 11.47 $ 8.71
91001-HP1-671 1 BEARING (6306) $ 17.35 $ 13.17
91006-HA0-003 2 BEARING (9MM) $ 19.1 $ 14.5
91008-HP1-671 1 BEARING $ 43.96 $ 32.16
91022-KA4-740 1 BEARING (33X38X8) $ 11.95 $ 9.07
91201-HP1-671 1 OIL SEAL (33X47X7) $ 9.25 $ 7.02
91202-HP1-671 1 OIL SEAL (30X44X7) $ 9.25 $ 7.02
91203-KA4-771 1 OIL SEAL (14X22X5) $ 2.64 $ 2
91203-MEB-671 1 OIL SEAL (20X33X5) $ 3.2 $ 2.43
13000-HP1-670 1 CRANKSHAFT $ 316.73 $ 209.07
91002-HP1-671 1 BEARING (17X42X13) $ 7.84 $ 5.95
91004-MEB-671 1 BEARING (20X32X14) $ 6.49 $ 4.93
91003-KJ1-003 1 BEARING, RADIAL BALL $ 14.56 $ 11.05
91005-HP1-671 1 BEARING (17X40X12) $ 7.84 $ 5.95
91006-HP1-671 1 BEARING (24X56X22.1) $ 30.07 $ 22
91201-ML3-873 1 O-RING (23.75MM) $ 2.47 $ 1.88
91207-ML3-871 1 OIL SEAL (31X40X7) $ 7.13 $ 5.41
91004-KY4-900 1 BEARING (6905U) $ 15.35 $ 11.65
91204-KF0-003 1 OIL SEAL (20X28X5) $ 4.53 $ 3.44
19300-HP1-671 1 THERMOSTAT ASSY. $ 34 $ 24.87
15331-958-000 1 ROTOR, OIL PUMP $ 21.95 $ 16.05
15332-958-000 1 ROTOR, OIL PUMP $ 18.82 $ 14.28

[hondadude101]

I just got a 2007 450er that I cant get started. It cranks but doesnt fire, i replaced the plug and it has fresh gas, and it started, but now it wont. It ran fine after it finally started, but the header was glowing red and it backfires bad. Could it be valves? any help would be appreciated. Thanks

-Andy

[Fast470r]

How about the clutch mod where you remove the jutter spring.

[rollie]

just added the valve adjustment how to. any other idea's let me know i still try to update this thread so it won't fall back into the pages.

[grant14]

might note that the 08+ Cams are different as well. So i assume the heads are different as well, but i don't know.

[quad71]

Originally posted by grant14
might note that the 08+ Cams are different as well. So i assume the heads are different as well, but i don't know. Only the e-start are different.

[JaredP]

The Rossier Pipe has an option for a 95Db kit pictured here is a YFZ silencer but the kit will work on all Rossier pipes

http://www.rossiereng.com/images/products/quiet_kit.jpg

[NikNacs67]

Haven't went through all the comments but Cannondale wheels (every model) will fit.

[Sqwrly]

When you do the green wire mod on the 06+ when you cut it what do you do with it then ? Im not catching on . Does it need to be touching another wire or what ?

[rhinomxer]

No, that would be bad. Just tape the cut ends off, it should not touch anything at all.

[DnB_racing]

Originally posted by Sqwrly
When you do the green wire mod on the 06+ when you cut it what do you do with it then ? Im not catching on . Does it need to be touching another wire or what ? what I usually do is kill 2 birds with one stone ......

on the same connector on the cdi, is a pink/grey stripe wire this wire is the carb throttle safety circuit (tors)

the green wire mod is isolating the green from the cdi,
then I take the other side of the green from harness to totally bypass the tors by grounding out the tors at the cdi

cut the pink/grey wire and isolate the harness side and splice the harness green to the cdi pink/grey

this does both green wire mod and tors eliminated,

you end up with the green from the cdi caped off and isolated, and the pink/grey from harness caped and isolated, and pink/grey from cdi spliced to the green that you would have dead ended from the harnes

[hondaxcracer]

Originally posted by Scro
The 04/05 models can not be converted to use the 06+ electric start components. The only way to get e-start on them is the Goki system.


how about a 05 to 06 motor swip? does the 05 carb plug in to the 06 hardness?

[DnB_racing]

Originally posted by hondaxcracer
how about a 05 to 06 motor swip? does the 05 carb plug in to the 06 hardness? the 05 doesnt have a connector for the TORS, but does have the tps connector...

I think the 2 tps connectors are different, but I forget... but it wouldnt be hard to swap connectors if needed, both use the same style pin inside the connectors


the pins inside the connectors can be removed with a solid leather sowing needle
on the pins there is a small fin that can be compressed to release it from the connector... slide the sowing needle between the pin and connector and you can usually pull out the pin from the connector

I hope I made that understandable??lol

[dantrx038]

does 06+ aem a-arms will fit on my 05?

[grant14]

the a-arms will fit but the hubs are different. so you would have to have a set of 06+ hubs to go with them.

[ben 22ltr]

Will 400ex a arms fit on a 05 450r?

[Scro]

Originally posted by ben 22ltr
Will 400ex a arms fit on a 05 450r?

No, the distance between the mounting points is different.

[rollie]

If anyone has info thats not already on the first page or info they would like posted post it here or PM me, This post may be 3 years old but i'm still lurking the forums :p

[tritty_wall]

does anyone have a picture of the Green wire and Tors mod? I just don't want to start cutting wire until I know for sure what I'm doing. I Get that i just have to cut the green one just not sure which end go where when doing the tors like DnB_racing has explaned.

Thanks, Tristin

[DnB_racing]

does anyone have a picture of the Green wire and Tors mod? I just don't want to start cutting wire until I know for sure what I'm doing. I Get that i just have to cut the green one just not sure which end go where when doing the tors like DnB_racing has explaned.

Thanks, Tristin
http://www.google.com/url?sa=t&rct=j&q=green%20wire%20mod&source=web&cd=2&cad=rja&ved=0CDcQtwIwAQ&url=http%3A%2F%2Fwww.youtube.com%2Fwatch%3Fv%3Dheg CMdruEYs&ei=z4uRUYnqG4rL0wHvk4CgDA&usg=AFQjCNFFGUSd7GcsRfXdINj2lXli2S2nqg

ok that's obviously the green wire mod....

now instead of isolating both sides of the green just isolate the cdi side
now on that same connector there is a grey/red wire-cut it
take the green from harness side and splice to grey/red from cdi side
isolate the harness side grey/red wire and you've bypassed the carb safety at the closest possible point

use heat shrink and solder for your connections tape over and its done

3 minute job tops.... simple:muscle:

[rollie]

Wow i made this 5 years ago haha.....i hope it's helped some people i still have a 450r! Haha