2004 CRF450/Laeger CT rebuild

[CADWELL]

Well the time has come to rebuild my hybrid. It'll be the first hybrid rebuild I've done although I have done some YFZ rebuilds, this hybrid and motor will be new to me. I told myself I wouldn't be going all out like on my YFZ rebuilds, but as we all know one thing leads to another. One thing that's always worried me about these Laegers are the limited availability of parts. I'm a huge Walsh fan, but when a trade presented itself for my previous all Walsh YFZ for this Laeger, I couldn't pass it up.

I took this hybrid straight to the track without revalving my shocks and it handled great. I rode the **** out of it but its been well over a year since its seen a track. I pulled out all my MX DVDs and have been slowly getting the itch. So I figured I'd get back into what I love doing and give this thing a little love.

I have an idea of the color scheme of grey and red. Top end rebuild with CP piston, OEM specs(wanna stay on pump gas). Thinking I'm gonna send my shocks out to Custom AXIS and have them converted to piggy backs as well. New tires with current DWT wheels with new PC.

Started the tear down.
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsf2798def.jpg

One of the best features of a hybrid....less wires...
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps55ae614b.jpg

Just about there. Still need to press some bearings and bushings out.
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps7e1ff5c4.jpg

One surprise I wasn't anticipating....wasn't looking forward to splitting cases, but I need a Right side case....
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpse0fbb533.jpg

[CADWELL]

Anybody have any tips on splitting CRF cases?

I've done plenty of YFZ motors, but was wondering if there's anything unique about this CRF motor. I'm also planning on replacing the Timing chain. Maybe the main bearing as well..

[laeger400]

I cant wait to see this build!

[CADWELL]

I cant wait to see this build!

Thanks man...me too haha...it may take a bit longer than what I want, but I'm sure it'll be worth the wait.

[CADWELL]

Not very much progress. Everything is in the PC shop who BTW I have to give a lot of props to. Mark over at NAPC (North American Powder Coating) in Tucson, AZ. Guy is a straight shooter and gave me a solid price to do the entire bike...

I'm currently gathering up the parts to split the cases and do a top end as well. Stuff has started to come in little by little in the mail. So far I've received some new meats, '04 right side case half, stem bearing kit and I have a delivery waiting for me at the UPS store from Rocky Mountain ATV...

Also I'm debating on what exactly to do with my shocks. I need some advice for anyone willing to give it. I've only given myself so much allowance to put into my shocks. I REALLY want to do a piggyback upgrade. Reason being I really like the slim line look, ease of shock removal and mainly the fact that where the resi's mount on the frame, theY get in the way of my Precision stabilizer linkage. BUT For the same price I can do a Titanium spring upgrade with longer hoses as piggy backs won't necessarily increase performance where at least the Ti's will lighten the shocks and longer hoses will allow me to mount on my radiator down tubes...

Can't go wrong with this combo...love it!
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps049ceda2.jpg

What should I do?
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsfa2b5e1d.jpg

The last thing you wanna see in the mail is a damaged box with a case half in it that's poked out on 3 sides...the worst packaging ever..What a coincidence that would be to receive a damaged case half because of poor packaging to replace a currently damaged case half lol...
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps4b06f5ae.jpg

[ryanowarrior]

Damn that stinks about the case did it hurt it any?

Me personally I wouldn't go with longer hoses on the front shocks..longer hoses just means it takes more time for fluid to travel to and from shock! Makin it perform less the more or longer u ride! If that makes since! Upgrade to piggy backs and springs while your at it..might cost more but u might regret it later? What's the weight difference between the 2 types for springs?

[CADWELL]

Damn that stinks about the case did it hurt it any?



Me personally I wouldn't go with longer hoses on the front shocks..longer hoses just means it takes more time for fluid to travel to and from shock! Makin it perform less the more or longer u ride! If that makes since! Upgrade to piggy backs and springs while your at it..might cost more but u might regret it later? What's the weight difference between the 2 types for springs?

I'm not quite sure yet as I haven't opened the box. I emailed the EBay vendor and waiting to hear from them. From what I can seen, no major damage other than slight rounding of the edges of the mating surface.

I talked to to Hygear about longer hoses and they said it wouldn't effect the performance at all even compared to piggybacks. Personally I'd love to do a Piggyback AND a Ti upgrade but it would take my completion of the build that much longer due to lack of funds.

The hoses would go from about 8" to about 1.5 FT ...just enough to go up and around the radiator...

[ryanowarrior]

I'm not quite sure yet as I haven't opened the box. I emailed the EBay vendor and waiting to hear from them. From what I can seen, no major damage other than slight rounding of the edges of the mating surface.

I talked to to Hygear about longer hoses and they said it wouldn't effect the performance at all even compared to piggybacks. Personally I'd love to do a Piggyback AND a Ti upgrade but it would take my completion of the build that much longer due to lack of funds.

The hoses would go from about 8" to about 1.5 FT ...just enough to go up and around the radiator...

That does blow hope it's not hurt or they take of it for ya

That's interesting my shock guy said the right opposite and he's worked for the best in the business..granted it was for the rear shock but figured they were all the same. For example just look at josh uppermans quad this past season look where rear shock rezzy is mounted! Gotta be there for a reason

[CADWELL]

That does blow hope it's not hurt or they take of it for ya


That's interesting my shock guy said the right opposite and he's worked for the best in the business..granted it was for the rear shock but figured they were all the same. For example just look at josh uppermans quad this past season look where rear shock rezzy is mounted! Gotta be there for a reason

Well I unboxed it and luckily the case half is still in good shape and not damaged. I held my breathe because I don't know exactly how many more 2004 CRF450 motors are out there for a decent price to get parts for.

If I think I know who your shock builder is(your sig haha) then I have alot of respect for him and couldn't agree more that he knows his chit. I know for a fact that he built probably the only or very first true FOX Evols for a Walsh 250/YZ which belongs to my friend Grant(Gtilley45) on here when not even FOX would build them.

That info came from Hygear though so I haven't asked Micah at Custom Axis about it yet. I could be wrong, but I think the reason Uppy's rear hose is so short because that is simply the design that Wayne from PEP came up with for the rear shock on a TRX platform. I've had plenty of shocks (rear mostly) that have had a pretty long hose...but what do I know. Either way I'm trying to hustle some left over YFZ stuff that I have left over to go ahead and do a Piggyback conversion and a Ti conversion so I'm keeping my fingers crossed.

[CADWELL]

Not much to update, however I did talk to Mark at North American PowderCoat and it looks like my stuff will be ready next week!!

I also picked up my package from RMATV. Mainly a bunch of gaskets and a timing chain to put my motor back together. All I need is my piston which will end up being a shelf CP piston, stock compression.

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps9397e9e6.jpg

[ryanowarrior]

Well I unboxed it and luckily the case half is still in good shape and not damaged. I held my breathe because I don't know exactly how many more 2004 CRF450 motors are out there for a decent price to get parts for.

If I think I know who your shock builder is(your sig haha) then I have alot of respect for him and couldn't agree more that he knows his chit. I know for a fact that he built probably the only or very first true FOX Evols for a Walsh 250/YZ which belongs to my friend Grant(Gtilley45) on here when not even FOX would build them.

That info came from Hygear though so I haven't asked Micah at Custom Axis about it yet. I could be wrong, but I think the reason Uppy's rear hose is so short because that is simply the design that Wayne from PEP came up with for the rear shock on a TRX platform. I've had plenty of shocks (rear mostly) that have had a pretty long hose...but what do I know. Either way I'm trying to hustle some left over YFZ stuff that I have left over to go ahead and do a Piggyback conversion and a Ti conversion so I'm keeping my fingers crossed.

That's great ya case wasn't messed up :D

Yup that's him he knows his ****..but ya know everybody has there different beliefs on what works the best and i respect that! speaking of Micah I talked to him today lol..my front shocks showed up that I ordered from him! He's a pretty good guy too! Ill have to say Axis is top notch! I placed my order last Monday and shocks showed up today! Very helpful

What colors are u doin on frame? Or did I miss that?

[CADWELL]

That's great ya case wasn't messed up :D

Yup that's him he knows his ****..but ya know everybody has there different beliefs on what works the best and i respect that! speaking of Micah I talked to him today lol..my front shocks showed up that I ordered from him! He's a pretty good guy too! Ill have to say Axis is top notch! I placed my order last Monday and shocks showed up today! Very helpful

What colors are u doin on frame? Or did I miss that?

That's a pretty quick turn around time man. It probably helps that the season is over also. Yeah I haven't talk to Micah on the phone yet, just through emails, but he's answered all my questions so far.

I'm gonna go with a grey and red scheme on the entire bike. Going with RD03 and GR21 on Cardinal Coating's color chart http://www.powdercoatingplus.com/wp-content/uploads/2012/02/PowderCardinalColorChart.pdf. The colors on line don't do it justice. That red isn't quite a true Honda red, but it's the closest of the other reds on that chart.

Also I'm gonna go with my White Fullbore front fender with a Red Laker rear, new DFR seat cover. I have a CF Quadtech hood on it now, but I really like that Red Fourwerx hood. Then to top it off, Sam at DFR is gonna work me up a graphic kit that will bring the white and red together.

[ryanowarrior]

Let me know how ya like them rear fenders...since the FB are gettin impossible to find these days

[CADWELL]

Let me know how ya like them rear fenders...since the FB are gettin impossible to find these days

Yeah it sucks because the rear fenders just get beat to shizz at the bends by the frame down tubes from the exhaust on one side and riding boots on both sides. My rear Fullbore is in damn good shape other than those areas. Sam at DFR says that Laker essentially is just as good a quality as FB, but I like the Fullbore front trim design. Plus DFR always has great sales on the Lakers. Rudy over there has a set of Clear Laker plastics for a TRX250r as well...they look crazy.

[ryanowarrior]

DFR have a website?

[CADWELL]

DFR have a website?

Here you go..

http://http://www.dirtfiendracing.com/

Call down there and pick Rudy's brain about anything, he knows his chit. He used to be one of the mechanics for one of the Can Am teams when they first made the scene. Sam down there is in charge of all the cosmetic side of Dirt Fiend Racing... He can make anything you want when it comes down to graphics....

[CADWELL]

I know it's been awhile, but I've made small progress on this build as I'm still waiting for the PC to get back and some motor stuff to split the cases. I've been updating this build on TRX250R.org, but I felt like it would be unfair to not update the fellow Hybrid fans here on the build. So here goes a quick update as far as where I'm at.

Went over the carb completely and re jetted as well as clean the Hot strat plunger out. Thing was gummed up pretty bad and should actually function for me now haha.

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsaf174bcf.jpg

I did my first rebuild of my YFZ back in '09 and this grey on this frame will be a common coloron the scheme I'm after...

http://i219.photobucket.com/albums/cc197/buttmusk/Misc%20stuff/011.jpg

I took my Spark's exhaust completely apart. I need to get them on the phone about possibly getting a replacement Can from them as many Hybrid owners know, the Canister and rear caliper don't like each other haha.

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsfe81a954.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpse3c51e6e.jpg

Packing was in bad shape.


I got my shocks packaged up and shipped to Custom AXIS for TLC. Going with a piggyback upgrade, PRS rear and service and revalve for all three.

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps44d6a491.jpg

Picked up some new beef for the rear...Going all LSR for the first time. I've always been a RPM guy, but we'll see how these Axcalibers hold up....

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps2468242d.jpg

The latest step I delved into was the motor tear down. To my surprise I found a couple nice surprises when I tore the motor down. Dual valve springs, Hinson clutch basket, excellent Nikasil plating and cross hatching on the cylinder.

http://i219.photobucket.com/albums/cc197/buttmusk/image_zps17d7c024.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/image_zps3baeb7b8.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsb7112048.jpg

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsab9a76d1.jpg

[CADWELL]

Have made some progress in the last couple weeks. Motor is all put together and also got all my PC back.


The head checked out and also made a nice discovery once again. Has Kibble White valves and springs all within spec still.
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsb958be53.jpg

Cases going back together after new OEM crank, main bearings and seals, new counter balancer shaft bearings and seals, new timing chain....
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsc2d94948.jpg

New shelf 12.5:1 CP Piston. Cross hatching on the cylinder was also in good shape.
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsf287c632.jpg

Engine all buttoned up and valves shimmed.
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps5b21d509.jpg

[CADWELL]

Was pretty excited to get all my PC back which gave me the oppertunitty to start putting this thing back together.

I love this grey I chose. I used it on a YFZ build I did back in '09 which I entered in the QOTM here on ATVriders. This time I wanted to feature alot of the Honda red to go with it. Grey and Red galore....you Buckeye fans will probably creme on yourselves haha.

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps1741f2fd.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsfa9a33f2.jpg

Here are few pics in the sunlight. Pics don't do it justice...

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps6b0679df.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps26881f99.jpg

Started putting all together again...

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsc3b4b6f3.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps27a11621.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps6e59aff5.jpg

[ryanowarrior]

Show a better pic of your stabilizer up front! I had to mount mine different!

[CADWELL]

Show a better pic of your stabilizer up front! I had to mount mine different!


Hope this helps man. It basicly mounts the same like it did on my YFZ...uses the same linkage...

http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps96f59976.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps0ab01346.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps31250dd6.jpg

[wfo4rv]

Looks good

[elkabanshee]

that's lookin good

[CADWELL]

Looks good


that's lookin good


Thanks guys!

[CADWELL]

Looks good


that's lookin good

Thanks a lot for the compliment fellas...

[CADWELL]

Well a few days ago I managed to get some stuff mounted to the frame and because Custom AXIS had my shocks a bit longer than I planned, I made some shocks out of T-posts just so I could get this thing on the ground.

There are still several things to get done on the build to fire up the motor. I placed an order with RMATV to get some everything I need on hand to button up the motor and exhaust to get it running. Sadly I was wanting to go with a new exhaust but after talking to DASA and Sparks, nothing was gonna able to be replaced or built unless I sent Sparks my exhaust. DASA just simply doesn't have a JIG for a Laeger/CRF so I've been in contact with White Chassis/laeger 400 about having a custom DASA welded up

I still need to install the fuel tank and a new petcock I have coming for to get the fuel squared away. Still need a chain to get the powertrain buttoned up as well.

Plastics and graphics are the very last thing that will go on the bike and Sam at Dirt Fiend Racing is working on that for me now. That will consist of a new Honda Red Laker rear plastic, New custom Dirt Fiend Racing seat cover and will be sticking with the front white Fullbore so I'll be going two tone with the plastics. QuadTech CF hood, QuadTech rad shrouds, CF tank cover. I'm excited to see the graphics because the will be more of a body wrap which means the number plates will be integrated with the graphics for on a 250r.


I had a ***** of a time popping the bead on one of the rear tires. I used all the different lubricants I thought would work even straight dish soap but they were all a no-go. I woke up the next morning and thought to myself there has to be something very slippery out there I can use...and then a light bulb turned on in my head LOL...
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsff281603.jpg

Here are some pics after I got her rolling..
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps9827c164.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zpsfd707c1c.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/image_zps0f0d4119.jpg

[laeger400]

Sweet!

[CADWELL]

Sweet!

Thanks Jerry!

[rinehart_mitch]

Damn Chris those are some sweet shocks!

Always going up and above, that thing will come out pretty bad ***, us local guys have been keeping Sam busy that's for sure, I just dropped mine off yet again for more stickers!

Can't wait till it's done we will have to hook up out at ACP or canyon, like the ol days... or get a title for that thing and make a dune trip

[CADWELL]

Damn Chris those are some sweet shocks!

Always going up and above, that thing will come out pretty bad ***, us local guys have been keeping Sam busy that's for sure, I just dropped mine off yet again for more stickers!

Can't wait till it's done we will have to hook up out at ACP or canyon, like the ol days... or get a title for that thing and make a dune trip

Thanks a lot Mitch...your build came out very nice also. Yep, Sam is the best when it comes down to graphics and I'm glad he's in Arizona close by!!! Ya your bike came together once they put their touch together, I'm hoping mine turns out nice also.

I'm planning on racing ACP on Nov. 16 the just for the fun factor. But I also want to get out to either Canyon or Motogrande to get some seat time before then. I definitely need to get a title for this thing so I feel more confident taking it to the Dunes...need to make a trip out there. Never been to Glamis, only Butter Cup and Gordon's Well....

[rinehart_mitch]

All it is is a confidence thing, camp out in the back washes you'll have nothing to worry bout most of the time...

I'll be In The frozen hell for that race, so best of luck

Can't wait to see how it comes out

[quadpornstar]

Can't you just get an off road users permit for glamis (the sticker) and put it on there? As long as you have that pass you'll be fine. Ridden mine out there many times, never had a problem...

[CADWELL]

Well I've just about buttoned up this build. I headed up to PHX to drop the wheeler of at Dirt Fiend Racing so Sam can give it the final touches. I installed a Custom DFR seat cover and the rear red Laker plastics. Graphics and number plates should go on this week. Hopefully it should be ready to hit ACP for this weekend's race, I'm ready to just get on this thing and ride it!





http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/20131108_111910_zps26fac12c.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/20131108_111449_zpsf67aa4cc.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/20131108_111346_zps65ba5ea4.jpg
http://i219.photobucket.com/albums/cc197/buttmusk/Laeger%20CRF/20131108_111332_zps2c7c9077.jpg