Dirt Bike Overhaul
Our Custom Street Tracker Build
At Mancos Motorsports, we love to refresh old bikes and make them look new again. For this dirt bike overhaul, we decided to go all out on a custom build. At first glance, it may look like a stock Honda but the demon is in the details. This project started out with a tattered and neglected ’06 Honda CRF 450. We gave it a face-lift with new plastics, a fresh seat cover, custom suspension and wheels. We also made some performance modifications to help the bike run even better.
Before our Modifications
When we started, this bike had old, damaged fenders, and a skateboard for a seat. Check out the “before” picture:
What we Changed
Not a pretty bike to start with, this old girl was just a basic used dirt bike. We wanted more. As we stripped her down, tossing the faded plastics and scratched, bent wheels, the soul of the bike was revealed. Although this machine was cosmetically neglected, we found the bones of the bike were in beautiful shape.
First things first, we addressed the heart of the mater; after opening up the motor we replaced the factory worn clutch and clutch basket with a Weisco unit. Next we rebuilt the water pump. During our inspection, the near-new top end checked out well within spec. With the valves lashed, the engine was ready and reliable. With a HiFlo air filter and Pro Circuit T4 forest legal pipe to help her breathe, she is ready for years of spirited riding.
From the factory, this motorcycle was equipped with 21-inch front and 19 inch rear wheels. We installed new 19-inch Did Dirt Star wheels on both the front and back. Then, we wrapped the wheels in Maxxis flat track tires. Adding shorter stiffer springs to the front and lowering the rear, we achieved the aggressive look of a street tracker.
To make it a dual sport bike, we had to add some street amenities. A high output D.C. stator and battery power the electronics. A LED headlamp and taillight improve visibility. The Trail Tech Vapor is an invaluable gauge system. Then, we added custom a wiring harness to relocate the CDI box and to install a key switch.
To keep her cruising under the radar we kept the cosmetics simple and clean. To clean up the bikes appearance, we choose a white Acerbis body kit and matching headlight surround. We added a new black full-gripper seat cover round it out. The front fender was also trimmed for a touch of the Supermoto look. Next, the engine covers were black coated. To reduce heat, we installed black fiberglass header wrap. Finally, for a touch of subtle flare, we polished the ASV Spring loaded leavers and Pro Circut pipe.
The Final Result
This build is one of our favorites, because it made a highly functional motorcycle. It is now comfortable to ride in any environment from city traffic to mountain single track and anywhere in between.
After our modifications, this street tracker looks as good as it runs. Here is what it looks like now:
Want Mancos Motorsports, LLC to do your motorcycle or dirt bike overhaul? Give us a call at (970) 882-3027 or stop by to talk about your machine and what you’d like it to look like. And don’t forget we work on all motorcycles, ATVs, UTVs, and OHVs too.