Last issue, we completed the modern (USD) fork swap, but were no completely happy with the performance of the forks. Check out the FORK OIL SWAP article elsewhere in this issue for how this was handled. Now, for the usual battery of information, question, answers and feedback, read on.

I've just completed "uncorking" my CRF, and what a difference it makes!  My only concern is with the spark plug.  It keeps getting all fouled up with deposits.  Is this a result of the mods, or should I be looking for another cause?  Thanks for your help.  Keep up the great work! 

Gratefully,

Rob D.

You’re fouling the plug for another reason. Either you have a dirty filter, a poorly oiled filter, a badly sealed filter, or junk old gas. There’s no way the jetting changes will contribute to a fouled plug.

Hi Rick

I have an intermittent problem with my CRF230 , when the bike gets serverly jolted over rough ground or landing jumps sometimes I get an almost total lose of power such as you would running out of fuel . The bike then carries on for a while running like its on full choke before it comes good again . Any help or suggestions would be appreciated .

Cheers

Steve Schulz

Check your float bowl for crud or water. It sounds like something is blocking your main jet every now and then.

Alright thanks for the help. Oh and on the sprocket if Rick kept it the same it would have 50 teeth right? And would the bike have a better power all the way through and a faster top end, or did it slow the accerleration?

Thanks agian for the help you guys are smart.

Styles Reidhead

Adding two teeth to the countershaft sprocket while keeping 50T on the rear will give you much more top and mellow out the acceleration in each gear. All things considered, the 230 with the larger c/s will blow away a stock bike through the gears.

I just wanted to thank Super Hunky for the excellent article on making the CRF230F work. I bought a 2006 for my wife's first bike (she's vertically challenged) and while we are still breaking it in performance as noted is erratic at best. I plan on making the jetting and baffle (baffle is a good word, these should have come with big orange pull tabs to yank the damn things out on delivery why they did not is *baffling*) modifications ASAP. I think I'll swap the tires as well. The suspension and gears can wait until she figures out there are more than two gears :)

I started my search tonight looking for some jetting information to correct the idling and starting issues and came away much richer from the excellent articles!

Again just a huge thank you, I really appreciate the information.

Sincerely,
Ran Hooper Jr.
So Cal M/C

Glad you enjoyed the articles. Once the missus gets faster, she'll demand all the mods.

I did the airbox, baffle and jet replacement just like you said to do. I really helps. It's a good light bike for an Eastern Single Tracking 51 year old.

Thank you,
John Pitts

Another satisfied customer. Next, try the forks.

I own a 2004 CRF230f, and I was wondering if I only took the baffle out of the muffler and did nothing to the intake, would i still have to rejet?

Lee Wefel

Certainly. Don’t do things half-way. Follow the instructions.

I just got a 2006 crf230. I am trying to do part one. But every one is telling me to go with a 45 not the stock 42 jet. What do you think? Is the stock jet going to be OK? I ride anywhere from 500 to  3,500 feet. Thanks for your help. Kevin

We put the power up kit in with those jets for a reason. Tell your friends to pound sand.

This is A++++++ the bike know feels like a 250 + ....very fast and quick.

Thanks.
Ivan

The stock skid plate on the 2005 CRF230 leaves a lot to be desired. Do you have any recommendations for an aftermarket skid plate?

Michael E. Henderson
Mississippi

We'll dive in that later on. For now, the stocker is doing an OK job.

I just picked up an 05 CRF230 and had them remove the air box restrictor, install the BBR exhaust, and the Honda Power Up jet kit......I am very pleased at this point......especially because I got that all for a little over $100 under MSRP.  I found this article and it will be my Bible so to speak for this bike.  I was wondering two things.....One how come you didn't replace the stock handle bars they seem a bit weak (if you were to do so any suggestions?).....Two do you think it's worth getting an aftermarket air filter for this bike??  I'll probably be changing the gearing next followed eventually by the suspension......Thanks a lot, by the way, this article is what made up my mind on the purchase!!

Adam Southergill

So far, I haven’t crashed the Honda, so I can’t complain about the bars yet. The stock air filter is OK, and will be replaced after a year or so of use.

Hello again. Here are some pictures of my 230.  I have finished doing my last mod which was the big bore and porting to match a new 32mm mikuni flat slide carb.  I put it together and tuned the carb cause it came extra rich.  I soldered the jets shut and drilled them with a smaller diameter.  Did the same for both the idle jet and the main.  I had to increase the size of the holes till I got proper idle and top end power. Now I am going to buy an assortment of jets that are close to the diameters that I drilled and play with that and the clip position on the carbs needle.

The bike pulls the front tire off the ground on throttle.  I bought all the parts from Dennis Kirk Carb was $160 throttle controls were another $40.  The rest was porting the head and intake to match 32mm carb. I made my own duct to the stock air box but I could have just hanged a filter on the end. It revs allot faster and the gears feel allot longer.  It feels like a different bike.  The mod has to be done in conjunction with other stuff like the big bore and a proper exhaust.  I still have to put a cam in it.  So I imagine it is going to wake up even better after the cam installation. 

I did a couple of hole shots or drag races and every time after second gear the bike would stand up on throttle and continue to travel in one tire.  Before I had to clutch it and rev it in the right gear to pop the front off the ground.  I just wanted to share my experience.  It might be useful to others that want to get the most out of the 230.  Thanks again for all the hot tips. 

Andres Anzalotta

Excellent job, Andres!  You are to be congratulated for such a good effort.

Hey, I bought a 05 CRF 230 and was wondering if these mods you recommended (baffle out, snorkle) makes a difference. I would love to do this, I was just wondering because my friend thinks his KX100 will beat my bike and Im trying to get all the mods I can on my bike. His bike has various parts like a Fatty pipe ( it was raced before he got it) and I don't want him to be able to smoke me. Any help would greatly be appreciated.

Thanks a lot!

Bill

Re-read the article and install the jets when you remove the baffles. Chances are the KX 100 will still edge you in a drag race if he's the right size for the bike.

hey how you doin looken at the project 230 looks good i did close to same but i used WP forks. Here is a few pics if ya care to see great info on project had everthing done almost when i read it first but its great for people who might be nerved about worken on there bike.

T. Gibson

Another fine job. Congrats!

Hey Rick,
I would like to know if the jetting would do a difference on my 230F since I already have the BBR Exhaust system??
Thanks
Best regards,
Nick M.

Putting the BBR pipe on would demand a jetting change.

When shimming the pre 1988 conventional fork on the CRF230 fork swap, a spacer was put on the bottom side of the head tube. Could it also be put on top as is the case with the inverted fork install? I am not sure why it was not spaced on the top rather than bottom. Perhaps a bearing race issue or was it just preference at install time? I plan on putting the spacer it on the top of the head tube as you did with the inverted fork but with a 1984 CR250 fork. Do you see any issues with that?

Eric

Shouldn’t be any problems at all to run the spacer on top.

I honestly believe that the 150 and 230 are throw back bikes and are really unique at this time in this sport with new high maintenance 4 strokes making up a large portion of off-road bike sales. These bikes however have a few problems to overcome and your testing/project bike is leading the way to finding great solutions. I am thankful for your insight because I love both our CRF 150 & 230.

One issue seems to come up over and over no matter where you look...Fuel capacity. Neither IMS nor Clarke appear to have any 3.0 + gallon fuel tanks in the works (admittedly these bikes get great fuel mileage...but). I really wish someone would design a well thought out +1 gallon tank, as I'm sure it would sell like hot cakes. With this problem, have you given any thought to testing some alternatives, such as the Acerbis .8 or 1.3 gallon front plate auxiliary tank (although not practical if you are going to rewind the stator, add a rectifier and lighting), mounting a stock XR250 tank, or some other possible larger fuel capacity alternative?

Many thanks,

Steve

I don’t see any real need for a larger tank, Steve, as the bike gets over 100 miles per tank in stock trim while trail riding. I’ll talk with IMS and see if they have anything planned. We haven’t planned on lighting.

Rick,

 I own a Honda 2004 230f stock.  My question is this; I would like to remove the factory exhaust system and add a BBR system to the bike, do I need to, or should I modify the bike's jets as illustrated on your project? 

Thanks,

Cali Novice

Absolutely put the jetting kit in if you install any aftermarket exhaust and baffle removal.

Hello Rick,

I noticed in your project the complaint on the black box rubbing.  Here’s the solution Baja Designs recommended when I installed there dual sport kit.  With a couple zip ties it will hide quite nicely under the gas tank.

Garry Janota

Superb! We’ll share this good tip with our readers, Garry.

Hi,
I currently own a 2004 Honda CRF230F. After reading what you did to your project bike, i was thinking about removing the air box restrictor. In your write-up you mentioned that when removing the baffle and the restrictor, we should change the jetting on the bike, if i only remove the restrictor, to you think it would be necessary to change the jettings?
thanks
Matt

No question about it.

Rick,

What a pleasure reading the whole series. The jetting & baffle change really made it feel like a different bike. As you pointed out, now the suspension is really showing itself to be weak. My son is about 5'8", 170 lbs and growing like a weed. He is turning into a pretty aggressive desert & trail rider, & is already bottoming out the stock setup. We just got back from a weekend at Dove springs, and he now runs circles around me (old dude on a DR 650).

I've recently picked up a donor 85 XR350 that I was going to use as a play bike to try to keep up with him, but I would sacrifice it to upgrade his 230. I am wondering if I could swap the front end from it onto the CRF. I know that you played around with many fork sets, but I didn't see any reference to this one. Any thoughts on the 350 forks? They seem to be heftier, & have more travel. What are the chances that I could swap the whole thing out? Might I be lucky enough that it is a bolt-up? What about the rear shock? It at least has a remote reservoir and is adjustable.

I know you are busy & don't have all of the answers, but any bit of info would be a help.

Thanks,

Ray Odrey

Yep, the forks will work OK, but they’ll feel way too stiff, as the XR350 weighs in a close to 300 pounds, while the 230 hits the scales at about 70 pounds less. You’ll have to do a lot of oil and spring changes to get these forks to be supple.

Great stuff!!!

I just got into this sport (as an adult) with my 14 yr old son. We purchased two CRF230's and couldn't find any good info on tricking them out. This is really great stuff. Had already installed pro-circuit exhaust but the carb mods were awesome. Looking for the tires next and the spoke job. Holding off on the rear shock due to the price. Everything I do cost me twice.

Thanks Again!

Jerry McCormick

Keep posted, as we’re not done yet.