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Old Today, 09:17 PM   #1
Pwnzilla OP
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Joined: Jan 2009
Oddometer: 228
CRF230F Dualsport Conversion Successful - All Mods Detailed

In 2011 I bought a new left-over 2009 Honda CRF230F. I fell in love with this bike. In my mind it's the best all-around trail bike available. Taking cost, cost of ownership, ease of mods, dependability, and fun factor into account.

I rode this bike for a couple seasons off road and had a blast. I decided that since I like this bike so much that I'd try to do the dual sport conversion. I live in PA and I read up on the local requirements for a street conversion and it didn't look too hard. I'll detail all the paperwork and processes at the end of the post.

I wanted to share everything I've done to this bike so others can enjoy this fantastic air cooled thumper.

I decided to use this bike for a dual sport for a couple reasons:

1) It's super fun to ride
2) It has 6 gears, which is great for gas mileage and top speed for highway use.
3) It uses the same engine as the CRF230L so oil requirements are met.
4) It uses the same clutch perch as the "L" so a standard motorcycle mirror will screw into the threaded hole the "L" uses stock.
5) The stater will handle lighting without a rewind.

I'll break down the parts lists into two sections, Performance and Dualsport. I'll be listing the part numbers for the harder to find items.

Performance:

Carburetor rejet:
  • OEM #135 main jet Part#99103-KPS-1350
  • OEM #45 pilot jet Part#99103-KPS-0450
  • OEM "power up needle" Part#16012-KPS-921
Air box baffle removed
FMF Powercore 4 slip-on exhaust
Note: the stock exhaust baffle can be removed with one T-25 screw. I've found that this is practically identical to the FMF except for the extra weight of the stock muffler. The FMF sounds slightly better
No-Toil pre-oiled two stage high flow air cleaner
Renthal 7/8 CR High bend bars
ODI locking grips
BBR 30% stiffer rear spring Part#660-HCF-1505
BBR 30% stiffer front springs Part#650-HCF-2305
Flatland Racing skid plate
Acerbis Rally Profile hand guards
MSR extended folding shift lever
Regina 520 o-ring chain

Dualsport:

Baja Designs Dualsport EZ-Mount kit Part#12-1050
Note: Includes headlight bucket. Headlight with high, low, and running lights. Horn. Front and rear turn signals. Rear sub-fender. Control panel for bars. Wiring harness(s). Rear brake light switch for rear lever. Rear tail light with running, brake, and license plate lights. License plate bracket. Key switch for lighting system. Mounting hardware. Instructions. Relocation of the CDI is required. Drilling a hole in the rear brake lever is required for the brake light switch. Slight modifications to battery box required.
Vapor Trail Tech Part#752-900 - digital speedometer/tachometer/odometer.
Note: Front brake caliper needs tapped for a screw to mount the speed sensor, this can be done with a steady hand and a sharp drill bit
Dunlop D606 DoT approved tires:
Front: size 90/90-21. Rear: size 120/90-18
JT Sprockets 14T counter-shaft sprocket Part#JTF327.14 14T
Note: stock is 13T, slight modification to chain slide required for 14T to fit.
Left folding Dualsport Mirror (http://www.procycle.us/bikepages/tw200.html)

Wolfman fender bag

Paperwork and Title Process in PA

Required items for street legal motorcycle in PA:
  • 1 mirror
  • Headlight with running-light, high, and low beams
  • Turn signals front and rear (this is a gray area, just do it anyway to avoid complications)
  • Horn
  • Odometer
  • Speedometer
  • Taillight with running-light, brake light, license plate light. Switch activated at lever(s).
  • DoT approved tires front and rear
  • Working front and rear brakes
  • Front and rear fenders
  • Spark arrested stock exhaust or equivalent db level
  • Exhaust heat shields
  1. Locate an Enhanced Safety Inspector (http://www.dmv.state.pa.us/pdotforms...edstations.pdf)
  2. Have an Enhanced Safety Inspection done on the bike after all modifications are complete. You will need the bike's Title in hand. You'll also need all invoices for the parts required for the conversion with sales tax paid.
  3. The Enhanced Safety Inspector will take photos and fill out the proper forms for submission to the state
  4. Take the Enhanced Safety Inspection photos and forms to your local notary along with the Title, Proof of Insurance and invoices.
  5. If your Title says "ORV" but does not specifically state "Off-Road Only" then you'll need to file for a "Modified" title. If your Title says "Off-Road Only" then you'll need to file for a "Reconstructed" title.
  6. If possible take an expired or existing motorcycle license plate with you to the notary to be transferred, it saves you money, and you can ride on it with a pink-slip.
  7. The notary will submit all of the photos and documents to the state for approval.
  8. The notary will issue you a pink-slip temporary registration.
  9. The final step is to get a normal state inspection done for the sticker that goes on your fork. Why you need an Enhanced and a Regular inspection is beyond me, more money I guess.
  10. At this point you're "legal" but it's a gray area as the new registration is not approved yet. Ride at your own risk.
  11. Wait for the notary to contact you with any issues the state had with your application. If it's approved then the notary will receive your plate and a registration card and sticker will come in the mail.

I've road tested it now that it's all legal. Top speed with the 14T:50T gearing is ~70mph, comfortable crusing speed ~55mph. The tires aren't too sketchy on pavement. It's so much fun to ride! It'll pull wheelies in 2nd gear no problem without clutch work. The lighting is a little weak at night but it does it's job. Baja Designs does offer a stater re-wire if you need to ride at night a lot and need a brighter bulb. I'm not sure what the gas mileage is yet. I'll report back on my findings.



I'll post some more photos if people are interested in how I mounted everything.

Let me know what you all think

I know that some are going to say "why not just buy a CRF250L?". I didn't because I've ridden that bike and it's a complete dog. It's too heavy for a 250, the transmission is too wide, the fuel injection re-mapping is a pain, upside down forks are a hassle, liquid cooling is a hassle, and has all the emissions bullsh*t. I like durable, low maintenance, air cooled bikes.

-Seth
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2009 Honda CRF230F
2013 Yamaha TW200
2014 Harley Iron

Pwnzilla screwed with this post Today at 09:46 PM
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Old Today, 09:43 PM   #2
TennesseeVol51
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Joined: Sep 2014
Location: The Tri-Land Alabama--Tennessee-Mississippi
Oddometer: 5
Super Job!! I really like what you did.

I would like to see pics of the list below

1-- Can you post a pic of your air filter and air box

2-- The renthal bars and risers

3-- Picutres of your wiring for blinkers both front and rear including the way you mounted the switch to the levers
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Old Today, 09:57 PM   #3
Pwnzilla OP
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Joined: Jan 2009
Oddometer: 228
Brake Light Switch, I used an old bicycle inner tube to cover the wire so it wouldn't get burnt by the header or get caught on anything:


Under Rear Sub-Fender for Taillight and Turn Signals:


Under Fender Showing Wire Route:


Taillight Assembly and License Plate Bracket:


Behind Headlight Bucket and Dash. I couldn't use the Renthal crossbar pad because of the ligthing key switch and Vapor computer. I'm using the stock risers:


I don't have a picture of the airbox exposed but here is a picture of the baffle that you remove. It just pulls out of the top of the air box, no tools required:
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2009 Honda CRF230F
2013 Yamaha TW200
2014 Harley Iron

Pwnzilla screwed with this post Today at 10:03 PM
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