[1kayaker]

So I just bought a used 450x and all was going just fine. It was a little hard to kick over, but I've heard these bikes can be tougher than the 250x. I did hear some pinging once in a while, but again a buddy with a shop told me that this was normal.... Anyway, it was really hard to start today, but finally got her going. Stopped to take a small break and when I tried to start it up, the entire crankcase cracked around the kick starter and now I either need to replace the entire engine (which might be cheaper labor wise than buying the parts and paying for the rebuild)
Any thoughts?

[JimDirt]

If you can find a used/EBay case , it will save you a bunch , but its common for them to break when kick starting if you let the kick start slam back , like if your foot comes off , , there are some topics here somewhere about reinforcing the case to prevent this from happening , i believe there is a part/stop in the "450X Parts" as well.......question .... why were you kick starting it instead of using the button ???

[1kayaker]

It was having a very hard time starting. I need a new battery for sure, but the break happened on the trail when using the electric starter. Of course the main crack must have started earlier in the day when kicking...

[JimDirt]

Wow , i have never heard of one cracking while using the E-Start , so is the crack in the clutch cover (the one that covers that whole side) ?? , or in the main case ???

[1kayaker]

The back behind the starter sheared off part of the crankcase and the cover. Its a minimum of $600 in parts PLUS LABOR. That's why I don't know what to do. Entire engine replacement which will be more expensive parts wise but cheaper labor wise, or vice versa….

[JimDirt]

Well doing it yourself would save a bit of money , its basically pulling the engine out , pulling the top end , and splitting the case ( no special tools needed to split the actual case) , its not really that difficult , about the only "specialty tools" you would need would be a flywheel puller and a clutch tool , most everything else just comes apart

OR , you might again , look on EBay for a complete bottom end , you could probably get one for a couple hundred and just put your top end on it , that will save quite a bit as well , and its easily done , as all it would be like is replacing a top end , with the exception of pulling the engine out (i would replace the timing chain as well) , so you would be in it maybe $300-$400 at most total with gaskets and everything and have a great bike when your done

EDIT: , i just did a quick look and found lots of 450R cases and 1 250X case , all under $200 , but did not find a 450X case , at least not yet , looks like people are wanting a bit of money for a complete bottom end , but that does not mean they are not out there , i will keep a eye out for a complete bottom end at a fair price and let you know if i spot one , as i am always on EBay looking for stuff i dont really need ... lol ...

[1kayaker]

used bottom end range $800-$1200 so far and that is without the crankcase covers… I guess pulling the engine myself would be the cheapest and if its not rocket science, I could probably get it done and LEARN about my bike… Just a bit daunting of a task to consider embarking upon..[/img]

[1kayaker]

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[JimDirt]

WOW !!

That is pretty bad , i have seen lots where they break the outer case (where the kick starter assembly is) , but have never seen the inner case break off like that , , but , yea , pulling the engine is easy , get stuck on anything just ask , and i think there are some posts around here showing the process , its basically pulling the subframe (or at least lifting it up) , and pulling Exhaust , Coil , Carb ,Chain (obvious) ,Kick Starter , Shifter , Over Flow Tank (between frame rails under skid plate) , Clutch Cable , Rear Brake Pedal Assembly , all Electrical Connections to motor , Radiator Coolant and Hoses ,Swingarm Pivot Bolt (make sure the bike is on a bike stand not the kick stand when removing this), and engine mounts (take them off the frame as well to give you room , then lift and tilt and it should come right out

Do yourself a favor and by the Factory Honda Service Manual (ken sells them here) , it will tell you everything you need to know and has lots of pictures for the mechanically impaired

[JimDirt]

Just so you know , that 450R motor in the For Sale section will not bolt up in your X , the frame is a different width and nothing will fit

Unless you have "other" plans , but it wont work in the X frame

[chopper]

Just so you know , that 450R motor in the For Sale section will not bolt up in your X , the frame is a different width and nothing will fit

Unless you have "other" plans , but it wont work in the X frame

This is not accurate, if you so choose you can in fact mount any 05-08 450R motor into the 450X frame. This is a direct bolt in swap, of course the 2 best features of the 450X will be lost in the swap (e start & wide ratio gearbox).

[JimDirt]

If you have done it then i stand corrected , though i have never put them side by side and measured with the exception of my 02 450R which IS different and the R engine will not bolt up directly without making parts , and everything i have read says the 2 bikes share nothing , i know i tried a 450X shifter (aftermarket) on my 02 R and had to shave down the back side of the foot pivot because it hit the ignition cover on my R , it was like 1/4" off , but again , i made my measurements off a 02 and my 06X though i did not measure the cradle to see if it was the same

[spaceboy]

Or do a 500AF conversion.

[crazybrother]

Just so you know , that 450R motor in the For Sale section will not bolt up in your X , the frame is a different width and nothing will fit

Unless you have "other" plans , but it wont work in the X frame

This is not accurate, if you so choose you can in fact mount any 05-08 450R motor into the 450X frame. This is a direct bolt in swap, of course the 2 best features of the 450X will be lost in the swap (e start & wide ratio gearbox).

This is true but you will need the 450R motor mounts and the radiator hose may hit the header...

[chopper]

Just so you know , that 450R motor in the For Sale section will not bolt up in your X , the frame is a different width and nothing will fit

Unless you have "other" plans , but it wont work in the X frame

This is not accurate, if you so choose you can in fact mount any 05-08 450R motor into the 450X frame. This is a direct bolt in swap, of course the 2 best features of the 450X will be lost in the swap (e start & wide ratio gearbox).

This is true but you will need the 450R motor mounts

Not quite but close , the fact is that the upper motor mounts must match the frame not the engine. Both the 450X and the 05-08 450R engines have their mounting points in the same location, thus the 450X upper brackets can be used with either engine. What you may have confusion about is when swapping the opposite from what is being discussed here , the 450X engine into the 450R frame. When mounting the 450X into the 450R frame the 450R upper motor mounts must be used from the same year model as the frame being used , this is due to Honda changing the angle in which the motor mounts into the frame. As for the hoses at the water pump , if the R engine is being used in the X frame and retaining the X radiators then a Y or a T fitting would be needed to join the 2 lower radiator hoses together prior to attaching to the water pump due to the R water pump having only 1 inlet vs the 2 on the X water pump , any clearance issues at the header should be simple to eliminate while doing this necessary plumbing modification.