Torture Test Magazine's 2003 CRF230F

 

This 2003 CRF230F has been in my possession since 2019 and has served as a trusty steed, mostly for leisurely rides. This is not the 2008 model that I owned years ago. On this 2003 model, initially, I kept the bike stock and simply enjoyed it for its fun and easy-to-ride nature. However, my desire to challenge myself led me to enter the 2022 Glen Helen 24 Hour Endurance Race, where I decided to make some mild modifications to optimize the bike for the race. My efforts paid off as I was able to secure a podium finish in 3rd place. The CRF230F has proven to be an all-around solid performer that is easy to handle and maintain, without breaking the bank.

Races and events this bike has completed:

Videos and other media:

 

Bike Setup

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Suspension, Steering, Controls, and Brakes

Front tire (primary wheel set): Tusk EMEX T-35 Soft/Intermediate 90/100-21. Available at Rocky Mountain ATV/MC

Front tube (primary wheel set): Nuetech Nitromousse Standard NM21-235. Available at Rocky Mountain ATV/MC

Front wheel (primary wheel set): OEM DID 21x1.60

Front brake rotor (primary wheel set): Tusk Stainless Steel Typhoon Brake Rotor. Available at Rocky Mountain ATV/MC

Front tire (secondary wheel set): Kenda Trakmaster II 80/100-21. Available at Rocky Mountain ATV/MC

Front tube (secondary wheel set): Nuetech Tubliss. Available at Rocky Mountain ATV/MC

Front wheel (secondary wheel set): OEM DID 21x1.60

Front brake rotor (primary wheel set): OEM

Front brake line: Galfer Steel Braided Brake Line 

  • Really not sure what exact brake line this was. It was longer than the original brake line and it was just laying around, so I used it because I needed a longer line.

Front forks: 41mm KYB open-chamber cartridge forks from the 1996-2004 generation of XR250R

Front fork valves: Racetech Type 3 Gold Valve Conversion Kit - Available at Rocky Mountain ATV/MC

Front fork springs: Whatever came in these forks I found on ebay

Front fork oil: Maxima 5W fork oil - Available at Rocky Mountain ATV/MC

Handlebars: Renthal 971 7/8" aluminum bar, Carmichael bend - Available at Rocky Mountain ATV/MC

Grips: ODI Lock-On Half Waffle - Available at Rocky Mountain ATV/MC

  • Note: I had to make a custom throttle cam to use these on the 230. I'll upload the STL file next time I make one.

Brake lever: Tusk Brake Lever - Available at Rocky Mountain ATV/MC

Clutch perch: Tusk Quick Adjust Clutch Assembly - Available at Rocky Mountain ATV/MC

Clutch lever: Tusk Quick Adjust Clutch Assembly Lever - Available at Rocky Mountain ATV/MC

Handguards: Tusk D-Flex Handguards - Available at Rocky Mountain ATV/MC

Rear brake: Tusk Carbon Compound Shoe. Available at Rocky Mountain ATV/MC

Shift lever: OEM

Rear brake pedal: OEM

Footpegs: OEM

Rear shock: Vonkat El Jefe Rear Shock - I'll be selling these on this website soon!

Rear shock spring: 585lb, comes with the Vonkat shock

Seat: OEM 

Seat cover:  Neutron Gripper Seat Cover - Available at Rocky Mountain ATV/MC

Rear wheel: OEM DID 

Rear tube (primary wheel set): Nuetech Nitromousse Standard NM18-305 - Available at Rocky Mountain ATV/MC

Rear tire (primary wheel set): Tusk EMEX T-35 Soft/Intermediate 110/100-18 - Available at Rocky Mountain ATV/MC

Electronics

Headlight: Tusk V2 LED Light Bar - Available at Rocky Mountain ATV/MC

Tail light: Tusk LED Taillight - Available at Rocky Mountain ATV/MC

Spark Plug: NGK DPR8EIX-9 Iridium - Available at Rocky Mountain ATV/MC

Stator: Fully-wound for ~80 watts peak output

Ignition controller: OEM

Regulator/Rectifier: Trail Tech Universal Regulator/Rectifier - Available at Rocky Mountain ATV/MC

Coil: OEM

Battery: Tusk Lithium Pro LiFePo4 battery - Available at Rocky Mountain ATV/MC

 

Fuel, Intake, and Exhaust systems

Fuel tank: Clarke 2.9 gallon tank - Available at Justgastanks

Petcock: OEM

Carburetor: OEM

Jetting:

  • 125 Main
  • 45 Pilot
  • 2003-2005 needle - middle notch
  • Standard float height

Air filter: Tusk First Line Air Filter - Available at Rocky Mountain ATV/MC

Exhaust pipe: China Special (Piece Of Junk) - Available at Amazon

 

Engine Components

Camshaft: OEM

Piston: OEM

Clutch: OEM

 

Final Drive

Countershaft sprocket: Primary Drive 12T Steel Front Sprocket - Available at Rocky Mountain ATV/MC

Drive chain: Primary Drive 520 ORH Gold X-Ring Chain - Available at Rocky Mountain ATV/MC

Rear sprocket: Primary Drive 50T Steel Rear Sprocket - Available at Rocky Mountain ATV/MC