2024 YAMAHA YFZ450R PROJECT – PART 2

On Nov 27, 2024

2024 YAMAHA YFZ450R PROJECT – Stage 2: Race-inspired upgrades from DBR, ITP and RWI

By the staff of Dirt Wheels

Nerf bars, a new grab bar, race-grade protection, and wheels and tires comprise stage two of our 2023 Yamaha YFZ450R build with parts from DBR Race Products, ITP Tires, and a new wheel manufacturer named RWI.

Last month, the focus of our 2024 Yamaha YFZ450R project was primarily performance, with intake, exhaust, and ignition upgrades manufactured and installed by Duncan Racing, along with drive and chassis protection bolt-on products. This month, we installed some race-inspired products that protect the racer and vital performance components while improving reliability. We’ve also upgraded the stock wheels and tires to be puncture-resistant, especially with lower air pressure for a soft ride and enhanced traction.

DBR RACE PRODUCTS

Chris Borning founded DBR—dedicated to his son Dominic Borning, who tragically passed away at a young age that same year—in 2021. Dominic’s passion for racing and building ATVs inspired Chris to develop ATV products with the best materials and fitment to withstand the rigors of racing. Furthermore, Chris has created some impressive hybrid race quads, including a two-stroke race quad, which his son Trenton currently races at the youth level.

These DBR nerf bars were easy to install and have a desirable, rigid fit with integrated heel guards. Their excellent construction is finished with your choice of powder-coated color. DBR’s optional Xtreme nerf-bar peg design extends aggressive teeth out to the ends of the bars. The peg height is also 1.5 inches lower than stock for added comfort and easier seated-to-standing transitions.

**The DBR battery box is stronger than stock with steel construction. It also has a vented design for faster cooling in hot environments. DBR also makes battery boxes for larger-size batteries.**

DBR NERF BARS & GRAB BAR

We ordered a set of DBR nerf bars in Yamaha Blue powder coat with black nets (other colors available for nerfs and nets). The color perfectly matched the stock Yamaha rear fenders and mid-section body plastic. Assembly was easy with basic metric wrenches and some drilling to bolt the nerfs to the DBR hardware. No modifications were required to stock parts. Only a little muscle is needed to bring everything together, but the fit is nearly perfect, with protection extending to the integrated heel guards. Once everything was fastened tight, the nerfs felt as if they were an extension of the frame with no rattles, loose fittings or flex. The upgraded Xtreme pegs are our favorite feature, extending to the outside tube. The pegs also rest 1.5 inches lower than the stock, which taller riders will appreciate. Comfort is multiplied with more room to hang off the seat in the corners and an easier transition between seating and standing.

Price: $579 with Xtreme pegs (standard pegs $499)

The rear grab bar we received is simplified for racing purposes without tabs for the stock taillight, which we removed, or a dune whip mount. However, you can order the grab bar in various powder-coat colors with both. It also comes with tabs for the number plate included in our package. Everything lined up excellently using the stock bolts and hardware.

Price: Starting at $95

DBR also offers an ATV Protection in a Box kit that includes standard nerf bars, a grab bar and a DBR Stump Jumper front bumper with a number plates for $649.99, a $65 savings.

To protect the expensive high-performance Vortex ignition we installed last month, we picked up a DBR EXO cage, which offers a snug mount to the DBR battery box. DBR’s EXO cage for the Vortex ignition offers easy-access mapping and fuel adjustments, which can be made in seconds with a screwdriver.

**Believe it or not, spark-plug caps do come loose and can delay your ride or even cost you a race. DBR’s spark-plug holder makes sure you’ve always got spark.**

DBR BATTERY BOX, EXO CAGE AND SPARK-PLUG CAP HOLD-DOWN

Made with steel and in your choice of color, the battery box is far stronger than the stock battery box and does not require airbox modification for installation. The bottom of the box includes four rubber grommets to cushion the battery, and a steel crossbar uses stock hardware and rubber mounting across the top of the battery to hold it securely in place. It has an integrated bracket to support the stock electric relay cluster and bolt holes for the Yamaha tip-over sensor, and you can bolt the stock ECU directly to it.

Price: $180 stock battery or $225 XL battery

In part one, we replaced our stock ECU with a high-performance and adjustable Vortex ignition, but DBR also makes a steel EXO cage for it with a mounting bracket that fastens to the DBR battery box. The EXO cage includes rubber grommets for a tight and secure fit, and there are four access holes at the bottom of the cage to change Vortex map settings, and make low-, mid-, and high-range fuel adjustments. The EXO cage mounts to the back of the battery box for adjustment access with a small screwdriver.

Price: Starting at $130

The DBR spark-plug cap hold-down does precisely what its name claims—it holds the spark-plug cap in place to eliminate the possibility of misfire, and protects the internals of that expensive Vortex ignition from damage.

Price: $45

**When the trail gets nasty, ITP’s toughest Holeshot tire is up to the task with a 6-ply design, heavily armored sidewalls and aggressive tread for every terrain.**

**In a world where sport quad wheel choices have dwindled to a few, it’s great to see a new wheel maker step up to the plate. RWI offers standard rolled-edge and beadlock wheels at a great value.**

ITP TIRES & RWI BEADLOCK WHEELS

Much of our riding in the Southwest involves conquering big rocks, embedded rocks and rocky climbs—did we mention rocks? While this YFZ will see plenty of MX and sand using a variety of tires, we’ve been itching to try out the ITP Holeshot HD tires in the worst conditions the Arizona desert can throw at it. We ordered a set in 20×11-9 sizing at the rear and 22×7-10 up front. ITP claims these are the toughest Holeshots they make. They are a little heavier with super-strong sidewalls and 6-ply-rated construction. They also have a wider stance than other Holeshot offerings with a flatter tread space. With all the added strength, the tread still offers tall and flexible knobbies for excellent traction in all conditions—perfect for our test loop that mixes sand, hardpack and rocks with constant elevation change. Initial testing predicts these tires have a longer life span than most while maintaining excellent grip; they hook up great!

Price: See your local shop/dealer

RWI’s ATV beadlock wheels are designed with advanced features to provide superior performance. These wheels are constructed from 6061 T6 aircraft-grade aluminum, and boast a universal bolt pattern design; reinforced rolled lip and single beadlock, reinforced nut plates; machined aluminum ring; OEM-quality Gloss Black powder coating; and an aluminum-braced valve stem. With a multi-bolt pattern design, they are compatible with most sport ATV brands and models, including Can-Am, Honda, Kawasaki, KTM, Polaris, Suzuki, and Yamaha modern and vintage three- and four-wheelers. You can do it all with one set of wheels for those with multiple brands in the garage, or race machines that mix different hub and spindle geometry. Weight is on par with competing aluminum beadlock wheel manufacturers, and the beadlocks have proven airtight.

Price: $95 for rolled lip without beadlock, $135 for beadlock, and $150 for double-beadlock rear wheels. Get a complete ATV race kit for front and rear, starting at $460.

WHAT’S NEXT?

In the next issue, we’ll tackle suspension, making the stock long-travel setup even longer. We’re happy to report that our new suspension components are almost ready for installation. So, who did we go with for A-arms and shocks? You’ll just have to wait and see. Stay tuned!

CONTACTS

DRB Race Products: dbratv.com, (507) 828-1233

ITP Tires: itptires.com, (909) 390-1905

RWI WHEELS: rwimotorsports.com