I finally got my Rally sorted out. The most complicated issue was the ecu tune. I live in Indonesia, there the second gen Rally is still 249cc, gen one stroke. My bike came with the "big and locked up tight" European ecu. It took months, but Maverick at 550 performance did his magic and was able to tune it. My bike has YSS shock Racetech springs and gold valve Full Blackwidow exh Airbox/big snorkel mod Ecu tune Hd clutch spring and full size 1st plate Pro taper, barkbusters Skid plate, rack Tires So i am somewhere around 9500 usd into it. Love it. I still feel that Honda delivered unfinished, zero real life features bike. So many issues could have been addressed for little money. Or how about offering the "R" versions. Nope, Honda sucks when delivering these smaller displacement bikes. I also have the new mt450, its stunning what u get from cfmoto. Thx for very good content.
I think this is a great build. To me the big benefit of the 300 is it's low starting cost and incredibly long maintenance intervals. Similar to your KTM500, had a CRF450L and it started at at a much higher price than CRF300. The 450 still needed an 1000usd ECU in order to get decent fueling. These race bikes, once tuned by factory for emissions specs, are just not that fun to ride which is why places like Taco moto exist. Even after that, the 450 still wasn't a great *trail* / adventure bike.. It took further mods: 300 seat, 500 tank, 300 tower.. the list goes on. All great bikes really, and I'd stay that 450L still didn't have the "friendliness" of my 300L, which is great because anybody can ride it.
Nice one Shonky, really enjoy your videos. My wife rides a 2014 crf250l and has done nearly 50 000 km of adventure. Only basic mods- full suspension, rack, screen, bashplate, barkbusters, handlebars, heated grips, spotlights, seat mods. Bike has got her from Adelaide to Chambers Pillar, Palm Valley, Uluru and many incredible trips to the Flinders. She refuses to upgrade to anything else. She points to your sticker in the Lyndhurst pub every time we're there.
Wow, sounds like she has got a very well setup bike and is using it! People sometimes forget that you don't need the latest, most powerful bikes to have great adventures. I have modified mine because I like to tinker and I have enjoyed sharing the development of my bike.Plus, I like to embarrass the big bike sometimes 😎
After owning just about every adventure bike sold, I finally realized I needed to build, for lack of a better term, the bike that would be right for me. I landed on the 250 Rally. I just had to get it through my head that even with an unlimited budget, I would never end up where I did with the rally. It's not necessarily the cheapest option, just the best...for me. I think that is part of the message to others it's not a budget bike...it's the best bike you can build for the money!
Haters don't take into account the pride taken in making a bike right for you, and ignore the fact that the cost can be spread over time, and in the places you need it. Each sequential mod can be directly compared and evaluated as to how much benefit it brings and actually makes you better understand what works and why. Keep up the good work!
Great content Shonky....never mind the haters, they're just stupid!! Excellent bike build and reliable!! I'm also done with Big Orange and its associates. Too many issues, costs etc. I've had 7 KTMs and at a point, you are just fed up and they are just getting worse. And, when they said they are eliminating 300 jobs in their home country of Austria to move that production to China, that infuriated me. Betting none of the Big Orange senior execs take a pay cut though!! I'm now back to Honda and Yamaha for my fleet. Cheers, GSJack
Ive spent money on mine, not as much obviously but I enjoy doing the upgrades as well. I only boight the thing to ride on the roads, turns out its ok for everything and thats what I do now.. on road and off road, camping, had it over two years and I have looked for something more suitable but I cant find one without compromising on many things, at least I can now cope with my bikes compromise which is power on the roads - I just enjoy chilling now and plan my overtakes some weeks in advance 😂
Nice one Sean, just done a quick conversion from AUD to UK Sterling, roughly £8800 which is good, in fact its bloody brilliant for what you have turned an already brilliant bike into what is now a very capable machine. She is still light, reliable and in my opinion one of the nicest looking bikes out there and of course you still have that superb Honda reliability. Looking forward to your next adventure 👍🏻
Thanks mate. I was wondering how the cost would convert and relate in other countries. I'm happy to hear it's still good value in the UK. I'm really enjoying this bike more and more with these mods. I just can't wait to ride it on its next adventure.
Just under 3000 km on the 300 rally bought in late December 23, I am 100 kg ..173cm. Still on stock tyres , stock suspension, stock exhaust , stock handlebars ….stock everything . Standing up eliminates some of the suspension issues. The tyres are a worry in the wet both on and off road…ok in dry conditions . The power is modest , but the low first gear is brilliant for tricky uphill and downhill sections . The weight is an issue on trails , with stock power delivery ….no front wheel lifts . When you wash this bike …it looks brand new again .😊 Have ridden several eight hour days on the Honda …cruising backroads , fire trails , motorway😮, it does it all , in stock form .Just slower on gnarly or jumpy stuff than Shonkys beast . Just buy one …ride steady …it is a ton of fun .
Yes, as I've always said... they are a great bike in stock form as long as you take it easy on the rougher stuff. Glad to hear you are enjoying your bike. 👍
Too right about the tires in the wet, came off mine and slid down the road when it was three weeks old. I'm planning a pair of Motoz Tractionators next. PS. I'm about 100 kilos with my kit on and I find the suspension great for my needs, I don't know what the fuss is about 🙂
You have a great bike. It’s definitely my unicorn. I have the 300 Rally, and I would love to have that sort of performance in mine. I’m just a little bit skeptical at this time about going that deep into it, for reliability purposes. But the real reason that I’m not jumping in this deep today is, that I don’t have the additional 3-4 grand to spend on it right now. I have the essentials, suspension, handlebars, hand guards, seat, tires, rack, even a modified ECU. So when I do decide to go all in, all I have to do is send the ECU back to 550 Performance, and they said they would flash it again for free. It’s just a fun bike to ride, and I know its reliable. I’m just hoping that you keep this bike for at least another year, just to prove that the bike still has the Honda reliability that we all count on. In my younger days of racing quads, Big Bore kits could some times cause different issues down the road. But from listening to the guys over at 550 Performance, I have a little more confidence in this kit, and I just hope to see you prove my assumptions to be correct. Sweet set up! I bet if I rode your bike, I’d quickly find the money to upgrade mine. Lol...
Don't worry, I'll be keeping this bike for a while longer. I have plenty of rides planned and want to test/prove that even with my riding abuse, the Honda reliability is still there.
Yep, that's the reality Sean. Look what Mad had to do to a 501 Husky. Seat rear support for rackless baggage shocky hub and much more. Spend 16000USD for a Kove and nothing to spend. Your video would surprise many and made excellent point. Thanks
Nothing like full disclosure. Well done. You took the more expensive route though, stepping through the stages and ditching those parts. All good, except for those people who are happy with the stock bike. I have a standard 250 Rally and love it.
They really are special machines. Absolutely love mine, but I’ve only started my long term journey with her. You’ve really taken yours to the top, and thanks for bringing us on the ride! Ride safe!!
My pleasure. I just wanted to show what is possible with these great bikes. I've had lots of great rides and big adventures with all the stages along the way.
WoW, the intent for any bike is such a personal thing from money & down the line from there. I've only recently discovered this version of the 300 by Honda but it's got a few things I like but honestly I am particular to Yamaha....maybe b/c it's blue but no matter, this bike has most the things stock that I want. As I save my money, I have a list of 7 dual sport bikes that I've done like this one in getting ALL the info I can about pro's/con's, all the possible upgrades I want/need, and how feasible it'll be for me to do them. My reasoning runs kinda parallel to yours but you've actually explained it verbally & visually which very few people do. Like I said, I just found the Rally model while looking at prices locally & KUDO's for the rear gas tank. I'd never heard of that "mod" & now I'll find your video to add all of this into my Dual Sport list & breakdowns. You've done a pretty good job of how you've laid out this info.... it's powerful in my opinion but I'm not moved by the guys who buy bike after bike to mod them for a channel. Some are great but I feel you sincere blood, sweat, & even some tears in this deal. Thanks for that.... you ought to have more subb's. peace mate
You honestly moved me.... lol, I ain't an easy sell mate, so when I use a word like, "Sincere", it means something! Now that I've found you, I'll be looking at a bunch more videos to see things I have missed. I briefly looked at your channel but didn't see the "Rear Gas Tank" install or info but I'll go look again. That is an interesting add-on & this bike already had a little bit larger gas tank than others in my lists. I'm a Texan so there's plenty of places to ride. I want to get the most for my money since I can't work any longer it's harder to come buy. Thanks for all the help. peace
@@user-dv7hb2sc9m So happy to have you as I subscriber. I didn't do a video of that rear tank installation as there was a lot of fabricating new brackets to make it fit. Camel ADV now does a similar rear tank for the CRF300.
@@ShonkyProductions >> yeah, I'll look it up since you shared it was possible. This type of issue is why I mentioned the feasibility of things I might do down the road. Making my own brackets would make it less feasible at this point of my life since I own very few tools now. I was a Heating/Air Conditioning Tech so I did own a lot of tools/meters but they are gone. But the way you laid all of this out was appealing to say the least. It's why I posted as I did b/c I waste a lot of time trying to get at info where the Channel doesn't have your skillsets at video or conversing on the subject.... you are a better all around guy, there's few of ppl like you so I thank you again & I'll be asking other questions. peace
Hi Shonky, thanks for another informative video. I’ve been to the local Honda dealership so many times now looking at these bikes. I really like what you’ve done with your machine. I reckon i could buy one and probably be happy with just a suspension upgrade and tyre change. I’ll give it some more thought and watch your videos again. Keep up the good work. Cheers 👍🇦🇺
My suspension is next high priority! I’m 6’1 215 ish plus gear,so it is REALLY soft. It’s honestly fine on the road until ,well, it’s not. Tends to pogo a bit in certain circumstances. I found a stage one ecu made a world of difference on the twitchy throttle. I’ve got two old XRs that are both geared pretty low as I like to crawl around a lot so it felt pretty terrible stock by comparison. I personally found that the ecu and uncorked exhaust were enough for me.
@@Splintermill Hi, thanks for letting me know. I’ve watched videos of them being tested off road and sat on the bike in the show room. Back end is definitely way too soft for me. Thanks for the info on your power upgrades. 👍🇦🇺
Great job Shonky. Very interesting. The equation possibly also improves if you did a breakdown of the different stages. Get a second hand crf300, and do stage 1.5 plus suspension and i guess it would be like $11-$12k and it's a fun little machine.
I have a 300 rally, and I love it and wouldn't get rid of it. I have recently purchased an xl650v transalp for a longer trip, and just because I like that style . I love the video's keep up the awesome content.
Fantastic! I most say that I think if you take the stock 300 rally and include only the performance mods it’s a very good value of a bike, I have been testing ktm 500 etc but just feel that the the road comfort of the Honda is so superior and then with a bit more bite in the engine it’s perfect! I have a desert x now but have said if I sell this one I will go with a 300 rally and now also do engine mods 👌
I have a 300 Rally, and I was given the opportunity to ride a KTM 350 dual sport, and although the KTM seemed like a serious off road performer, and I’m sure it is, it was no where near as comfortable on the road as my Rally.
Great wrap up Shonky and that's less than expected and thanks for posting. People still ask me when you gunna get another bike..why and what I say ? After 7 years on the 250 Rally I still have places I want to take it and still have fun on it. Slow yes but gets me there.
Loving this build mate. Was amazed at your power wheelies a vid or two ago. I really want to upgrade from my old bush pig. But. Love the one you're with......
Thanks. Yes, my bike is so good now... plenty of power for having a little wheelie or wheel spinning fun. The grass is not always greener on the other side, so yes, Love the one you're with.
love my 300 Rally, also own a GS 1200, I'd trade power for less weight any day for off road, and it's not too shabby on road. It's definitely a swiss army knife. great vid mate.
Good value I say, considering you've got the exact setup you want plus Honda reliability and quality. Really appreciate your methodical and determined approach Sean, you're a credit to riders everywhere. I agree light is right, still wish they'd make a 450+cc Rally though! Cheers, Tim
nice... I purchased two camel tanks and was going to install them but without a panner frame I thought I would snap it off with my tusk setup... Any problems ... We are in Africa right now.
Thx for the great content. I am building my CRF300l. I have narrowed exhaust to 2 options and would appreciate your insight. Could you comment on the difference between the Akrapovic and Yoshi systems. I see you have the Akra slip on and a number of your friends have the Yoshi. Could you please advise on loudness/tone, weight and seize of end can. I am wanting the benefits of the added power but not too loud so I can comfortably ride all day in an Adventure set up. Safe riding and thx for all the info.
That’s an impressive build, you’ve done a very good job on that. One question….did you consider a CRF450 as a starting point, expensive I know but 20kg less weight and great stock suspension.
Thanks. I did consider the CRF450L but I wanted longer service intervals and less vibrations from the motor for longer rides. The CRF450 is basically an enduro motor, where as the CRF300 motor is a road bike motor that was designed to sit comfortably at high revs all day with good service intervals.
I really think you are the only one out there doing such detailed videos on all these mods so thank you! Question. Did you do all the work yourself? I really want to do the Big Bore and Cams but a little nervous to dive in. So far I have done all my upgrades myself on my Rally which are pretty extensive. I am very mechanically inclined but not experienced (if that makes sense).
Yes, I did it all myself. The hardest thing for me was checking and adjusting the valve shims as I'd never done that before. Watch plenty of videos and take your time. Get someone that's done it to help you or at least watch you, if you can.
Thanks Michael, those 5,000km are exactly what I use on my bike. Knowing, if needed, I can push them out further. Honda recommends 12,000km service intervals.
Changing bikes from spec has never been cheap. Main thing is that you are happy with your mods. You don't have to please the crowd. Happy days, Günter/Nürnberg PS: Just ended up with a used CRF 300 L instead of a Kove 450 Rally everybody advised me to buy. What a boring choice ;-)
I could never do a video like this in case the wife watched it haha the cost of mods as far as the wife knows are about half of what the actually cost lol
Forgot to mention, after watching this video the next day I think that these mods make picking up a well used bike for not much (maybe with some mods already) and rebuilding it to Stage 4 would be an excellent project.
Nice one mate...just a quick question..well 2 actually. What's a stage 4 conversion as opposed to say a 2 and 3?. And how much do you reckon the bike weighs? keep up the great content
Thanks for your comment. Stage 4 refers to the 550 Performance Stage 4 mods... 301cc big bore kit, performance cams and a matching tune. I haven't weighed it recently, but I will soon, so make sure you subscribe and keep a look out for that update.
Good stuff mate, I've dropped tonnes of cash on engine mods over the years. I worked with a bloke once and he spent what you spent total on chasing Harley HP on a Dyna he had. I wish I had have been smarter about spending my hard earned. sounds like you got a great bike for a song
Thanks. As you said, it's easy to spend cash on bikes , especially chasing horsepower. My goal has always been to maximise the potential of the CRF300 and I think I've done it.
if you bought a crf450rl you would not need to do the big bore or suspension and total cost would be similar with more power and better suspension but shorter service intervals. YOU DIDN'T INCLUDE THE LABOUR FOR FITTING BIG BORE KIT $$ which is beyond the capabilities of most back yard mechanics. Good vid to put the costs out there, well done.
You also forgot more engine vibrations and less fuel economy with a larger enduro based bike. Here in Australia the 450rl needs an exhaust and ECU to unleash full power. I did all the labour myself so that's why it's not in the cost breakdown.
Hi I have spent quite a lot on mods to my 300 rally as well I have a Rally raid level 1 suspension front and rear which was expensive delivered to Perth but is good. I think if I did it again I would just get a rear shock/spring and do the front forks myself I saw someone’s video where they used stock dr650 springs and plex valves. I have a motox full exhaust and a 550 ecu stage 1.5 and a airbox lid from them and a uni filter. I did have some over heating issues when sitting on the highway at 110kph after contacting 550 performance they said that they had heard of issues when the db killer and spark arrestor are installed. I have removed them and the bike is running better and overheating seems to be solved. I will try a eBay slip on muffler. I have stock gearing but am a bit disappointed with the top speed cruising as it seems to struggle 120 is flat out on flat ground and no wind. Otherwise it is fantastic I got the rally because I wanted a reliable lightweight bike with long service intervals and I don’t think there is anything else that does all of that.
Do you have radiator guards? If so, without the factory plastic louvers directing air into the radiator, you may experience overheating issues. Unfortunately with the overdrive 6th gear, the bike will struggle past 110-120kph. What size tyre are you using on the rear?
Hi Sean I have been in contact with 550 performance and they said it was a issue that they had experienced with the motox exhaust and db killer and or spark arrester I have removed both and the overheating seems to have been fixed and a little at highway speeds. I have the stock tyre still on at the moment and stock gearing. I did a test run without the db killer etc and got a top speed of 135 kmh indicated on speedo which is 125 on gps. I guess you get what you pay for the motox is a cheap exhaust. @@ShonkyProductions
The worth is not in the total dollars, it's in how much fun, enjoyment and satisfaction we experience in building the bike that we try to make, to suits our ideal ride. Sometimes we succeeded and sometimes we move on. But at the end of the day, we know it's my bike, and had fun doing it. 🖖
What a great video. Thanks. I love you bike. I have two questions though, what is the real world performance like compared to the original and is a lower 'stage' engine mod possible? The second question is what did you do with the original rally screen front-end?
Thanks. There are plenty of stages from 550 Performance from Stock improved right up to my Stage 4. My original tower is just sitting on a shelf in my shed.
Where did you source your exhaust from? I also bought full MotoX and then removed it as too loud and didn’t feel it was any better than stock except for weight.
Yeah, I'd rather ride something I know will get me home. My 300L has never let me down. Neither did my 250L, for that matter. I imagine getting KTM parts in the middle of nowhere is not easy either. But hey, ride your own ride I guess.
I'm just about done building out my Kove 450 for dual sport adventures and beginner rally racing. Rough estimate: grand total of bike + mods $11,770USD / 17,969AUD.
Are you running non modify slipper clutch in your bike? I have the Rally here in Indonesia (its still 250, no bump in stroke, but the rest is same as 300). Got the suspension sorted (YSS shock, RaceTech gold valve/springs). I eliminated the judder springs, installed full size friction plate and hd springs from Thailand). Working with Maverick to tune my ECU, what a pain in the a*s, it's Euro 5 but this weird 250 cc, Maverick and 550 Performance are great. By the time I am done, I will have about $3000 USD in mods to get a good bike. I keep on looking, but the Rally is the modern around the world bike, 155 ks of reliable, real world riding power machine, parts support.......... Nice vids, thx.
@ShonkyProductions Still have to fix my terrible on/off idle fueling, like u say the engine falls flat at 8k.....It is all much harder to do with my weird 250cc engine and the "big pin", tightly locked up ECU. Here in Indonesia, some guys swap the harness for non Euro harness/ecu. The quest for my unicorn Rally continues.......Thx the good vids u post.
Thanks for the transparency, it helps future buyers like myself make an informed decision on their next purchase but I did have one question. Because of the total price of the build so far, is there any particular reason that when you were looking at bikes you didn't consider the drz400e? I only ask as a new drz comes in at just under $11k and you wouldn't need to spend any money on engine performance mods or suspension upgrades. I know its an older designed bike, maybe that went into your decision making but I'd be genuinely interested to hear what made you choose the crf if you knew you'd have to spend more on it than the drz. I've looked into the 15/44 sprocket mod (for the drz) and apparently they both have the same rpm at 100 k/h so it seems that the extra gear in the crf isn't a deal maker although I'll admit you'd have more low end torque in the crf at lower speeds as you would likely loose that in the drz after you change the gearing
I did consider the DRZ400 when I was looking for a lightweight adventure bike. I have ridden a DRZ400 for 5 days on a Cape York tour and know they are a great bike. But as I'd tried the enduro to adventure conversion before with my KTM530, I was looking for something a bit more versatile and comfortable on the road.
@@ShonkyProductions Cheers mate, I haven't rode either of them so I've got no idea what ticks the most boxes for my needs So I gather everything you said about the ktm can be applied to the drz except for the high maintenance? The comfort with the crf which would inevitably fall into the highway ability I can understand coming out on top, as just because you can change the gearing on a drz to make them rev the same doesn't exactly make them even on the highway (comfort, riding position etc) am i right? Are there any mods that you think a new rider who's got no bike to compare against could do if they chose the drz instead to bring it up the crf's comfort level if they didn't want to invest much into the bike beyond the initial purchase price? would a new seat, wind shield, new pegs etc suffice or is the crf just on another level in terms of comfort? The only reason I'm being so frugal is that I still need room in my budget to buy all of my riding and adv gear
@@JoshSinnott97I had a drz400 and loved it. Great machine. I own a 300 Rally now, and the most notable difference in the bikes for me, is that I really like the fuel injection. But that’s certainly not a deal breaker for me. I’ve had carburetors all my life. Fuel injection is such a luxury! If I could had found a really sweet deal on another DRZ before buying my Rally, I would have probably bought it. I only chose the Rally because it was available, and I got a decent interest rate through Honda. And with the cash that I had to buy a used DRZ, I was able to put that down on the Rally and have a payment well under $100 a month. So it was as easy decision. Especially since I couldn’t find a nice DRZ at the time. But I can tell you this, no matter which bike you choose, your definitely going to want to upgrade the seat!
Thanks! It's good to hear from somebody who owns both. The fuel injection and fuel economy are what's making me lean towards the crf but I'm somebody who basically needs to make an excel spreadsheet before I buy anything lol. I'm wanting to buy a new bike which would obviously make the drz a harder sell for the price but I want to be able to know (whatever I end up buying) it's reliable and I don't need to fix a previous owners problems as that's something I'm going through with my car at the moment. I know the drz has the 15/44 mod but I think that would sacrifice the low down torque and you'd need to rely on the clutch to get through technical tracks which for me being a new rider is a bigger compromise. Do you miss the power of the drz or is the crf enough stock? Have you had a chance to take it on soft sand? It won't be long and I'll have my P's and will actually be able to test ride both and I think I'll find the crf the winner but am a bit worried I'll want more power with the amount of people doing engine mods to the 300
Pritty penny spend on that but they are ment to be great adventure bikes so what kinda BHP you looking with all the mods and what does that do to the MPG over all with both tank ?
As this bike doesn’t redline in top, are you sure you are losing top speed? I would have thought the extra torque may actually have increased overall reachable top speed……
I don't think I was talking about top speed in this video, but probably what I was referring to in another video was with lower gearing the bike reaches the top of its power curve earlier in each gear. With my final 15/40 gearing it let's each gear rev out further and really works well with the power and power delivery. Top speed with my final setup is still untested...
I was considering to buy 300 rally over a Tenere 700 in UK and came across this video. Thanks for sharing the price. I think I know what yo buy now 😜🫶🏻
Yes, but...what was done in the front end? The kits I see are still single side spring and other side damping...which sucks, no matter how you slice it. Did you slide new units in each side?
The crazy part? In Denmark, due to registration taxes you couldn't even buy a stock bike for your total price. Certainly, this cannot be the reason that we are supposedly the happiest country in the world...
That is so pathetic. I just don’t understand that... It’s crazy how this machine fluctuates in price, depending on where you are in the world. Even in the US, there is a considerable difference in price from state to state. I am very lucky, I paid $6400 US out the door for mine, and other people who I have spoken to from other states have paid close to $8000US. Senseless.
It is your money and your time of course, but buying a cheap bike and spend so much for what at the end it is still a cheap bike makes little sense to me.
You can’t use that overpriced KTM as a comparison as nobody will buy it at that price. A good 2nd hand late model 500 will cost as low as $10,000 plus the current 500 series since 2013 is now proven to be capable of 50-100,000 km of trouble free riding. To each their own.
