So far, we've opened up the breathing on the bike and re-jetted it properly. Then we made the rear suspension worlds better with the installation of a Works Performance shock.

Now our attention gets turned to the pipe. We used the BBR pipe, a complete system that bolts right on in place of the stock exhaust system. The BBR is pricey compared to some of the other pipes on the market, but BBR has a reputation for filling niche markets regardless of the price. They make such exotic things as aluminum frames for the CRF 150, and even mini bikes!

The complete system sells for $299.95 and fits both the CRF150 and 230F and the exhaust goes from the headpipe to the tail section and comes with a removable USDA Forest Service approved spark arrester installed. Unlike most of the other pipes available, the BBR is ceramic coated and has a stepped header for power gains throughout the RPM range. It also accepts the OEM Honda endcap from CRF150/230F for super quiet sound output.

Features include a billet aluminum endcap, an aluminum heat shield, 1.5 hp gain over stock exhaust and a tapered header. It's available with gold or black anodized muffler can. Part numbers are: 210-HCF-1501 Exhaust System CRF150/230F (03-05) (Gold Muffler) and 210-HCF-1501 Exhaust System CRF150/230F (03-05) (Black Muffler)

Installation is covered in the photos/captions, step at a time. We had a bit of a hassle bolting the pipe into place, as things didn't line up perfectly. Eventually, we loosened up the header pipe nuts and then were able to get the center/main mount snugged down. Then the muffler was too high to allow the rear bolt to get situated.

After a bit of head scratching, we decided to use cave-man tactics on the problem. 200 pounds of writer were pressed on the top of the muffler and the entire rear section was bent down about 3/8ths of an inch. Problem solved and the exhaust system seemed no worse for the abuse.

The spark arrestor screen was removed from the muffler, as we don't have such laws in Baja. Jeez, in fact no one in recent memory has set the desert on fire around here.

When the bike was started, it had a nice, healthy sound to it. It barked more like a 500, than a mild-mannered 230. Some might call it loud; I called it sweet.

For those who need a quieter sound emitting from the pipe, they can pop on the stock end from the 230 directly to the BBR. If you want to use the trick looking billet end of the BBR pipe, you can use their Quiet Exhaust Insert for $39.95

Simply replace your BBR standard exhaust screen with this computer designed unit and reduce the sound level of your bike. It fits all BBR exhaust systems with a removable spark arrester screen and reduces sound output with minimal increase in back pressure, without ruining your bike's power delivery. Part number: 220-BBR-1004 BBR.

When we rode the bike, it sure felt a whole lot faster than with the stock exhaust. The exhaust note was satisfying and most of the gain was from mid-range through the top end. All things considered, the entire engine response was much cleaner and crisper. The project bike is well on its to becoming an ideal bike.

Stay tuned

Project CRF 230F sits awaiting an exhaust system

Remove the right side rear panel

Using a 12mm socket, remove the center pipe holding bolt

Remove the bolt holding the muffler; 12 mm works here

The joint holding bolt is removed next; 12 mm with an extention works best

Wiggle the rear section of the pipe to free the joint. If it's been on a while, penetrating oil might be required

Bare head pipe with the rear section removed

Complete stock rear section

Two 10 mm cap nuts hold the head pipe on

Head pipe removed

Stock head pipe

Complete stock exhaust system

Stock exhaust system weighed in at 6.5 pounds

Complete BBR system

BBR system weighed in at 4.75 pounds

We removed the billet end cap from the BBR

End cap removed with spark arrestor screen. We removed the screen

Install the head pipe loosely at first

Slip the new exhaust together

We had to lean on the muffler to line the mounts

Installed unit looks good and runs even better

Completed package