I have the '05 450. It's great.
As of what I have read on the Internet and of what my friends have experienced here's a few issues.
* '03: Starter gear problems common. Solution: Install '04 starter gears.
* '04: Valve issues: exhaust valve breakdown, expensive head jobs. Solution: Install Kibblewhite Black Diamond DRZ400 valves BEFORE they crash.
* '04: Some starting issues. Solution: Install Manual cam chain tensioner to help starter motor spin up.
* '03-'04: very cold start problems, Solution: Full throttle while crankin.
* '05: kick starter idler gear stub axle breakdown. Solution: Dont use the kick starter, or at least be gentle. I don't know if newer axle fits or if they are stronger.
* '05: crank vent spews oil into air box. Solution: Install extra foam filters in vent hose.
I haven't seen or heard(read)any problems related to '06 and up. Maybe they are bulletproof?
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