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JimmyTheHog 02-04-2011 08:49 PM

JTH's HD 883 Dual Sport'ster conversion
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Theres been some interest in this build, so thought I would post the development progress and hopefully get some insight from the inmates, as there are alot of challenges.

Ive wanted to do this for years, but kept putting it off, but recently have seen a few nicely done conversions that have been the inspiration and ambition to finally give it a try.

So, with a vision in mind, I started with a stock 03 HD 883 Hugger, 100th anniversary, that I picked up on new years ever last year. Next day began tearing it appart.

JimmyTheHog 02-04-2011 08:51 PM

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Tear down...

JimmyTheHog 02-04-2011 08:55 PM

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KTM front end mock-up. Bearings and stem length are perfect fit...

JimmyTheHog 02-04-2011 09:02 PM

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Now the details:
- Trail Tech 8" head light
- Tracker 1" bars
- Joker Machine 1" bar clamps
- Applied Racing Triple Clamps
- Stock controls - no rewiring required (grips gotta go though...)
- Tach/Speedo mount custom designed & fab'ed billet bracket
- Steering stop custom des/fab billet bracket
- UFO front fender - KTM RFS
- New brake line 52" sst from CC
- Front wheel & caliper from KTM 525 - soon to have wider Sun rim for TKC80

JimmyTheHog 02-04-2011 09:04 PM

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Tach/speedo mount... sorry for the bad cell phone pic..

JimmyTheHog 02-04-2011 09:06 PM

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Steering stop - bolts to bottom triple clamp.

JimmyTheHog 02-04-2011 09:13 PM

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So, the front end is mostly done. Moving on to the rear end - swingarm / monoshock mount.

The plan is to mock up the stock swingarm with extensions to lengthen it, install the new 18" rear wheel, and get the geometry set right before jumping into design of the swingarm / mount.

Here is the rear wheel from Buchanan's:
- 18" Sun rim
- Storz billet alum hub
- TKC80 140/80-18

JimmyTheHog 02-04-2011 09:14 PM

Waiting for my swingarm mock-up extensions to come in from fab....

JimmyTheHog 02-04-2011 09:14 PM

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Forgot picture....

marret 02-05-2011 04:48 AM

Looking great.

What year front end are you using?

Thanks for posting.

JimmyTheHog 02-05-2011 07:13 AM

The forks are from a 2003 KTM 525 EXC (which you see sitting next to it in sad shape) and have been reworked by Hlebo Bros racing suspension for a 230 lb rider. I dont have the specs as the PO did the work and didnt know.

We'll see if they are adequete when the build is done. I had a dream last night that I was riding it and it worked perfectly...:D

jphish 02-05-2011 07:31 AM

Very Cool ! You are an Arti'st. Like a Ulysses - but a few steps farther.

jphish 02-05-2011 07:33 AM

PS: Final drive - chain or belt ??

JimmyTheHog 02-05-2011 07:54 AM


Originally Posted by jphish (Post 15116159)
PS: Final drive - chain or belt ??

It will be a 530 chain. The sprockets are on order: 24/51 tooth.

The hardest part is the wait for the parts to come in !

johnwesley 02-05-2011 11:07 AM

hey Jimmy thanks for putting this up looks like its going to come out great. This makes two builds going on in the forum with a sporty. I hope you guys stay far enough ahead of me to make it easier to follow suit. I already see I should have went with the ktm forks to make the forks a bolt on deal. We'll see how hard the conversion will be for the yz set up.

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