ADVrider (
-   Some Assembly Required (
-   -   the project that shouldn't be (

johnwesley 02-19-2011 11:30 AM

the project that shouldn't be
Projects come and go mentally, I contemplate them and then research. The start of it is in the mind as one considers the options and work that maybe need to finish it, and then, is it worth the effort? This project is one that I have put through the mental stages many times and have always come to the conclusion that it is not worth the effort. There are better bikes to build, better performance, better handling, and less weight. Logic has won out time after time, but this time I have to build it. I have to get the idea out of my head so that I can go on. If it flops then that fine, at least I have it out of my head and can move on. So now that this is solved next up is what model would work best? This takes lots of research and time. It is a bike that I am not familiar with so I start from scratch. Joining forums and reading all I can absorb. This studying lead me to the xl1200s, basically is is Harley's Screaming Eagle edition. Dual plug lighting heads, 10:1 compression and single fire ignition. In the suspension department we have fully adjustable forks and shocks, with dual disk brakes and twin piston calipers. None of that maters thought because it just good ebay stuff because we are going to change this out for MX suspension.

Now that the introduction is done here is where we start

the thing that causes me the most concern is the rear suspension. It is stock with dual shocks and moves in a 1.14:1 ratio. Not ideal if you want a suspension that is matched front to rear with lots of travel. So out comes the math and the mock up for travel with different shock placements.

after a lot of work I come up with a workable 1.73:1 ratio and a single shock mount with possibilities of 2:1 and a little longer swingarm. Shock placement ala ATK. It works for me and frees up room.

Next up is drawing up a steering stem to mount the forks triples with and use stock HD bearings.

The stem drawings are sent off to the machine shop and the swingarm to BTRmoto. Wheels are at woody's and I am in a holding pattern waiting on parts

(none) 02-19-2011 02:09 PM

I'm gonna be watching this. Very nice.

johnwesley 02-19-2011 05:17 PM

this one is inspirational

Czechsix 02-19-2011 10:40 PM

1 Attachment(s)
In on one...subbed

eternalRider 02-19-2011 10:54 PM

Looks good what what are your plans for it? I'll be watching:clap

jdrocks 02-20-2011 04:53 AM


Originally Posted by johnwesley (Post 15231146)

lordy, you must be dreamin' of some travels.

did you happen to see the photo of the desert race prepped HD that was on the forum? got a plan for fuel? what's the target weight?

i like that screw jack holding up the bike, in the best tradition of garage bike builders...use what ya have at hand. i have a few of those old jacks myself.

johnwesley 02-20-2011 06:33 AM

right now the fuel plan is to build a cell that goes between the fender struts an just behind the drivers seat. Hope to get 4 gallons from it which will give 7.3 total. I want to try and keep the peanut tank as I like the look of it.

I have seen the other builds for the true off-road bikes. here are two that come to mind

this one from Australia is what shows me I may be able to build one and the reason to throw out logic and just do it

then a forum member built this one with minor modds, just wheel and shocks. Don't let the tank fool ya it has to many plug wires :deal

JD from weight stand point I'd be happy to keep it under 500. It will be no fly weight like the V649HP. If someone likes to see results from weight reduction efforts this is the bike. Everything on it is heavy, all thick wall steel. even the fenders weight several pounds. Easy to get the weight down
below is the stock specs with this build the ground clearance goes up to 5"+/- as does the seat height

Length 88.5 in.
Weight 501 lbs.
Ground Clearance 6.7 in.
Wheelbase 60.2 in.
Seat Height 28.0 in.

In stock form this bike isn't bad a s a adv bike along the lines of a scrambler type bike as it has 6.1" of travel and 6.7" clearance with a 19" front wheel.

the 650r was a bike I considered strongly, but just never found that deal I wanted. I found this bike for about what the 650 is going for here

SamM 02-20-2011 06:53 AM

I've thought seriously about doing something similar but using the Blast engine instead of the V-twin. The 500cc engine can be pushed out to 625cc's fairly easily.

Cool build. Can't wait to see what you come up with.


JimmyTheHog 02-20-2011 06:56 AM

Hey John - Looks like we share the same insanity :evil
Im trying to get these ideas out of my head too.

Im still trying to figure out the rear shock mount locations and so far, the best I can see looks like what you said - ATK style. I have a 13.2" lg shock, 2.7" travel, and gives ~ 2.57:1 ratio at the mounting points I picked. I'll post them soon.

Looking forward to your rear fuel cell - Nice posts :clap

johnwesley 02-20-2011 07:24 AM

yea that doesn't give us a good travel. try mounting the shock 90degrees from level and use the factory top mount

EDIT:I do not have my swingarm any more or I would go look at it and see

johnwesley 02-20-2011 01:30 PM

just for fun i weighed a few things to see what kind of weight may be possible to loose. with just front wheel brakes and rear wheel we have a reduction of 40 lbs which brings the wet weight of the sporty to 486. I'm sure you can get another 15-20lbs off. the thick steel fenders are heavy, as most things on American iron. It will be interesting to see what the weight will end up at

madeouttaglass 02-25-2011 04:43 PM

Nice looking bike. Here's a simpler one I did last fall:

P7HVN 02-27-2011 07:16 PM

What are you going to do with those shocks you took off, and how long are they? Looking for replacements for my stock XR1200 shocks....

johnwesley 02-27-2011 07:31 PM

I'm going to sell them. I am in Nicaragua right now and will measure them when I get home

johnwesley 03-02-2011 07:17 AM

They are 13" from eye center to eye center.

Times are GMT -7.   It's 11:30 PM.

Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2015