Project Cosette (Yet Another Sportster conversion)

[WhicheverAnyWayCan]

Hi,

It has been 14 months since I purchased the sportster and this is what it looked like when I purchased it Sept '11.



Got rid of 16" apehanger handlebar and 6" riser. Gunslinger seat was very uncomfortable so I sent it off to Day-Long for customized seat.. Added large windshield. Here is what it looks like.. might not be as pretty but was comfortable for long-distance riding.





Day 1 (11/16/12): Removed dual drag pipe exhaust, 12" rear shocks, and few chrome parts (for look).



Day 2 (11/17/12): Removed rear fender, battery, oil reservoir, and rear tire.



The 2003 KTM 525 fork with Brembro brake system (mastery cylinder and caliper line) arrived:



Yes, I know! I am working in a very limited space! The shed is 8'x12' but I am also currently in process of expanding the shed to 24'x12' and hopefully be done by mid December. I will be using Timber Frame structure method in hope to use it as an example to start a small Timber Frame company cutting them into kits for customers who are interested in low-budget kit.

Cosette is a 1998 XLHugger 883 with a 1200cc conversion kit using a Buell Thunderstorm heads, 1200 cylinders, 10.5 high compression piston, Screaming Eagles .536 cams, and S&S Super E carb. The plan is to take engine apart and do the following:

- Replace Screaming Eagle cams with stock H-D 'W' cams.
- Get 2004-2006 XB or XL 1200 heads and 2004 or later XL 1200 cylinders.
- Get aluminum pistons from NRHS.

The purpose of going with this set-up is to handle pretty much any type of octane fuel including the poor octane down in South America. The stock 'W' cams has a short overlap and closing time so this is the reason for choosing it. The 2004 and later has a larger fin allowing for better cooling off and the 2004-2006 heads has a better chamber handling turbulence very well especially when using very poor octane fuel down in South America. With .030" clearance on the squish band and usage of aluminum pistons it will give better cooling off making this configuration a better set-up without any catastrophic failure.

I'll be selling parts off this harley in the flea market and over at XLforum as well as local craig's list and local trading magazine. Parts: front/rear/oil reservoir/fuel tank as package, heads/cylinders/pistons/cams kit as package, 21" front aluminum cast rim w/tire, 16" rear fat boy/sportster rear rim with new tire (700mi), chrome set, fork, and 2 handlebars(one new and unopened). I'll list it there in Flea Market once I have cleaned them throughout and decide on the price.

Stay tuned for the progress.. I will be moving this project slow as grandma molasses due to being a poor man.. My KLR ( seen in pic above) is for sale too and you can find it in Flea Market.

[pennswoodsed]

Will you be going to chain drive or extra belt with you ? 19"and 18" tires ?
Thanks,Ed

[WhicheverAnyWayCan]

Originally Posted by pennswoodsed

Will you be going to chain drive or extra belt with you ? 19"and 18" tires ?
Thanks,Ed

I am on the fence between 21" front and 17" rear but I haven't decided on that until I mount the KTM fork on then I will play around with it a bit. Possible 20"f and 17"r?

Will be going chain too.. most likely using the following:
*5-speed trans sprocket spacer HD #33334-85 ------------$20
*Mainshaft Oil Seal HD #12050 -----------$4
*Quad Oil Seal HD# 11165------------$3
*Renthal R3-2 O-Ring 520 chain X114 links --------$80
*48 Tooth 520 rear sprocket Chris Products (PBI ?)#205348 ------------$60
*21 Tooth 520 front sprocket PBI # 277X-21-----------$35

The chain may need to be cut short before locking the master link.

[bk brkr baker]

20" front ?
Good luck finding replacement tires in that odd size on the road.
If you step too far away from the common, you may find yourself alone.

[WhicheverAnyWayCan]

Originally Posted by bk brkr baker

20" front ?
Good luck finding replacement tires in that odd size on the road.
If you step too far away from the common, you may find yourself alone.

I can see why you are pointing it out.. in that case, 21 or 19.. I have not really get to that point yet.. My current focus point is the engine itself downgrading from high performance to regular 1200cc with high tolerate for poor octane fuel.

Thanks for pointing it out, appreciate it man!

[JimmyTheHog]

For reference, when i did my chain conversion, it took 124 links with the following:
- 56 rear sprocket
- 25 front sprocket
- 4" extended swingarm

I went taller on the sprockets (both front and rear) to gain clearance over the swingarm pivot. Otherwise, with the longer travel suspension and swingarm angle, the chain would wear on the chain slider. Now its fine with this setup.

[ValuePack]

Subscribed.

So what's the rise on the bars that are mounted now? The wife just inherited her dad's'07 Heritage, and there's no way she's riding it with the mondo apes that are on it now. What you've got on there looks more appropriate.

[Krasniewski]

Lookin' great so far! Keep it up. I had an 883 Sporty... everytime I see a conversion I kick myself for selling her.

Best of luck - can't wait to see how she turns out!

[kellymac530]

Those forks look like a great choice for a project like this, but I am not sure about them being from a 2003 525 KTM....
Every KTM I have seen since before 2003 has had USD forks. My guess on those would be maybe '98 KTM forks. This is important for seals and spring choices.

Cool build though and keep posting pics

[WhicheverAnyWayCan]

Originally Posted by kellymac530

Those forks look like a great choice for a project like this, but I am not sure about them being from a 2003 525 KTM....
Every KTM I have seen since before 2003 has had USD forks. My guess on those would be maybe '98 KTM forks. This is important for seals and spring choices.

Cool build though and keep posting pics

Kellymac,

Would you please help me to get the info I need to order seals, axle, and if the KTM Supermoto front fender would work with this? Is there any way I can identify the fork by finding part # on it or no? I tried to inquire on KTMForums.com to no avail.

[kellymac530]

WAWC,
I believe those are the 50mm KTM Magnum Marocchi forks from the circa 1998 era.
The seals are available. but sometimes are hard to find.

The Sumo fender will fit just fine. At most you will need to oval 2 holes a bit, but I doubt it.

Make sure you use at least some Seal Saver Neopreene covers on the forks. The saels are a bit fragile on those and cleanliness is next to Godliness on those forks...

If you have a micrometer or caliper just measure the diameter of the forks, they should be 50mm upper tubes. That should help a bit.

[DRjoe]

Are you sure there not wp 50mm extremes?

[kellymac530]

Originally Posted by DRjoe

Are you sure there not wp 50mm extremes?

They could be, but alot of the wp Xs I see are aluminum colored and not annodized black like that....some are though so you very well could be right.

The Marzocchis had a little tab cast into the top of the lower tube where the fork protector would slide. I have not seen that on my earlier WP Xs forks....again not positive though and do not claim to know alot.

To WAWC,
Look at the bottom casting of the forks around where the axle fits there will likely be a WP cast into it or some kind of brand cast into it like Magnum or something other than KTM which has run both of those.

[kellymac530]

These are WP 50mm Extremes...no tab.

These below are the Marzocchi magnums that I am speaking about...discusses them in like the 4th or 5th paragraph

http://www.motorcyclespecs.co.za/mod...0_exc%2098.htm

[kellymac530]

From this listing it looks like Joe is right. WP 50mm Xs

http://www.ebay.com/itm/99-KTM300EXC...9a0268&vxp=mtr