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Old 12-03-2011, 08:37 PM   #1
harcus OP
Beastly Adventurer
 
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Joined: Feb 2005
Location: Edge of the Wasatch
Oddometer: 1,298
2012 KTM 500 EXC as a Lightweight Dual Sport

The purpose of this thread is to summarize the setup of a 500 EXC into a lightweight dual sport machine. This was a major reason for my purchase of this machine.

Disclaimer - I make & sell upgrade conversion parts at Globetrottin.com. Hopefully this is not considered a conflict of interest.

I purchased one of these critters from my local dealer here in Salt Lake in mid Oct 2012. Here it is in the back yard on the first day home (complete with "fly swatter" mirrors)....



One week later, I went out & trashed it for 120 miles for a breakin run. Also collected data on what worked & what didn't. The weather was going bad & I feared not many "data collection" days remained.

First thing I did upon return was a Desmog. This was based on the typical fuel canister issues we all know of & love. The desmog is detailed here...

http://www.advrider.com/forums/showt...682150&page=17

Another thing learned was how vulnerable the radiators were. I need a brace...onto the list.

So, here is the list so far of planned changes. Some of this is based off of my experience is setting up my 07 990 Adv for similar off road use.

1. Bash plate, full coverage

2. Extended fuel tank forward - Maybe a 13 - 15 liter, not too big

3. Extended fuel tank aft - Somehow integrated into the luggage rack system

4. Luggage rack system - Capability to carry about 40-50 lbs

5. Weather proof soft panniers for rack

6. Radiator brace - Noted

7. Heated grips - Maybe PWM controlled to minimize power impact

8. Bar risers - Need about 1.3 inches to fit my 6' 1" frame

9. Head lights - Worst hi beam I have seen in years - Add LED light system

10. Windshield, DS - I have a dual sport WS I have been developing.

11. Seat - Don't know improvement, maybe

12. Subframe of composite with integrated rack - The OEM alum subframe & plastic are beautiful bu not made for creek crossings or much load.

13. Handguards - OEMs are whimpy. Most after markets aren't much better.

14. Fuel tank side bags - Seem to work well on the big bike

There are probably more items I will discover along the way but that is enough for now.

What do I love about this bike? It's a near 60 HP Schwinn. Beautiful suspension, light weight, every thing (almost) that I expected. It weighed in at 266 lbs with a near full fuel tank (2.25 gal) on my Weight Watchers scales. Assuming I can keep the weight of the mods within reason, I will still have a sub 300 lb bike capable of 300 mile range & lightweight camping. This will be 1/2 the weight of my 990 which will allow access to more remote parts of the earth.

That, dear readers, is the point!

So here is the execution of the list. Sorry, the picture won't necessarily be colored in the order above. My ADD issues....


Step 1 - The bash plate


Here it is...







This is what I call full coverage meaning it covers not just the bottom but the rotor & clutch covers. Out here we have these rock things that reach out & attack you. Protect your covers! This is made of composite & weighs slightly over xx lbs.

The fab of this item is detailed for those interested over here...

http://www.advrider.com/forums/showthread.php?t=742360



2. Extended fuel tank forward - Maybe a 13 - 15 liter, not too big


Coming soon...


3. Extended fuel tank aft - Somehow integrated into the luggage rack system

Coming soon...


4. Luggage rack system - Capability to carry about 40-50 lbs


Coming soon...


5. Weather proof soft panniers for rack


Coming soon...


6. Radiator brace - Noted


Coming soon...


7. Heated grips - Maybe PWM controlled to minimize power impact

Coming soon...


8. Bar risers - Need about 1.3 inches to fit my 6' 1" frame

Coming soon...


9. Head lights - Worst hi beam I have seen in years - Add LED light system

Coming soon...


10. Windshield, DS - I have a dual sport WS I have been developing.


Coming soon...


11. Seat - Don't know improvement, maybe

Coming soon...

12. Subframe of composite with integrated rack & fuel tanks - The OEM alum subframe & plastic are beautiful but not made for creek crossings or much load.

Coming soon...

13. Handguards - OEMs are whimpy. Most after markets aren't much
better.

Coming soon...


14. Fuel tank side bags - Seem to work well on the big bike


Coming soon...


More to come -------
__________________
Want Creative Adventure Products? - See Globetrottin.com

Current rides - '14 KTM 1190 R Adv <2k, '07 990Adv 39k, '12 500EXC 7k, '09 GasGas 300 Raga

harcus screwed with this post 12-03-2011 at 08:45 PM
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