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Old 10-06-2012, 09:50 AM   #76
elgato gordo
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Joined: Oct 2007
Location: ABQ, NM
Oddometer: 510
Late to the party

kajj
Just stumbled on this thread and now read thru the entire thing. Really like what you have done with the bike and the bad a$$ fairing.

I think these bikes are great fun to ride and you get some extra enjoyment working on them. The looks are 2nd in my book because I always end up trashing something sooner or later after a couple of dirt naps.
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Old 10-06-2012, 09:56 AM   #77
kajj OP
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Joined: Aug 2011
Location: In northern Sweden
Oddometer: 191
Got my new set of OEM DL1000 wheel spacers. They make a perfect fit:
Now I only have to extend the threads on the wheel axle and cut it in the right length




Also installed a new chain and rear sprocket.



II tried to remove the front sprocket but that sucker wont move


Things to do!

* mount new brake line
* Find a 310mm disc
* Finish wheel axle
* fabricate brake caliper adapter
* headlight rubbermount................ok
* new rally fairing
* carbonfiber dash, relocate swithes and power outlets
* relocate turn signals
* Weld and paint sidestand
* Install HID lights
* mount radiator guard
* cut front fender and fabricate mount.
* change sprockets and chain....................2/3 ok
* Air filters
* paint lugage rack
* tighten side mirror mounts
* check rear wheel/swingarm bearings................ok
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Old 10-06-2012, 08:40 PM   #78
rlbowers03
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Location: Boise
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Quote:
Originally Posted by kajj View Post

II tried to remove the front sprocket but that sucker wont move


I had the same problem! I ended up taking it to a friend that owns a X-Large air compressor and an impact wrench. We hit approx 100ft lbs of torque before that thing came loose

Good luck
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Old 10-07-2012, 01:31 AM   #79
kajj OP
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Location: In northern Sweden
Oddometer: 191
Extreme offroad adventure episode 1

A short vid a friend and I put together. Nothing to serious, just having fun on the trail.
Not that god quality but enjoy


I have one more that should be up in a few weeks.
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Old 10-07-2012, 06:31 AM   #80
kajj OP
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Location: In northern Sweden
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Front fender

So. I need a front fender. And I prefer a low fender to keep the mud and gravel away from the radiator and engine.
But I can not mount the Versys fender as it is supposed to be mounted.

Hmm, I need a custom bracket from the fork legs to support the fender.
Well I had this available


Some time later I now have this
Don`t look to bad and is really sturdy. The nuts might be a bit too close to the tire, but it should be fine.




This mount is adjustable, and I can move the fender up and down depending on the terrain.
If it gets to muddy, just move it up a bit to get more clearance.

Things to do!

* mount new brake line
* Find a 310mm disc
* Finish wheel axle
* fabricate brake caliper adapter
* headlight rubbermount....................................... .........ok
* new rally fairing
* carbonfiber dash, relocate swithes and power outlets
* relocate turn signals
* Weld and paint sidestand
* Install HID lights
* mount radiator guard
* cut front fender and fabricate mount...........................ok
* change sprockets and chain.......................................2/3 ok
* Air filters
* paint lugage rack
* tighten side mirror mounts...........................................o k
* check rear wheel/swingarm bearings...........................ok
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Old 10-07-2012, 07:46 PM   #81
1reddawg
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Location: Monteagle Tenn.
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Quote:
Originally Posted by kajj View Post
A short vid a friend and I put together. Nothing to serious, just having fun on the trail.
Not that god quality but enjoy


I have one more that should be up in a few weeks.
Looks like alot of Fun!!Thanks fur sharing!!
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Old 10-12-2012, 01:42 PM   #82
kajj OP
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Location: In northern Sweden
Oddometer: 191
Time to mount some new stuff to the beast

Touratech radiator guard.


This model are made for the 2009- Versys radiator but the only thing to do to make it fit my 2008 was to move the
protection for the radiator fan to the rear radiator mountings and to bend the front mountings so that they got the same
angle as the radiator guard.



Machined front wheel alxe, Hel brake line (in DRZ 400 lenght), Moto-master 310mm wave brake disc.
I was looking for a OEM DL1000 left front disc but manage to find this one from Moto-master for a really good price.








Things to do!

* mount new brake line.............................................. .....ok
* Find a 310 mm disc.............................................. .........ok
* Finish wheel axle.............................................. ............ok
* fabricate brake caliper adapter
* headlight rubbermount....................................... .........ok
* new rally fairing
* carbon fiber dash, relocate switches and power outlets
* relocate turn signals
* Weld and paint sidestand
* Install HID lights
* mount radiator guard............................................. .....ok
* cut front fender and fabricate mount...........................ok
* change sprockets and chain.......................................2/3 ok
* Air filters
* paint luggage rack
* tighten side mirror mounts...........................................o k
* check rear wheel/swingarm bearings...........................ok
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Old 10-12-2012, 08:22 PM   #83
nedodjija
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Location: Pocatello ID
Oddometer: 657
Love it!
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Old 10-13-2012, 01:05 PM   #84
zandesiro
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Location: Polygyros, Greece...
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Thumb

Cool...

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Old 10-14-2012, 04:52 AM   #85
kajj OP
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Location: In northern Sweden
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Front sprocket round 2

Got my self a cheap impact wrench with a torque at 450 Nm. The front sprocket nut was gone in less then 10 seconds



The old front sprocket had about 25000 km on it.


Things to do!

* mount new brake line.............................................. .....ok
* Find a 310 mm disc.............................................. .........ok
* Finish wheel axle.............................................. ............ok
* fabricate brake caliper adapter
* headlight rubbermount....................................... .........ok
* new rally fairing
* carbon fiber dash, relocate switches and power outlets
* relocate turn signals
* Weld and paint sidestand
* Install HID lights
* mount radiator guard............................................. .....ok
* cut front fender and fabricate mount...........................ok
* change sprockets and chain.......................................3/3 ok
* Air filters
* paint luggage rack
* tighten side mirror mounts...........................................o k
* check rear wheel/swingarm bearings...........................ok
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Old 10-20-2012, 06:05 AM   #86
kajj OP
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Location: In northern Sweden
Oddometer: 191
Air filters

I have found some dust that got past the OEM air filter and decided to try adding one pair of UNI pod filters to the
intake stack. It will of course decrease air flow a bit. but I thought I should try it out and see how it works.


I removed some material from the inside of the filters to get a better fit to the bellmouths.





The filters do compress a little when the lid for the airbox is mounted. Should be fine thou.



And some eye candy


Now, back to designing that brake caliper adapter.

Things to do!

* mount new brake line.............................................. ......ok
* Find a 310 mm disc.............................................. ........ok
* Finish wheel axle.............................................. ............ok
* fabricate brake caliper adapter
* headlight rubbermount....................................... ... .........ok
* new rally fairing
* carbon fiber dash, relocate switches and power outlets
* relocate turn signals
* Weld and paint sidestand
* Install HID lights
* mount radiator guard............................................. .....ok
* cut front fender and fabricate mount..............................ok
* change sprockets and chain...................................3/3 ok
* Air filters........................................... .........................ok
* paint luggage rack
* tighten side mirror mounts...........................................o k
* check rear wheel/swingarm bearings............................ok
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Old 10-21-2012, 03:39 AM   #87
Smola67
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Location: Inman SC
Oddometer: 229
I think with that dl 19" and that tiny fender, you will find that water and many other things will fly off that front rubber and go straight for your helmet.
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Old 10-21-2012, 04:55 AM   #88
kajj OP
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Location: In northern Sweden
Oddometer: 191
Quote:
Originally Posted by Smola67 View Post
I think with that dl 19" and that tiny fender, you will find that water and many other things will fly off that front rubber and go straight for your helmet.
Well I have been riding with that wheel and fender combo for about 5 month and I have not had any problems with it.
Plenty of mud/water/sand and gravel.

In some pics you can see I am trying out a high motard front fender. But this setup did not work that well and I had
those problems that you described. So now I am going back to the low fender as this offered more protection for the
radiator and the rest of the bike. Sure you get some spray on top of the front fender when going through mud but
nothing that flings up to the headlight or higher.
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Old 10-21-2012, 05:18 AM   #89
Smola67
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Cool deal.
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Old 10-21-2012, 04:57 PM   #90
aiMhi
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Kajj - I really like how your bike is coming along man. I will shoot you some pics of my new fairing which is sick looking- hoping to have the mounting done in a couple days. Might need to work something out for you,.
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