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Old 12-06-2007, 02:11 PM   #256
jgas
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I do it all on my 02 520. I've raced everything from MX, (outdoor, not SX), to National Enduros. Raced in local HS, and Enduros. It's managed grocery store duty, lots of dual sport/adventure, been used to make new single track as a pack mule, and been raced in GNCC. I don't keep a speedo hooked up so I don't know how many miles, and usually don't have an odometer, don't know how many miles, but I'd guess at least 25,000. This weekend it's going to carry me around Last Man Standing while I volunteer as a course official. The motor/trans has never been opened up, no major repairs.

I've replaced countless wheel bearings and chain/sprockets. The only mods are a 15 oz heavier flywheel, KTM cooling fan, handlebar risers, better headlight and talilight, and a Guts seat.
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Old 02-13-2008, 09:55 AM   #257
Cycletroll
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Location: Northern New Mexico
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Hey gang! Time to join a great thread I just bought a very clean '04 450EXC. It's set up nicely with a Scotts damper, a bunch of Enduro Engineering goodies and a skidplate. Only has 107hrs on it and they look to be mellow ones It is not (yet) street legal.

So, my question is: which DS kit? The Trick Dual Sport kits look well thought out. I'm just wondering, given that the bike already has a head and tail light, if there is a simpler way to set it up.

Looking forward to reporting on many miles of fun on this bike!
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Old 02-13-2008, 11:14 AM   #258
Jeff@TheQuadShop
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Location: Crestwood, Kentucky
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Quote:
Originally Posted by Cycletroll
Hey gang! Time to join a great thread I just bought a very clean '04 450EXC. It's set up nicely with a Scotts damper, a bunch of Enduro Engineering goodies and a skidplate. Only has 107hrs on it and they look to be mellow ones It is not (yet) street legal.

So, my question is: which DS kit? The Trick Dual Sport kits look well thought out. I'm just wondering, given that the bike already has a head and tail light, if there is a simpler way to set it up.

Looking forward to reporting on many miles of fun on this bike!
I get my DS stuff from here http://www.procycle.us/main/dskit.htm You can pick and choose whatever parts you need. Nice guy with great prices and customer service.
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Old 02-13-2008, 01:25 PM   #259
Sheep Shagger
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Location: Where men are men and sheep get nervous
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Quote:
Originally Posted by Cycletroll
Hey gang! Time to join a great thread I just bought a very clean '04 450EXC. It's set up nicely with a Scotts damper, a bunch of Enduro Engineering goodies and a skidplate. Only has 107hrs on it and they look to be mellow ones It is not (yet) street legal.

So, my question is: which DS kit? The Trick Dual Sport kits look well thought out. I'm just wondering, given that the bike already has a head and tail light, if there is a simpler way to set it up.

Looking forward to reporting on many miles of fun on this bike!
http://www.cyclezonektm.com/
It's made from KTM parts from EU bikes, since they are street legal, and use far nicer switches than the 07 & 08 KTM US models. It's all just plug-in and replacing old parts, the cleanest solution.

Trick Dual Sport and Baja Designs etc all make nice kit's, but OEM KTM parts is the nicest in my opinion.
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Old 02-13-2008, 05:30 PM   #260
Stu
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KTM Parts

I agree. The KTM parts make the best install and give the most reliable product. The LC4 switch gear plugged right into my 525 EXC wiring harness so I had more room on my handlebar and I had a way to shut the lights off. Cycle Zone can supply the parts and they are plug-n-play pretty much. The color of the wires may not match but the function is the same. Just note the differences so you can troubleshoot down the road when you have forgotten what you did.

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Old 02-14-2008, 12:45 AM   #261
gaspipe
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Joined: Jul 2004
Location: Pickwick Lake, Tennessippi
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I think I might even change the oil on the red-headed stepchild bike, the 450EXC, and run it in Baja with dogwater 'til it blows up. If it doesn't blow up, I'll come home when the rear tire is worn out. Or a bone is sticking through the skin.

One thing I have noticed in having looked at quite a few of the (maybe old style ?? ) HT Racing coolers is the poorly machined gasket surface. The back plate on the reservoir is a poor match to the rest of the surface, and IMHO, that where the oil leak issues on those things come from, if you have a leak. I resurfaced that area on my HT cooler in the milling machine, and so far, no worries.

The shitty OE headlight and UFO led taillight will have to do the job, and hopefully I won't crash in the dark as is the usual course of events for me in Mexico

No cush hub. No fancy seat. No rack. No big stator. A rekluse auto clutch, 20mm offset clamps, steering damper, and an Acerbis godzilla fuel tank is all it has.

If whatever I'm going to bring won't fit in my Wolfy tank panniers (that I use as rear bags) or the Enduro tank bag, it's not coming with me.

Run her 'til she blows is what I say.
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Old 02-14-2008, 05:21 AM   #262
alpiv
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Quote:
Originally Posted by gaspipe
I think I might even change the oil on the red-headed stepchild bike, the 450EXC, and run it in Baja with dogwater 'til it blows up. If it doesn't blow up, I'll come home when the rear tire is worn out. Or a bone is sticking through the skin.
Your just hard core ain't cha...

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Old 02-14-2008, 06:14 AM   #263
Stu
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Quote:
Originally Posted by gaspipe
One thing I have noticed in having looked at quite a few of the (maybe old style ?? ) HT Racing coolers is the poorly machined gasket surface. The back plate on the reservoir is a poor match to the rest of the surface, and IMHO, that where the oil leak issues on those things come from, if you have a leak. I resurfaced that area on my HT cooler in the milling machine, and so far, no worries.

The shitty OE headlight and UFO led taillight will have to do the job, and hopefully I won't crash in the dark as is the usual course of events for me in Mexico
The HT cooler matter is ancient history, gasser.

Quote:
Originally Posted by gaspipe
No cush hub. No fancy seat. No rack. No big stator. A rekluse auto clutch, 20mm offset clamps, steering damper, and an Acerbis godzilla fuel tank is all it has.

If whatever I'm going to bring won't fit in my Wolfy tank panniers (that I use as rear bags) or the Enduro tank bag, it's not coming with me.

Run her 'til she blows is what I say.
Hey, you forgot to remount your trashed front fender. And why the godzilla tank? Don't you really like living on the edge as you imply? And what are you putting in those Wolfy bags? Your lattes, croissants, lace-edged red rags?

Stu
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Old 02-14-2008, 05:03 PM   #264
gaspipe
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Location: Pickwick Lake, Tennessippi
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Quote:
Originally Posted by Stu
The HT cooler matter is ancient history, gasser.
It sure isn't if you have one of them with the poorly machined surface. There's no gasket in the world that will seal it for long.

Quote:
Hey, you forgot to remount your trashed front fender. And why the godzilla tank? Don't you really like living on the edge as you imply? And what are you putting in those Wolfy bags? Your lattes, croissants, lace-edged red rags?
You can take the little tank, and when you have to push your bike 30 miles through some Baja singletrack, we'll see who's living on the edge then.

(BTW - I'm kidding)

Seriously, I've have come across a few of the older coolers on bikes that are running the long hard trips (multi-thousand mile offroad ones) and they all leaked. The new rubberized gasket will last for a while, but the issue is the machined surface, and it is not hard to rectify for a perfect seal with a good mill.

The other thing is, IMHO, the 3 gallonish tanks are a tad too small for the long rides through nowhere, and the 6.6 Acerbis is a bit bigger than I'd prefer, but it's alway best to have more than ya need then not enough, eh?

The ol' gaspipe clunker.....



Run her 'til she blows.
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Old 02-14-2008, 06:30 PM   #265
Stu
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coolers & tanks

Gasser,

My HT cooler doesn't leak. It seeps a little at the surface that mates with the case half, but certainly nothing to worry about, unless you are an obsessive / compulsive German like I am and don't like ANY seeps and dust collection.

The HT racing vane with the stock lean jetting is giving me 50 MPG on the throttle or otherwise 60+ MPG. I am not certain I would need a larger tank if my Clarke 3.1 would do for the distance you suggest in Baja. I would need the larger Acerbis tank for the 250 mile distances going up to Prudhoe Bay. Want to go up there with me in June?

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Old 02-14-2008, 07:41 PM   #266
gaspipe
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Location: Pickwick Lake, Tennessippi
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Quote:
Originally Posted by Stu
My HT cooler doesn't leak.
You got a good one. Most were/are, but there are plenty of weepy, drippy ones. Like I said, easy and cheap to fix.

Quote:
....would do for the distance you suggest in Baja.
I'm not trying to belittle anyone here at all, so please don't construe it as that.

It's not the about the distance I suggest - it's thinking you're AOK getting from one place to another that's 120 miles away, and then finding out 100 miles into it that it's impassible, and having to go back, and then realizing that because you've been fighting siltbeds for 60 miles, you've used half again as much fuel as you figured on. That's the outer edge of exploration/adventure on a bike, and that's where too much is usually just enough when the stuff goes bad. BTDT. Handling suffers a bit, but much less than your feet do on a long desert walk.

On the more beaten path, the level of redundancy isn't as critical, but it sure sucks to see something and not be able to go explore it because fuel is an issue. It happens.

I'll probably be on the other end of Canada this summer if plans go well.
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gaspipe screwed with this post 02-14-2008 at 09:02 PM
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Old 02-14-2008, 08:33 PM   #267
Stu
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Leaks & dribbles

I dribble, not my HT cooler....

Your point about exploring up sand washes is well taken. There are not a lot of those in Kansas or Colorado so gas mileage is better.

Eastern Canada?!? Are you just desperate to ride? I did read with considerable fascination the report of the guy riding from Goose Bay to the St. Lawrence river in January. -61 degrees. That got my attention. Survival, not adventure, riding.

Will you be on Troy & Sean's Arkansas run Ap. 4~7? I'll be there.

Stu
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Old 02-14-2008, 08:47 PM   #268
Beemer Pat
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Wow! You two sure are having fun. I have a '04 525 with a HT cooler that I put on in '05. I have no leaks. Stu.
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Old 02-14-2008, 09:04 PM   #269
gaspipe
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Quote:
Originally Posted by Stu
Will you be on Troy & Sean's Arkansas run Ap. 4~7? I'll be there.
I'll be somewhere in Mexico around then.

Adios,

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Old 02-15-2008, 12:58 AM   #270
mcnut
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Location: Bakersfield CA & Sammamish WA
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Big Tanks

FYI When considering fuel tanks for an RFS there is a tank that falls between the 3-3.4 gal and the 6.6 gal. But it is expensive and hard to find in the us. Have a look:


http://www.justgastanks.com/store/in...roducts_id=484


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