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Old 06-02-2014, 05:10 AM   #1
JayBo1 OP
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JayBo's journey to Dakar 2015

My entry is in and a sure-fire acceptance - balance owing shows as "nil" and entry paid "14.800 Euro". My deferred entry from 2014, after my little disaster in Safari 2013 on day 1, seems to have paved the way nicely for me.

So I figure I'd better start preparing my rally bike. Have to turn a pile of parts into a useable, reliable KTM 450RFR. So here's the starting point:


There's a frame ...:


... some fuel tanks, fairings and guards ...:


...and a couple of engines to choose from:

I think I'll choose the brand new engine that I just took out of the delivery box.

There's also some wheels and forks lying around this place somewhere.

So I have my work cut out for me. A growing list of parts to be replaced where I have already found some wear and damage. I'll keep this thread up to date with progress as I build up to sending the bike to France to catch the ASO boat to Buenos Aires ready for Dakar start on January 4'th, 2015.
Ciao for now.
JayBo
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Old 06-02-2014, 05:13 AM   #2
2upAussie990
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Live the dream mate, all the best with the build and race.
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Old 06-02-2014, 05:16 AM   #3
Matt
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This will be more epic than an Elefant rebuild.
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Old 06-02-2014, 05:22 AM   #4
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Loving this Thread already.
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Old 06-02-2014, 05:27 AM   #5
ciedema
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Excellent - there hasn't been much to read since the end of KLX700 thread.
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Old 06-02-2014, 05:27 AM   #6
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That's one piles of bits.

Subscribed.
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Old 06-02-2014, 05:31 AM   #7
JayBo1 OP
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Quote:
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This will be more epic than an Elefant rebuild.
Good one Matt. I wondered whether I'd get caught with that one. The Elefant rebuild is on hold - it's one of my "post Dakar" plans.
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Old 06-02-2014, 05:33 AM   #8
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I'm in!
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Old 06-02-2014, 05:40 AM   #9
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One of the parts that needs to be replaced is one of the bolts that forms part of the rear suspension linkage system. There have been a few of these failures on the 450RFR and the factory apparently now have an improved version. The head seems to fracture. I found mine like this when I started the bike teardown:


...and when I started to turn it, the very slightest pressure on it made it look like this:


To get the bolt out required a bearing puller and some patience. I rejected a few suggestions of using hammers and mallets.
Anyone want to hazard a guess at the cost of the replacement part?
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Old 06-02-2014, 05:40 AM   #10
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Way to go JayBo1.
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Old 06-02-2014, 05:42 AM   #11
Tiggs
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That frame looks the same as my TRX850 frame!

All the best with the challenge ahead, I look forward to following your journey.
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Old 06-02-2014, 05:48 AM   #12
ciedema
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Quote:
Originally Posted by JayBo1 View Post
Anyone want to hazard a guess at the cost of the replacement part?
Cheap enough that getting someone to turn one out is viable.
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Old 06-02-2014, 05:49 AM   #13
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In..
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Old 06-02-2014, 05:53 AM   #14
Sundowner
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I hope you took notes when you pulled it apart.
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Old 06-02-2014, 05:54 AM   #15
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