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Old 10-30-2008, 06:39 PM   #1
Mudguts OP
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Joined: Jan 2006
Location: Some were in , lostralia
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Birth of a rallye bike

Birth of a Rally bike


Stage 1, sourcing a bike,

Well with lot of research, I decided on a KTM 525 maybe not the best bike for long haul rallies, but the best I could afford, the bike I purchase was a second hand
2005 KTM 525 with 4500km on the lock


The first to do is to rip into to and check everything is in good working order, drain all oils fields and give my baby new blood

While I was doing this a quick valve gap check and in section for damage
After this I pulled the forks apart for a clean & service and too drop in .48 springs
To suit my weight better .While the fork are out I’ve cleaned the head stem bearings
And applied fresh grease.

Next is the rear shock a quick clean and swap out the spring for a new better suited for my weight again while the shock was out I’ve pull the swing arm off for a clean and fresh grease. I discovered the rebound adjuster needle was broken no big deal as it needed a service any way, and a common issue,

The first Ride was just day trip in the local area Toolangi, bike performed well only one issue that was the water pump seal, $20 and fifteen minutes all fixed.

Stage 2

Spending lots of cash

With a bit of internet research, I ordered the flowing parts

16l safari tank
Stealth sprockets 15 /50t
DID vmx 250 chain
Full set wheel bearing and spacers
RS concept rallye faring & nav cluster
Thumper racing 570 big bore kit
Stage 2 cam
Touratech road book,
Ohlin steering damper.
EVS neck brace
09 Shift recon pant and jersey

And now I have run out of money (for Now), and waiting on all the parts to turn up
To my door.
After waiting near on three months I finally had the cash to pay the freight from France a whooping $886Aud for a whole 6kg (30kg cubic) was actually more the fairings. These things had better be good!!!

I also was assured the my 570 big bore kit would be delivered in the same week
About bloody time.

The only thing now I have changed my mind, Oh well I just sell the kit locally
To one of my brother mate for there KTM Motard

Stage 3 the fun part , opening boxes and pulling apart bikes .

An Artist impression of finished project




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Mudguts screwed with this post 10-30-2008 at 06:49 PM
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Old 10-30-2008, 07:04 PM   #2
craig525
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you forgot the most important mod cush hub
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Old 10-30-2008, 07:18 PM   #3
Mudguts OP
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No , i thought my rear wheel of the 950 would fit , but does not ,

Not real big deal ATM as will only doing short day ride and testing loading on the ute for now any way .

But i will be building another set of wheels with cush rear hub ,
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Old 10-30-2008, 08:49 PM   #4
MymoJoe
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nice

very nice little project..

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Old 10-30-2008, 09:02 PM   #5
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Great! You'll have to keep us posted with pics...
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Old 10-30-2008, 09:05 PM   #6
rhino_343
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What's the story with the bash plate in the photo??
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Old 10-30-2008, 09:42 PM   #7
Richard M
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Rally parts

I've just sold my 525 from last years safari & have all the rally gear for sale including 16l tank pm me or call mobile.

cheers
Richard
0411853810
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Old 10-30-2008, 09:48 PM   #8
ChrisCrossed
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Quote:
Originally Posted by craig525
you forgot the most important mod cush hub
you forgot the most important mod learning to navigate

Looks good. Condo will be an ADV benefit this year, wonderful stuff!
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Old 10-31-2008, 06:18 AM   #9
M.R.
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Quote:
Originally Posted by rhino_343
What's the story with the bash plate in the photo??
Looks like the water cell on the far side. the water you have to carry but hope to never use
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Old 10-31-2008, 02:22 PM   #10
ranui rocket
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sexy machine

mudguts how much for the rs concepts screen and cluster cheers
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Old 11-01-2008, 08:09 PM   #11
Mudguts OP
when in doubt GAS IT
 
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Quote:
Originally Posted by ranui rocket
mudguts how much for the rs concepts screen and cluster cheers
Cost too much try $2100, mind you 885 of that was freight ,

Checked the tracking on the freight sent on friday in melbourne on sunday delivery later today i hope , not bad from france

Mudguts screwed with this post 11-02-2008 at 05:28 PM
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Old 11-23-2008, 03:07 PM   #12
macuser
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Anxiously waiting on the pictures :)

Love this kind of stuff...
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2003 KTM 640 Adventure I made from an enduro model
2000 KTM 50 Pro Senior air-cooled
1998 KX 100; had(2007 KTM 450EXC, 2003 KTM 450SX 6sp, electric start, 18";1999 WR400 Baja Designs)
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Old 11-23-2008, 04:32 PM   #13
Mudguts OP
when in doubt GAS IT
 
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Joined: Jan 2006
Location: Some were in , lostralia
Oddometer: 2,028
Quote:
Originally Posted by macuser
Anxiously waiting on the pictures :)

Love this kind of stuff...

Anxiosly waiting to for company Gift vouchers buy a new camera .

Might Do some thing about it this week.

Mudguts screwed with this post 11-23-2008 at 05:05 PM
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Old 11-23-2008, 04:54 PM   #14
jtb
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Quote:
Originally Posted by macuser
Anxiously waiting on the pictures :)

Love this kind of stuff...
Me too!
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Old 11-23-2008, 09:23 PM   #15
macuser
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Quote:
Originally Posted by Mudguts
Anxiosly waiting to for company Gift vouchers buy a new camera .

Might Do some thing about it this week.
What's the "RS concept rallye faring & nav cluster" worth?
I have a 2007 KTM 450EXC and I'm curious what it'd cost to 'fix' it up. $11,500 for the full conversion kit, but I'm interested in the fairing costs.
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2003 KTM 640 Adventure I made from an enduro model
2000 KTM 50 Pro Senior air-cooled
1998 KX 100; had(2007 KTM 450EXC, 2003 KTM 450SX 6sp, electric start, 18";1999 WR400 Baja Designs)
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