Birth of a rallye bike

Mudguts · 10-30-2008, 06:39 PM

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

craig525 · 10-30-2008, 07:04 PM

you forgot the most important mod cush hub

Mudguts · 10-30-2008, 07:18 PM

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 ,

MymoJoe · 10-30-2008, 08:49 PM

very nice little project..

jtb · 10-30-2008, 09:02 PM

Great! You'll have to keep us posted with pics...

rhino_343 · 10-30-2008, 09:05 PM

What's the story with the bash plate in the photo??

Richard M · 10-30-2008, 09:42 PM

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

ChrisCrossed · 10-30-2008, 09:48 PM

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!

M.R. · 10-31-2008, 06:18 AM

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

ranui rocket · 10-31-2008, 02:22 PM

mudguts how much for the rs concepts screen and cluster cheers

Mudguts · 11-01-2008, 08:09 PM

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

macuser · 11-23-2008, 03:07 PM

Anxiously waiting on the pictures :)

Love this kind of stuff...

Mudguts · 11-23-2008, 04:32 PM

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.

jtb · 11-23-2008, 04:54 PM

Quote:

Originally Posted by macuser

Anxiously waiting on the pictures :)

Love this kind of stuff...

Me too!

macuser · 11-23-2008, 09:23 PM

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.

10-30-2008, 06:39 PM	#1
Mudguts ^OP when in doubt GAS IT Joined: Jan 2006 Location: Some were in , lostralia Oddometer: 1,668	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 Attached Images Mudguts screwed with this post 10-30-2008 at 06:49 PM

10-30-2008, 08:49 PM	#4
MymoJoe Ride Ride Ride Joined: Sep 2005 Location: Fernvale QLD not close enough to the desert Oddometer: 2,424	nice very nice little project.. __________________ Simpson Trip 2008 http://www.advrider.com/forums/showt...33#post7397233 Life should NOT be a journey to the grave with the intention of arriving safely in a well-preserved body, but rather to skid in sideways, body thoroughly used up, totally worn out and screaming "WOO HOO - what a ride!"

10-30-2008, 09:02 PM	#5
jtb Beastly Adventurer Joined: Dec 2003 Location: Hawkesbury NSW Australia Oddometer: 1,810	Great! You'll have to keep us posted with pics... __________________ If you always do what you always did, you always get what you always got!

10-30-2008, 09:05 PM	#6
rhino_343 Southern Explorer Joined: Mar 2007 Location: Yallingup Western Australia Oddometer: 2,088	What's the story with the bash plate in the photo?? __________________ Moto Guzzi Griso 1100 Yamaha WR450F for sale! Yamaha WR250R for sale! KTM 990 Adventure Southern Explorers trail and adventure riding group contact me for details

10-30-2008, 09:42 PM	#7
Richard M Doesntplaywellwithothers Joined: Apr 2006 Location: Brisbane,Australia Oddometer: 547	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 __________________ There isn't alot lot of Room on the Edge when you get up There.

10-30-2008, 07:04 PM	#2
craig525 Beastly Adventurer Joined: Apr 2008 Location: Lilydale Oddometer: 1,100	you forgot the most important mod cush hub

10-30-2008, 07:18 PM	#3
Mudguts ^OP when in doubt GAS IT Joined: Jan 2006 Location: Some were in , lostralia Oddometer: 1,668	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 ,

10-31-2008, 02:22 PM	#10
ranui rocket Adventurer Joined: Aug 2008 Oddometer: 53	sexy machine mudguts how much for the rs concepts screen and cluster cheers

11-23-2008, 03:07 PM	#12
macuser Gnarly Adventurer Joined: Jan 2008 Location: Calgary, Alberta Canada Oddometer: 447	Anxiously waiting on the pictures :) Love this kind of stuff... __________________ 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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