JW's BRP XRR Build 2012

[Sean-0]

Nice update .. thanks for the pics on the subframe ..could you do a few close ups of mounting points for me ?

how would you rate it as in built wise .. welds ect ..does it look or feel stronger

im glued to this build

[Cumbacheech]

WoW!!!

[jwalters]

Well, I've come to expect the unexpected with any bike build but now that I got the suspension back on, I had a rolling chassis and was able to support the bike by a rear stand only. This freed up the belly of the bike for an oil change. I started loosening the skid plate bolts, and wouldn't you know it, I had a stripped bolt. Fortunately, I had a metal drill bit and an easy out on hand. After an hour of trial and error, I was able to free the stubborn stripped bolt.

[jwalters]

Here you go Sean-O. I'll let you decide on the build quality. Good enough for me.

Originally Posted by Sean-0

Nice update .. thanks for the pics on the subframe ..could you do a few close ups of mounting points for me ?

how would you rate it as in built wise .. welds ect ..does it look or feel stronger

im glued to this build

[SamM]

Very nice!

[jwalters]

I have to be honest, its a bit tough working on bikes when the weather and scenery is this nice. I should be doing this project in another couple months after the snow hints, but I'm inpatient!

[Sean-0]

Yep i do like it ... looks an easy option to making from scratch ... i like the steel idea as its easy to fix on the rd ... most farmers will have a stick welder ... but not to may have a ally 1

i was looking at just the subframe but looking at yours i think the rear rack is the go ...watching with interest ...keep me posted on how fit goes ...exhaust and so forth

[jwalters]

Yep, I think with some basic MIG welding skills, you could easily make one of these and customize it exactly for your usage. Might be a fun project! Post pics on here if you do.

Originally Posted by Sean-0

Yep i do like it ... looks an easy option to making from scratch ... i like the steel idea as its easy to fix on the rd ... most farmers will have a stick welder ... but not to may have a ally 1

i was looking at just the subframe but looking at yours i think the rear rack is the go ...watching with interest ...keep me posted on how fit goes ...exhaust and so forth

[jwalters]

Made some progress after work today. I pulled off the stock stator and installed the new 200 watt Ricky Stator. I'll be running a full DC system, since I have HID head lights, so the 200 watt stator will be run through an aftermarket regulator/rectifier as well.

Stock Stator (notice all the empty winding spools)



Aftermarket 200W Ricky Stator:


As you can see I still have some gasket cleaning to do. The old green gasket material is on there really good. I took a razorblade and carefully removed what I could, making sure I didn't gouge the soft aluminum. I'm soaking the remainder in WD-40 overnight and see if that will loosen it up further. Anyone know of other solvents that work well to remove old gaskets?

Anyways, while I wait for BikeBandit to deliver my new gaskets, I will get started installing my new control cables. Once the gasket arrives, I'll button up the engine and take it to the car wash to give it a thorough rise before topping off fluids and installing the sub-frame plastic.

That's it for now.

[jwalters]

More progress! I am waiting on some gaskets for the left side stator cover, so I decided to work on the rear sub-frame for a few days and get the old plastic back on. First thing first was to disassemle, inspect and clean the plastic, airbox, etc.



Next step was to do some damage control on the rear fender. I think a previous exhaust system melted, bent, twisted and gouged the rear fender into what it is here. I decided the best course of action was to cut it off and sand it down, and call it character. So that's what I did!





Plastic mocked up:




I was pretty happy with things up to this point. In the picture above you'll notice that the luggage rack on the steel sub-frame sits close to the rear fender, so I need to order a lower profile tail light. I'm looking into this one from Baja Designs:

[jwalters]

Next I started to add the hardware to the Acerbis tank so it can be mounted to the bike. Let's just say I am very dissapointed in the quality of the hardware that came with the tank.

Check out this bracket, the nut was welded on crooked so I couldn't even thread the bolt through.



Fortunately, I had Hondakaguy's Tank Brace so I didn't need to use the brackets that came with the tank.


After some trial and error, I think i figured out where the orings, bolts and spacers go on the tank. But I posted a message on the XR650R thread just to be safe. I'm calling this job done. On to some electrical work tomorrow.
-jw

[bomber1965]

Originally Posted by jwalters

Anyone know of other solvents that work well to remove old gaskets?

[jwalters]

Originally Posted by bomber1965

Of course! Thanks, i'm going to see if I can find this at the auto parts store.

[jwalters]

Made a bit more progress last night. I have a little fitment issue with my steel subframe. I noticed the hangar for my FMF exhaust won't reach the bolt/mount location on the sub frame because the extra support tube for the rear rack hits my exhaust. Obvioiusly, this isn't a show stopper, but it will require me to either make a bracket and use the existing hole or measure and cut a new hole in the tubing for the exhaust pipe hangar bolt.

I'm going to think about this for a day or two before I get out the drill bits and see what other solutions might be out there. I have plenty of wiring to do in the mean time....

[jwalters]

I got a quick response from Globetrottin, and they confirmed some exhausts may not fit quite right with the rear rack. Great customer service! The minor tweaking is a small price to pay for the integrated rack. Knowing I wasn't doing anything glaringly wrong, I decided to just bolt the exhaust to the rack down tube.

I'm happy with the result: