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Old 03-24-2013, 11:46 PM   #436
Luke OP
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Joined: Aug 2004
Location: Idiotville, OR
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Alrighty; it's been looking like a motorcycle for a while, now it's starting to work like a motorcycle. Lots of detail work to finish, but it's getting there.

Chain slider. Rather than go with a premade one I built one from plastic and aluminum. I built one before for my Husqvarna and it worked out well, so this is a repeat project.

Start with some plastic that's about the right size and clamp it in place:





Then put the other side block on and bolt it all together:





Aluminum side plates were added, and then one of the plastic side plates was cut and some spacers added to line it up with the chain.





As seen above, I also made a sidestand. I was going to stick with the centerstand but it hit the chain guide. Making it miss the chain guide while not sticking way too far down below the bike was going to require completely rebuilding it, so a new sidestand seemed like a better idea. Unfortunately the original sidestand wouldn't work as it hangs too low and would also interfere with the skid plate. The sidestand mount is an extension of the left exhaust hanger.

Start with the mount and pivot:



Attach it to the exhaust mount:





Make sure the sidestand tube goes in the right direction when retracted:



Weld the tube on, cut it to length, add the spring perches:



Finally add a foot and a boot hook:



End result:


There was no space on the outside of the sidestand -the exhaust is right there- so the springs are on the inside. Two identical springs are easier to fit than finding a nested pair of springs that would work well. The springs are really easy to install, but have a lot of leverage so they hold the sidestand up well.

Retracted:


Extended:
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Old 03-25-2013, 12:19 AM   #437
Luke OP
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Another part to be made was a combination mount for a steering damper,speedometer, and hour meter.

I measured up the parts and made a plan.


The holes were all started using a center bit on the mill then drilled out on the drill press. The press is actually a much better drill than the mill, but is much less precise at starting holes.




The drilling was mostly done but I burnt out the xmas tree bit trying to make the cutout for the steering damper arm. I'll freehand it with the angle grinder when I install the damper.








A quick inner fender to keep back tire from flinging muck into the air filter and coils:


And it was time for a test ride:



I could have taken more pictures, but there wasn't much light left and I was having too much fun riding. It's running really well. Lots of power, and the handling is decent. There are some problems of course, but they're pretty much all tuning issues: jetting, lowering the footpegs, that sort of thing. No 'have to cut the frame' issues. And hopefully I'll get some decent video of this thing running.
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Old 03-25-2013, 12:27 AM   #438
Mr. Fisherman
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Nice job...
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Old 03-25-2013, 04:02 AM   #439
oregoncoast
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Only 33 days until tech inspection in Mexicali!!
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Old 03-25-2013, 07:26 AM   #440
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That is a great looking side stand, nice work.
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Old 03-25-2013, 09:20 AM   #441
DustyRags
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Looks awesome!
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Old 03-25-2013, 09:24 AM   #442
TwinDuro
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Fantastic! The side-stand looks awesome.
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Old 03-25-2013, 06:21 PM   #443
TonyfromOR
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Beautiful work! So what is the final weight of this beast?
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Old 03-25-2013, 08:04 PM   #444
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Nice work Luke. Love you sharing the fabrication steps. It's really coming along!
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Old 03-31-2013, 07:02 PM   #445
Ladybug0048
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Things are looking good. I can't wait to see it in action at the D100. I'll be there cheering you on
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Old 03-31-2013, 09:16 PM   #446
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Couple of pics...

A beautiful and sunny Easter morning, Luke hard at work early in the AM;



Later in the afternoon;



Luke has worked mega-hours on this beast, hopefully he will be rewarded with a great ride in Mexico!
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Old 03-31-2013, 09:21 PM   #447
Mr. Fisherman
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How about another side stand for the other side... a split center stand if you will? Could be interesting and come in handy for flats... though a simple stick stand might be quicker and easier... It wouldn't be nearly as odd or creative...
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Old 04-01-2013, 12:28 AM   #448
Luke OP
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A lot's been done recently, but not much of that was taking pictures. The projects left are getting smaller and smaller.

Here's one; cleaning up the wiring to the starter and stator, I wanted to figure out what gage to use. Lighter wire is much easier to route than the heavy stuff. So I measured the starter current. 80amps. Better use the thick stuff.






The rock guard (not heavy enough to be called a skid plate) was hopefullt the last of the big projects. Proving that the polishing wheel isn't just for carb floats:


Not the greatest mounting, but it will hopefully do:


I also added crash bars, they were NOS from ebay, but were for the 650 so a couple of the mounting points had to be moved. Otherwise they're great, and have three mounting points instead of 2 that most 500/550 guards have.



Rick and I rode for about an hour today, it was really good to get some time on the bike. It's running pretty well, just have a lot of tuning to do on it. And four days to do it in before going to Odessa. I may be revalving the suspension in the campsite.
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Old 04-01-2013, 08:56 PM   #449
oregoncoast
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Luke came down to the coast today to do some jetting and other tweaking. I met him at Sandlake in case he needed any assistance. These two vehicles will hopefully be able to pose together again....on May 1st in San Jose del Cabo!





And here's a little video of Luke tearing across the flats wide-open. He was not happy with the top speed, so he might be doing some tinkering He hit just under 70 mph.


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Old 04-01-2013, 10:48 PM   #450
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Like OC posted, a little high speed testing today.

The handling was a little twitchy at first, but lower tire pressure and a little less preload on the rear shocks fixed that up.

It might be running a little rich:


Closer; dropping the main jets by a couple of sizes made it almost 10mph faster.



It just feels like it runs out of breath by 70, so something is up. I'll do a break-in service and then see if anything can be done about it. First up will be to replace the zig-zag air intake.




Parking in sand is easy. Un-parking would have been pretty hard if it weren't wet.




The beach is solid enough for the sidestand.
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