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Old 11-17-2012, 03:24 PM   #1
WhicheverAnyWayCan OP
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Location: Seven Springs NC
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Project Cosette (Yet Another Sportster conversion)

Edit on June 10, 2015

I am editting the first post because most of pics from this page to page 7 has been lost due to my divorce with Smugmug. There must have been some sort of miscommunication with them and they boot me off including my photo so I have moved to Photobucket. In meantime, here is a pre-build info before I send you off to page 7 to see the building process.


A bit history.. My friend who was mechanic at Harley dealer at the time.. he bought the bike looking like this.. 98 XLH 883



Then he converted that into this..




Disaster strike when he sold it to "someone his wife know" and he financed it to the buyer.. big mistake.. Was able to recover it.. sold it to me. Fuel tank was messed up, poor wiring job, etc. Wiring harness will need to be replaced, the center console is messed up badly on inside.. You can see that paint job for fuel tank is not matching with front/rear fender & oil tank.



So I decided to convert it into a Dual Sport bike so I could ride it anywhere..

The stripping begin..




Parted out parts I won't need.. mostly dead weight anyway..

Front end replaced with KTM 50mm White Powder Extreme forks and Triple Tree with top part from Applied Racing. It bolt on perfect without any modification!



Rims replaced with Buchanan's SunRims rims from Buchanan's Spoke in CA. Billet aluminum hub ordered to go with front end for better strength and HD steel hub was used for rear. HD hub weight 9 lbs and billet aluminum would be 6lbs but it is $300 so I decided $300 wasn't worth 3 lbs difference.



Let me go ahead and send you off to Page 7 and start at #101.

WhicheverAnyWayCan screwed with this post 06-10-2015 at 04:03 AM
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Old 11-18-2012, 12:52 PM   #2
pennswoodsed
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chain drive

Will you be going to chain drive or extra belt with you ? 19"and 18" tires ?
Thanks,Ed

pennswoodsed screwed with this post 11-18-2012 at 12:52 PM Reason: clarity
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Old 11-18-2012, 01:36 PM   #3
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Originally Posted by pennswoodsed View Post
Will you be going to chain drive or extra belt with you ? 19"and 18" tires ?
Thanks,Ed
I am on the fence between 21" front and 17" rear but I haven't decided on that until I mount the KTM fork on then I will play around with it a bit. Possible 20"f and 17"r?

Will be going chain too.. most likely using the following:
*5-speed trans sprocket spacer HD #33334-85 ------------$20
*Mainshaft Oil Seal HD #12050 -----------$4
*Quad Oil Seal HD# 11165------------$3
*Renthal R3-2 O-Ring 520 chain X114 links --------$80
*48 Tooth 520 rear sprocket Chris Products (PBI ?)#205348 ------------$60
*21 Tooth 520 front sprocket PBI # 277X-21-----------$35

The chain may need to be cut short before locking the master link.
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Old 11-18-2012, 07:53 PM   #4
bk brkr baker
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20" front ?
Good luck finding replacement tires in that odd size on the road.
If you step too far away from the common, you may find yourself alone.
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Old 11-18-2012, 08:01 PM   #5
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Originally Posted by bk brkr baker View Post
20" front ?
Good luck finding replacement tires in that odd size on the road.
If you step too far away from the common, you may find yourself alone.
I can see why you are pointing it out.. in that case, 21 or 19.. I have not really get to that point yet.. My current focus point is the engine itself downgrading from high performance to regular 1200cc with high tolerate for poor octane fuel.

Thanks for pointing it out, appreciate it man!
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Old 11-18-2012, 08:39 PM   #6
JimmyTheHog
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For reference, when i did my chain conversion, it took 124 links with the following:
- 56 rear sprocket
- 25 front sprocket
- 4" extended swingarm

I went taller on the sprockets (both front and rear) to gain clearance over the swingarm pivot. Otherwise, with the longer travel suspension and swingarm angle, the chain would wear on the chain slider. Now its fine with this setup.
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Old 11-19-2012, 06:26 PM   #7
ValuePack
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Subscribed.

So what's the rise on the bars that are mounted now? The wife just inherited her dad's'07 Heritage, and there's no way she's riding it with the mondo apes that are on it now. What you've got on there looks more appropriate.
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Old 11-22-2012, 09:28 AM   #8
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Lookin' great so far! Keep it up. I had an 883 Sporty... everytime I see a conversion I kick myself for selling her.

Best of luck - can't wait to see how she turns out!
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Old 11-22-2012, 07:35 PM   #9
kellymac530
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Those forks look like a great choice for a project like this, but I am not sure about them being from a 2003 525 KTM....
Every KTM I have seen since before 2003 has had USD forks. My guess on those would be maybe '98 KTM forks. This is important for seals and spring choices.

Cool build though and keep posting pics
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Old 12-31-2012, 12:07 PM   #10
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Quote:
Originally Posted by kellymac530 View Post
Those forks look like a great choice for a project like this, but I am not sure about them being from a 2003 525 KTM....
Every KTM I have seen since before 2003 has had USD forks. My guess on those would be maybe '98 KTM forks. This is important for seals and spring choices.

Cool build though and keep posting pics
Kellymac,

Would you please help me to get the info I need to order seals, axle, and if the KTM Supermoto front fender would work with this? Is there any way I can identify the fork by finding part # on it or no? I tried to inquire on KTMForums.com to no avail.
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Old 12-31-2012, 02:21 PM   #11
kellymac530
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WAWC,
I believe those are the 50mm KTM Magnum Marocchi forks from the circa 1998 era.
The seals are available. but sometimes are hard to find.

The Sumo fender will fit just fine. At most you will need to oval 2 holes a bit, but I doubt it.

Make sure you use at least some Seal Saver Neopreene covers on the forks. The saels are a bit fragile on those and cleanliness is next to Godliness on those forks...

If you have a micrometer or caliper just measure the diameter of the forks, they should be 50mm upper tubes. That should help a bit.
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kellymac530 screwed with this post 12-31-2012 at 02:37 PM Reason: mis spoke on the mm
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Old 12-31-2012, 05:06 PM   #12
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Are you sure there not wp 50mm extremes?
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Old 12-31-2012, 05:39 PM   #13
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Are you sure there not wp 50mm extremes?
They could be, but alot of the wp Xs I see are aluminum colored and not annodized black like that....some are though so you very well could be right.

The Marzocchis had a little tab cast into the top of the lower tube where the fork protector would slide. I have not seen that on my earlier WP Xs forks....again not positive though and do not claim to know alot.

To WAWC,
Look at the bottom casting of the forks around where the axle fits there will likely be a WP cast into it or some kind of brand cast into it like Magnum or something other than KTM which has run both of those.
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Old 12-31-2012, 05:49 PM   #14
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These are WP 50mm Extremes...no tab.

These below are the Marzocchi magnums that I am speaking about...discusses them in like the 4th or 5th paragraph

http://www.motorcyclespecs.co.za/mod...0_exc%2098.htm
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Old 12-31-2012, 06:01 PM   #15
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From this listing it looks like Joe is right. WP 50mm Xs

http://www.ebay.com/itm/99-KTM300EXC...9a0268&vxp=mtr
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