21 Front End Conversion On 1100GS

Discussion in 'GS Boxers' started by tksmith, Jul 27, 2010.

  1. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Hi Guys

    Don't post over here often, pretty much keep to the Australian Regional forum. However I have been wrestling with this for a while and finally bit the bullet and did it. After a lot of teeth gnashing it has turned out (so far) to be a no brainer!! :evil

    <p>Well, I got sick of watching those KTM 9x0 pilots make the sand look easy so I bit the bullet and set about researching and subsequently getting the Old Girls front hoop upped to 21 inches. The process has been a long time in the planning stages and recently the "actual" doing has happened rather quickly. Firstly a big thanks to these patient people who have provided me with advice along the way:</p>
    <p> </p>
    <ul>
    <li>Rob Turton from Tyres4Bikes in Brisvegas</li>
    <li>Woody from Woddy's Wheel Works in the US</li>
    <li>Mitch from Warners Wheels Kawana</li>
    <li>Bruce from Ash's Wheel Works in Brisveags also</li>
    </ul>
    <p>Once I found that I could get a front hub second hand from the US for a measly US$50.00 I thought maybe it won't coast me a AU$1000-AU$1500 to do it! I set about badgering all those guys above for info on what the rim and lacing would cost and found that I could be able to have the whole thing done and dusted for AU$800 including the tyre!!</p>
    <p>Following are the things I had to decide on the get the spec right:</p>
    <ul>
    <li>Rim choice.
    <ul>
    <li> The 1100GS has a 40 spoke wheel so that was a limiting factor.</li>
    <li>21" rims could be had in 1.85 or 2.15 widths. Rob Turton came to the rescue here and advised the 2.15 is the go for tyre choice as fitted to the 9x0 KTM ADV's</li>
    <li>Excel make a Takasago rim in a 21" 40 spoke with a 2.15 width. Problem sorted.</li>
    </ul>
    </li>
    <li>Lace pattern and spokes.
    <ul>
    <li>The BMW hub is not conventional and has the nipples in the hub not the rim. Basically exactly opposite to the norm.</li>
    <li>Mitch at Warner's Wheels did a fine job of making the custom spokes and nipples to fit. Basically nipples in both ends.</li>
    <li>The spokes had to clear the brake calliper. Have to suck it and see.</li>
    </ul>
    </li>
    </ul>
    <p>Well I would just have to take a leap of faith and get it laced up to see if the calliper thing was going to be an issue. Woody said that 1 in 50 he does will need some of the brake calliper ground back to clear the spokes, so I thought well, so be it.</p>
    <p>Got the wheel back from Warner's yesterday</p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rims2.jpg" border="0" /></p>
    <p>Zip tied it to the back and headed for home, hoping that the brake calliper thing was just a big deal about nothing!!</p>
    <p>I got home and started pulling the front out of the old girl, wondering what I would do if the spokes were too close to the calliper to grind enough away!! Well I need not have lost any sleep as it went in and clearance was fine <img src="plugins/editors/tinymce/jscripts/tiny_mce/plugins/emotions/img/smiley-sealed.gif" border="0" alt="Sealed" title="Sealed" /></p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rim02.jpg" border="0" /></p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rim05.jpg" border="0" /></p>
    <p>Now all that remains is to fit a tire and see if I need to space up the Telelever Brace to accommodate the knobby or not. I was able to lay a round Castrol brake fluid bottle in the rim which would be about the same diameter as the tyre and it went through with the lower guard on!! That's good new as there is nearly 10mm extra clearance to the brace after the guard is removed. Might even fit the EO9 in there without spacer, just remove the lower guard. Intend to take it off anyway as they are good for nothing but clogging up with mud and clay out on the trail anyway.</p>
    <p>So here it is (minus the EO9)</p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rim01.jpg" border="0" /></p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rim13.jpg" border="0" /></p>
    <p><img src="http://adventurerider.com.au/images/stories/21inch/21 inch rim06.jpg" border="0" /></p>
    <p> </p>
    <p>Watch This Space</p>
    #1
  2. Whale Rider

    Whale Rider Been here awhile

    Joined:
    May 16, 2010
    Oddometer:
    188
    Location:
    DownUnderNZ
    tksmith 21" front wheel is a good option I retro fitted a R100GS wheel into the 1100 sets them up beatifully for off road in my opinion it transforms the bike it should be a factory option still handles fine on the tarmac.
    #2
  3. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    :clap:clap:clap:clap

    Any Pics?
    #3
  4. Jackazz

    Jackazz Been here awhile

    Joined:
    Apr 1, 2006
    Oddometer:
    841
    Location:
    Western Wa
    Now all that remains is to fit a tire and see if I need to space up the Telelever Brace to accommodate the knobby or not.



    On my 21" I had to use spacers to clear my knobby but it's worked great for well over a year. You'll love the 21".
    #4
  5. charliemik

    charliemik Been here awhile

    Joined:
    Aug 30, 2007
    Oddometer:
    420
    Location:
    Flagstaff AZ
    You guys are just adding fuel to the fire. I keep thinking of getting a 21 laced up for my 1100 but the price sure keeps me at bay. If I do decide to pull the trigger, I'll probably just get a used hub and fire it off to Woody's and let him deal with it.

    Post some ride impressions when you get it all set up.
    #5
  6. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Popping in to Rob Turtons on Friday hopefuly to get an E09 :clap

    I'll give it a run on the weekend and have some news. :ear
    #6
  7. hasenwerk

    hasenwerk Long timer

    Joined:
    Sep 11, 2008
    Oddometer:
    1,353
    Location:
    Quesnel, BC
    Anyone playing with the idea if installing a 18" rear wheel? I have an extra set of rims for my 11GS and am thinking of pulling the trigger on a project like this too!
    #7
  8. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Have heard that the 18" rear has two drawbacks.

    1/ Makes 1st gear too tall (Probably OK on 1150 GSA as 1st is a stump puller anyway :D)

    2/ Makes the centre stand ineffective. Probably just a little welding to fix that though.

    Apparently there is room in the swing arm for the tire but just.
    #8
  9. hasenwerk

    hasenwerk Long timer

    Joined:
    Sep 11, 2008
    Oddometer:
    1,353
    Location:
    Quesnel, BC
    Isn't 1st on the 1100 GS the same as 1st on the 1150 GSA?

    My center stand is a PITA to get down without some lifting of the bike in some way... the 18" should only make the rear of the bike 12mm taller so not that big of a deal... just seems that the 18/21 combo has a LOT more choice than even the 17/21 combo...
    #9
  10. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Got my E09 on the rim this arvo !! :clap:clap

    Throw it on tonight when I get home and see if I need to space the telelever. Pics to follow.:deal
    #10
  11. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Bummer.....Spacers Needed

    more info here
    #11
  12. Jackazz

    Jackazz Been here awhile

    Joined:
    Apr 1, 2006
    Oddometer:
    841
    Location:
    Western Wa
    I'd like to see your plate solution. For the past year I've been running 4 spacers but I like the idea of some brake line protection.
    Tim
    #12
  13. Whale Rider

    Whale Rider Been here awhile

    Joined:
    May 16, 2010
    Oddometer:
    188
    Location:
    DownUnderNZ
    #13
  14. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Nice one Whale Rider

    Bringing the lines out and down beside the wheel. Good lateral thinking. Removes the vulnerability all together. Are the lower brake lines stock? Looks like you had them remade with different bends near the top banjo's.

    Gear still turning here. 12mm gives you 12mm clearance from the line splitter mount to the tyre, yes?:ear
    #14
  15. Whale Rider

    Whale Rider Been here awhile

    Joined:
    May 16, 2010
    Oddometer:
    188
    Location:
    DownUnderNZ
    Hello TK the brake pipes are stock only changed end for end ie: the top banjo end connected to the calliper. cant remember if I swapped them side for side but they fit in nicely like that. I cut the lug that holds the top banjo fitting in place flush with the fork bridge and then ground a new flat and drilled and tapped a new hole to hold the brass T to the fork bridge. The pipes come out the side in front of the fork tubes and not underneath out the back as is standard I then cut the front guard in half and cut the piece out that went under the fork bridge as it no longer fits when the spacers are in. Then I made a new piece out of panel steel that goes in there to protect the brake pipes and remounted the front and rear parts of the guard job done. Plenty of clearnace above the tire with the 12mm spacers. I have travelled over 5000 kms with it now on as many metal roads as I can find handles great. Cheers whale rider :wink: :wink:
    #15
  16. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Very interesting stuff WR. Now I look at it, I see how the stock lines work, well done. I'll fashion up a coupe of spacer, good to know that you have had no trouble with 12mm, what tyres have you run on it? Is your rim a 2.15"?

    Cheers

    Todd
    #16
  17. Whale Rider

    Whale Rider Been here awhile

    Joined:
    May 16, 2010
    Oddometer:
    188
    Location:
    DownUnderNZ
    TK, The front wheel is a standard R100GS front wheel I think they are a 1.85" rim just changed the bearings and new spacer turned up to get it back from the 25mm to 20mm axle I am running a standard TKC 80 90/90-21 tubless tire, sticks to the road rain or shine.
    regards WR
    #17
  18. tksmith

    tksmith Another GS Freak

    Joined:
    Jan 16, 2007
    Oddometer:
    1,087
    Location:
    Peachester State Forest..Usually :-D
    Thanks mate.
    #18
  19. hasenwerk

    hasenwerk Long timer

    Joined:
    Sep 11, 2008
    Oddometer:
    1,353
    Location:
    Quesnel, BC
    Any updates on this? I am about to pull the trigger on a 21" conversion from Woody's and want to make sure it'll all work for me.

    I would like to be able to use the stock mud guard and just install a 15 to 20mm spacer in there to make everything work.

    Also, in real world 50 / 50 tarmac and dirt road riding, what would be a deciding factor between 1.85 and 2.15" wide wheels?
    #19
  20. Whale Rider

    Whale Rider Been here awhile

    Joined:
    May 16, 2010
    Oddometer:
    188
    Location:
    DownUnderNZ
    hasenwerk my rim wa a 1.85" because it was a standard rim off a R100GS still is tubeless not sure about the 2.15" there maybe issues with side clearance of the tire we will have to ask tksmith if he has his fitted yet. Becareful when adding the spacers as there is only a certain amount you can lift the inner tubes up before they come out of the plastic sleeves in the lower fork legs (see parts breakdown) you can feel it if you move it up and down while you have everything loose. Good luck the 21" front wheel it transforms the bike. I think you will either have to modify the front guard or leave it off. Is yours a 1100 or 1150 21" front wheel will fit the 1150 front end with the front guard off no other mods required.
    regards WR
    #20