Aussie 1150gs Rally hybrid

Discussion in 'GS Boxers' started by seancampbell, Apr 1, 2007.

  1. seancampbell

    seancampbell Been here awhile

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    Here are the first pics of my project. After seeing what Jim Rowley had done to his R1100gs and looking at the BMW dakar & HPN bikes, I thought I'd give it a go myself.

    I bought a '99 BMW 1150GS that has been smashed, the motor was dead with smashed cases and the bike was in 10 boxes, but the price was right.
    Add another motor, Yamaha YZ450 front end, Suzuki DR650 'Safari' 32L tank and a KTM 660 rally fairing and this is what you get...

    Attached Files:

    #1
  2. seancampbell

    seancampbell Been here awhile

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    Here is another pic taken after my first test ride. The test ride went great except that the fuel line split and sprayed fuel all over my leg and onto the motor and exhaust!!!

    Attached Files:

    #2
  3. Maverick75

    Maverick75 Rat

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    that is totally sick.
    Where can i get one?
    Seriously man, how does it go o/r with the new front end? It's a bit like the HP2 never made in the 1150, with an adv tank!
    #3
  4. seancampbell

    seancampbell Been here awhile

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    The new front end is GREAT! All I added was 0.52kg fork springs to the standard '05 YZ450 forks. Off road it soaks up any bumps, rocks rock ledges with ease. It feels so much more like a dirt bike. If I don't look down at the heads I could swear i'm riding a "normal" dirt bike.

    In the front end conversion I added a "back bone" that is welded to the front subframe and bolted to the rear sub frame, like the HP2. This "back bone also supports the tank.
    #4
  5. gsd4me

    gsd4me 90% bluff

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    Sean. That`s a great looking bike, what did you have to do to get the tank to fit and more importantly, to work?
    #5
  6. scotsmun

    scotsmun Been here awhile

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    Looks great mate:clap
    #6
  7. seancampbell

    seancampbell Been here awhile

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    After looking at photos of every big tank I could find, I thought the DR650 Safari Would be close to fitting straight up. It had to clear the heads, so it couldn't come down too low (like the KTM 640 Adv) and also had to clear the alternator. I looked at a few DR650's with the standard tank and it looked good. So without ever seeing on I ordered a Safari tank and crossed my fingers...

    The tank arrived and I placed it on the bike... Perfect! I bought some Suzuki DR650 rubber tank mounts and hung a bracket off the "back bone" just like the factory Suzuki DR650.

    I've got the build photo's but they are on my work computer, I'll post them this week.
    #7
  8. Maverick75

    Maverick75 Rat

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    what rake/trail did you set?
    hay, BMW cylinder heads are just oversized oggy knobbs anyway!:rofl
    It's an interesting conversion , is this a non ABS bike?
    #8
  9. Maverick75

    Maverick75 Rat

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    i mean 'was' this a non ABS bike
    #9
  10. seancampbell

    seancampbell Been here awhile

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    The rake/trail is still the same. Just with USD forks. I was given a few tips from Jim Rowley on the rake/trail (thanks Jim).

    The bike WAS an ABS model, Just unpluged and then cut the computer conector off!
    #10
  11. gsd4me

    gsd4me 90% bluff

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    I used to run Heinrich tanks on my airheads back in the 70s and 80s and want a bigger tank for my 1100GS, but they are so bloody expensive. This looks like a cost effective answer.
    #11
  12. crash a-ron

    crash a-ron mmm...burnt steel

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    That bike looks fantastic! Where did you get the fairing?? Is it a stock KTM part? Is it aftermarket? I'd love to get one like that...
    #12
  13. seancampbell

    seancampbell Been here awhile

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    The fairing is a fiberglass copy of a KTM 660 Rally fairing, I think '99. I got it from a bike shop in the Northern Teritory, Racers edge (I think) they made a mould of them and now sell the fiberglass copy. About $200 AUD
    #13
  14. Ricardo Kuhn

    Ricardo Kuhn a.k.a. Mr Rico Suave

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    Sean awesome Job...

    very inspirational, sound like the job when like the brezze..

    if you have any more fotos of the process will be great, so we can apreciate the construction process and design challenges..

    congratulation on your own new bike.
    #14
  15. TUCKERS

    TUCKERS the famous james

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    I have always been impressed by Aussie ingenuity. The stuff that comes out of there is nothing short of incredible. There must be something in the beer or something! Really good job, well done Man!
    #15
  16. seancampbell

    seancampbell Been here awhile

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    This is a pic of the steering head. I was very impressed by Jim Rowley's conversion. Unlike Jim I didn't have a CR steering head to weld on so I started from scratch. I hade a mate (thats a good friend to all you in the states) machine a steering head out of alloy then machine the BMW front sub frame to take it. Then all that was left was to weld it together and add some bracing for strength. Again thanks to Jim for his advice. This forum is great!

    You can also see the "Back bone or spine" that was added to replace the supports for the BMW front sub frame. This "back bone" now ties the front sub frame to the rear sub frame - just like the HP2! This "back bone" supports and locates the new fuel tank. (you can just see the fuel tank mount welded under the "back bone"

    Notice one of the 2 smaller oil coolers off a BMW 1100R road bike which now sit in the same spot as the BMW/HPN dakar bikes.

    Attached Files:

    #16
  17. seancampbell

    seancampbell Been here awhile

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    Here is the rear sub frame and the back of the "back bone" where it is bolted to the sub frame. The original sub frame was cut away just leaving the rear shock mount and the frame mounts. Then a mount was made for the "back bone" to bolt to. This mount also doubles as the seat mount.

    The rest of the rear sub fram was built to support the Suzuki DR650 seat and a small rear guard (UFO universal). An Acerbis tail light and small blinkers were also added.

    Notice that the top of the airbox has been removed. This new space is where the computer now sits. Also you can see the new external fuel pump and just infront of it is the cradle that holds a new battery (YTX12 not the 19 amp hour original). So far this battery has had no problems starting the bike.

    The mess of wiring you can see has been placed (forced) back into the original fuse box (the fuse box was trimmed down to fit in the slimmer rear sub frame.

    Attached Files:

    #17
  18. seancampbell

    seancampbell Been here awhile

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    This is a photo from the rear showing how slim the bike is now. It realy feels just like a "normal" dirt bike. Standing up and gripping the seat with your knees feels perfect. It is now SO much better off road.

    Attached Files:

    • rear.JPG
      rear.JPG
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    #18
  19. gsd4me

    gsd4me 90% bluff

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    As they say, " mother is the necessity of invention", or something like that. I`m wondering if that tank would fit with the telelever set up and the standard seat?
    #19
  20. seancampbell

    seancampbell Been here awhile

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    NO, the tank will not fit with the standard suspension, Everything except the altanator has been removed from under the tank. No ABS unit, No computer (moved to above airbox) a much smaller battery has been installed flat under the tank.

    Also the Safari tank needs a frame to mount it on, you might be able to do it but it would sit MUCH higher than mine.
    #20