G650X Challenge RS

Discussion in 'New Zealand' started by pampaX, Mar 2, 2011.

  1. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    After a long time after doing first draft bracket :norton I'm now attempting to do an improved version :huh.

    Lets start with disassemble

    First the bracket out of the bike
    [​IMG]

    [​IMG]

    The weight of the whole unit
    [​IMG]

    Here having removed the lateral fairing holder, i.e. the part I will start with
    [​IMG]

    Some rust forming on one of the lights for some reason (besides the fact that water is hitting it the other one is not quite as bad)
    [​IMG]

    The rubber mounted light holder bolt
    [​IMG]

    Another take at the main bones of the tower, now without anything else
    [​IMG]

    So what I'm trying to do is
    1. to build one main bracket bone like the ones above this time tidier, also lower. The reason to be lower is I'm going to build a separate part to hold dash, road book holder and GPS holder ....:1drink
    2. reuse the other bits, like fairing holder and indicator even maybe the dash holder
    3. allocate space for the fuse box
    4. maybe some space for tools
    5. devise a way to cover water coming from the front wheel

    :eek1
  2. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    So clean out of laser cutter :rofl

    [​IMG]

    [​IMG]

    put main bolts and verify it fits
    [​IMG]

    closer
    [​IMG]


    so far so good, next drill rest of the holes and verify it goes together :1drink otherwise redo :cry
  3. Bli55

    Bli55 -

    Joined:
    Mar 7, 2012
    Oddometer:
    524
    Location:
    Russia, N56 E49.
    pampaX, loving your thread!! :evil

    How about some more laser-cutting goodness? And in more manageable screen size? :D
  4. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    Thanks for your comments

    I have a few pics of all put together, version #3 that I need to filter and make available ... will get to do it soon ...
    the screen size its not bad some people believe it gets on the way however it doesn't happen. Only problem I have is on rough offroad it may come close to your chest :evil. I want to build a low screen for that sort of application, but need to do more mods to the tower so it doesn't protrude that much if I had a lower screen or it can be moved ...

    On the next video you can see one of the problems with the tower :eek1 as it is now although the wiring seems much better now
    <iframe width="560" height="315" src="http://www.youtube.com/embed/Or0osdYlTeg" frameborder="0" allowfullscreen></iframe>
  5. Oaters

    Oaters Old - not bold - moto riding addict

    Joined:
    Jul 9, 2005
    Oddometer:
    1,058
    Location:
    Awakairangi, Aotearoa
    excellent little vid Pablo - riding the 'Pram Track' vicariously with you - enjoyable - I'm reminded how much these tracks change with the vagaries of the elements - have to pinch myself to think that I once took an 1150GS through there - thanks for posting
  6. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    Hi long time since we rode together aye, the track wasn't too bad i has been graded recently so its quite good, although a bit loose for road tyres.

    I heard you 1150 has gain 50 extra cc :1drink
  7. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    After a while of finishing this finally got around to post the pics.

    After some trial an error this is what I ended up with
    [​IMG]

    Installed looks like
    [​IMG]

    Now for the power box position on the bracket
    [​IMG]

    view from above
    [​IMG]

    front
    [​IMG]

    all the parts at this stage, the looser cutter was getting tired :evil
    [​IMG]
    this two pieces are the mountings for the dashboard, route holder, or map, etc (it turns out they don't work quite well but that's what I have now) ... they're have the rubber mount for vibration dampening
    [​IMG]
  8. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    ok accidentally hit submit oh well (amateur)

    another close up
    [​IMG]

    now to the assembly line, this is the main part the backbone if you like
    [​IMG]

    next step is putting the side holders
    [​IMG]

    the rest
    [​IMG]

    all together ready for another test
    [​IMG]

    fitting test, anyway
    and it does fit
    [​IMG]

    Then installed with all the lights, spacers, zip-ties for cables, loc-nut nuts etc
    [​IMG]

    So, next is a modification to indicator holders and cable tidy up. Note its done however haven't got pics yet
    I'm still not happy with the dashboard holder, but will have to wait as I'm working on something else that also has 3 letters like BMW and has one letter in common but in different position, also has 2 wheels :lol3

    Things I was considering where in no particular order
    1. weight
    2. strength
    3. support vibration
    4. access to all the bits
    5. space to put cables tidy
    6. use as little bolt and nuts types as possible
    7. Make it a single unit that can be fully detached from the bike without having to put the biek apart
    8. Clear for steering, mirrors, handlebars, cables etc
  9. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    4,252
    Location:
    Rotoiti, North Is, New Zealand
    The 4 square centimeters of your bracket that is filling my entire screen looks pretty good. Any chance of resizing the pics so we can see the whole job at once? :evil

    Cheers
    Clint
  10. Rosie!

    Rosie! Little MissAdventure

    Joined:
    Feb 25, 2006
    Oddometer:
    472
    Location:
    Rotorua, NZ
    See, if you had two monitors like me :deal the pics would still be too wide :fpalm
  11. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    Ok ok I thought that was going to be the case ...:1drink tonight or tomorrow
  12. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    Ok pics are now smaller hope I don't get told of by the moderator again :rofl
  13. Bli55

    Bli55 -

    Joined:
    Mar 7, 2012
    Oddometer:
    524
    Location:
    Russia, N56 E49.
    pampaX,
    any news on your 2nd version?

    Also, re-read your thread and the adjustable levers really got me thinking!! :evil

    Except the spacer for clutch lever, did it fit OK?
    Reason I ask is that X-Ch uses a clutch cable with a thicker than average outer sheath and it won't fit some universal levers - is this one able to accept stock clutch cable?
    How about the brake - fit OK?

    Cheers! :freaky
  14. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    Hi the second version got bent on incursion to a very nasty uphill section or rather on the way out of there when the battery went flat and had to push bike. I made another version #3, it seems slightly better although I'm yet to take some pics.

    The levers went ok. the only thing was the clutch side were the pin didn't fit. However it had alloy bush which I replaced with a narrower one I made out of spare bit of alloy I had laying around :1drink. I may have some pics somewhere, but it wasn't a big problem.
  15. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    It was surprisingly hard to get a rotor for the rear finally got the one from Stephen

    [​IMG]
  16. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    The problem with the axle nuts on the bike is that they're of an unusual size. Then I also have another bike thus I decided to buy the ktm ones someone recommended as they're only $12 for both. That way I only have one tool for wheels for both bikes on my bumbag :clap
    [​IMG]

    front
    [​IMG]

    sorry for crappy pics
  17. pampaX

    pampaX Been here awhile

    Joined:
    Aug 3, 2007
    Oddometer:
    444
    This is the pin I was talking about
    [​IMG]

    [​IMG]
  18. BikerBobber

    BikerBobber Trying to get lost

    Joined:
    Feb 28, 2011
    Oddometer:
    1,277
    Location:
    Seeleys Bay, Ontario
    Do these fit the stock axle?
    Where did you buy the nuts from?
    Thanks!
    Bob
    Edit - never mind. Needed to read the whole thread ;)
    From my mobile
  19. Gangplank

    Gangplank Advenchaintourer

    Joined:
    Jul 20, 2003
    Oddometer:
    2,316
    Location:
    Las Vegas
    Any idea what size socket fits the KTM nuts?

    Also, what size axle and threading are they bolting on to? I have a F650GS w/ YZ250F front end and I'd love to reduce the 3 different sizes I need to make a change.
  20. Bli55

    Bli55 -

    Joined:
    Mar 7, 2012
    Oddometer:
    524
    Location:
    Russia, N56 E49.
    Gangplank,

    ktm wheel nuts are M20 * 1.5 , 27mm socket, part number 50310099000