HPN - I just want one

Discussion in 'Airheads' started by Dakar83, May 4, 2012.

  1. Tanami

    Tanami Under The Weather

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    Far, Far Away.
    Nice. great work and lookin good.
    #21
  2. bully1

    bully1 Long timer

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    Looking good Jono :deal
    #22
  3. camgregus

    camgregus riding gently now

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    on the banks of the mighty mississippi, AR side
    :lurk
    #23
  4. Dakar83

    Dakar83 Been here awhile

    Joined:
    Jan 30, 2012
    Oddometer:
    259
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    The frame was sent for powder coating but with a slight difference. I had been put on to a local shop that would bead blast then apply a zinc based undercoat that would be baked on after which the color coat would be baked on, Twice baked !
    This theory being if the powder coating gets chipped you won't get rust running under the color coat thanks to the zinc treatment. I am not an expert on these matters but it sounded like a good plan. I was happy with results and love the colour.


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    The WP50 forks fitted up nicely, added a Wilber's shock prepped for my weight as it was a while ago. Oops there' incentive to loose a few kilo's
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    I'm going to have to find a caliper adaptor for the 60mm spacing on the WP50's to take the Braking 300mm rotor with standard Brembo Caliper. The thinking is that a 320 rotor will be to much or too sensitive on a dirt bike, the standard 260mm ktm rotor would be a bit under gunned for the extra weight

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    I can find caliper adapters for later model WP forks with a 90mm spacing on the fork leg, to work with a 320 rotor for a super mortared setup. But nothing for 60mm spacing to a 300mm rotor. For a while the KTM online parts catalogue had me confused as it shows the 98 LC4 Adventure running WP50 extremes with a 300 rotor. I ordered one of the calipers with adaptor to suit this model and it was no different to the one that came with the forks and 260mm disk (very confusing)

    Last week I found a German shop selling a spacer for the WP50's with 60mm spacing to fit a 320 rotor. It looks like this could be modified for the 300 rotor so I've ordered one ...
    In the interim I may have to go back to the standard 260 rotor until the solution is found.
    #24
  5. Houseoffubar

    Houseoffubar HoFmetalworks.com

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    Very, very nice!:clap
    #25
  6. Dakar83

    Dakar83 Been here awhile

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    Perth WA
    Here is the standard caliper and adaptor pictured next to the new rotor
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    Here is the Spacer plate on order
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    #26
  7. beeks76

    beeks76 Your What Hurts???

    Joined:
    May 30, 2004
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    This isn't fair, I can't see the pic's.
    #27
  8. hardwaregrrl

    hardwaregrrl ignore list

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    Atlanta
    +1....:cry
    #28
  9. Dakar83

    Dakar83 Been here awhile

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    Perth WA
    Hmmm sorry you can't see the pics, not sure why some can and others can't. They are loaded to the tapatalk picture hosting service.

    On with the story, I should be able to catch up with progress to date soon.

    I guess all this hunting around for a donor g/s had me programmed to look out for a deal. I spotted an ad for a 85 GSPD, the pics looked good and I talked to the owner interstate. He had a buyer fall through and was willing to drop his price a little. One problem it was not running the original engine. That had a pulled stud on the right hand cylinder, so another mother had been purchased and built up at Motohansa with a 1000 Seibinrock performance kit. On further enquiry the old motor and 800 pots were available and could be thrown in. An idea formed and I ended up with the third and definitely final g/s.

    The plan is to take the rebuilt 1000 motor and use it for the Project bike, then fix the old motor and put it back in the 85 g/s PD and sell it on to a new home.

    Here is a pick of the latest acquisition on the afternoon it arrived. It came across the Nullaboor on the back of a truck. Started up beautifully and we went for a ride, it was terrific really smooth and plenty of herbs!

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    #29
  10. WRC51

    WRC51 Been here awhile

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    Sep 8, 2008
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    430
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    Hydesville, Calif
    Very nice, your project is moving along beautifully. And the "third and final" GS aint that bad either.
    #30
  11. Hulked Up

    Hulked Up Been here awhile

    Joined:
    Feb 20, 2006
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    287
    Location:
    Western Massachusetts
    I saw one of these bikes recently and fell in love with it. I know virtually nothing about Airheads, but I'm eager to follow this build-up. Subscribed.
    #31
  12. Dakar83

    Dakar83 Been here awhile

    Joined:
    Jan 30, 2012
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    Perth WA
    Thanks for subscribing folks,

    Next tyre choice: Mitas Dakar E09D's, here is the pitch from the distributors site
    E-09 'Adventure' and E-09 'Dakar': Tough cross-ply construction and an aggressive block tread make it supremely capable in difficult terrains like sand, mud and loose rock. Already a superb high-performance off-road rally tyre, Mitas recently reinforced the carcass and upgraded the compound to produce the (almost indestructible) Dakar version. Choose the regular ('Adventure') version where easy fitting & removal or minimal unsprung weight are important, while the beefier 'Dakar' version offers improved puncture and chip resistance and is a better choice for serious riding in Australian off-road conditions. To help reduce confusion, we use the designations E09A and E09D to differentiate between the two. Telling them apart when new is easy: the Dakar version has a yellow stripe on the tread.

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    #32
  13. ontic

    ontic

    Joined:
    Jul 14, 2008
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    1,316
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    Melbourne

    Great project!

    Are those forks really WP50's? I haven't seen those fork lowers before- they look quite different to any I have seen online before.
    I've seen two different fork lowers that differ in their caliper bracket lugs only, the forks like mine that came with 260mm rotors, and forks from other ktms that came with 300mm rotors.
    You can see both in a post I made from the Unholy Union II thread
    http://www.advrider.com/forums/showpost.php?p=17036437&postcount=192
    basically the 300mm equipped forks had lugs that stuck out further. Yours have entirely different fork lowers (with a little KTM logo and all). I'm just interested as these are the forks I've gone with and intend to keep for a very long time so I want to know everything I can about them.

    I also thought those HE relocation brackets were to move the stock bracket for a 260mm rotor out in order to fit a 320mm rotor? Maybe they make one for 260-300 as well. As I never actually had a stock caliper bracket on hand, I've knocked together my own caliper bracket thing (out of two later brackets for USD forks) for a 320mm rotor that I am using with the KTM brembo master cylinder.
    http://i1213.photobucket.com/albums/cc479/onticboxer/R80GS/25042012277.jpg
    Seems very 'responsive' on the road but no time on the dirt yet. It seemed to handle a full knobby on wet bitumen without being too sensitive, so I think it should be OK for the dirt too. Hardwaregrrl who posted before is running a 320mm rotor (with G/S master cylinder I think) and has a fair bit of time in the dirt with it.

    Anyway, love your work. It is looking fantastic. I've been subscribed since your first post, but it was time for a post.
    Cheers,
    #33
  14. Dakar83

    Dakar83 Been here awhile

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    Thanks Ontic

    To the best of my knowledge they are WP50 extremes. They are date stamped June 98 on the casting and came off a 98 LC4 640 Adventure or possibly a 620 see pic from the KTM parts catalogue below.
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    Here is a pic of the only information cast onto the sliders.
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    Good to hear that your bike handles the 320 rotor well, that may be the way I have to go. I think the standard 260mm rotor just won't be enough.

    So far I have seen 3 variations on the WP50 fork caliper mountings.
    The type depicted below that I think ran to 1997, it has 60mm spaced caliper mounting points. I have these
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    The later 1998 onwards version that is by far the most common with a 90mm spacing between the caliper mounting points

    What looks like an older ie pre 97 version that I have only seen once, posted somewhere on this forum.
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    #34
  15. Dakar83

    Dakar83 Been here awhile

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    The gear box off the donor bike, a 1983 plate was actually stamped 1989 so it must have been changed out in the past. Decided to use this one and leave the 85 PD's gear box for its restoration but use its non matching motor (hope that wasn't too confusing)

    Dave cleaned up and reconditioned the box which was actually in really good shape. Dropped in a 5% lower 1st gear and a 5% higher 5th. Here it is..

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    #35
  16. Dakar83

    Dakar83 Been here awhile

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    Time to take the donor motor out of the 85PD
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    Dave opens her up and checks it out
    The bottom end is all new, as are the pots and high compression pistons. It just needs a new timing chain and gaskets. Will also add twin sparked gas flowed heads and a sump extension and oil cooler. It gets hot out here!

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    Oh also installed stainless push rod tubes and new rubbers. A heavy duty clutch spring and oil resistant clutch plate.
    #36
  17. Dakar83

    Dakar83 Been here awhile

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    Oddometer:
    259
    Location:
    Perth WA
    Nice new paint job and boxes of shiny new bits!

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    Time to put the engine into the frame.

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    Dave had to modify the center stand spring hangers to clear the sump extension. He did a really neat job!

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    Then fitted the enduralast alternator and the oil cooler
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    Moving along well now and up to date with progress. I'll post again when there is more to report.

    PS excuse typos this is all posted from my phone and the keyboard is a wee bit small
    #37
  18. hardwaregrrl

    hardwaregrrl ignore list

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    :tb:raabia:tb:tb:tb
    #38
  19. Bigger Al

    Bigger Al Still a stupid tire guy

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    Auburn, CA
    I'm with her! :tb :beer :thumbup Nicely done!
    #39
  20. Dakar83

    Dakar83 Been here awhile

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    Perth WA
    Not much more to report Dave's flat out with work

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    New switches and desert colored grips, complete with finger prints!
    I am not sure about the grip color, still easy enough to change if they don't work out.

    The bean can replacement cover arrived, nice looking piece and fits well.
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    Also been looking for a fender extender for the rear baja guard, something to shield the battery. HPN advertise an under seat 4.5L water tank made of polyethylene. It also acts as a battery guard so this would be the go and also allow water to be carried down low rather than in a bottle in the soft bags.

    Hope to get a few hours in this weekend
    #40