JTH's HD 883 Dual Sport'ster conversion

Discussion in 'Some Assembly Required' started by JimmyTheHog, Feb 4, 2011.

  1. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Thanks! Here is another page from my notes. Note that when you put the stiffer spings into the KTM forks, you may need to turn down the plastic spring guide to make them fit. I did for the 0.7 spings. The 0.6's might be ok - not sure since I didnt start with them. 0.6's have smaller diameter spring wire.

    ..

    Attached Files:

  2. BadKarma

    BadKarma Long timer

    Joined:
    Dec 29, 2011
    Oddometer:
    2,261
    Location:
    Rocky Mountains, USA
    Wow! thanks Jimmy, that's more than I was looking for but exactly what I need! I'm not cleared for actual physical work yet but at least I can start gathering parts, we've still got at least 8 weeks of winter left here, Hope to have my Sport on the road and off for the spring thaw! :clap
  3. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Just got the message from Evan on the tank - he wont know the cost of a production run version until he makes the first one. So, we'll have to wait and see.
  4. RSRennsport

    RSRennsport Navigator

    Joined:
    Jan 25, 2012
    Oddometer:
    64
    Location:
    Weisse Hoelle / Michigan
    I am fairly new to this group even though I have been in the business for some time and you probably heard it all before, but I must say, that your build is the most inspiring task I have seen in a very long time. Well thought through and well executed. A prime example on how it should be done.

    I know Willy G wouldn't agree, but the hell with him. :lol3
  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Got my bike back last night with the new 1250cc kit, cams, carb rejet - I was having serious withdrawls. Took it out for a short ride - extra power feels great, but still breaking it in, so not reving it too high yet. The real fun will begin after 150mile break in.

    I went with black cylinders - thought it went well with the color scheme of the bike. Here are a few pics..

    [​IMG]

    [​IMG]
  6. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    I installed the new skid plate today too ~ after some minor rework. I had the rear mounting holes off by almost an inch - Oops :hmmmmm- Oh well, it was an easy rework.

    Installation takes one bolt / nut in the front, and two bolts underneath with mounting bracket to the frame.

    The install... Front bolt first makes it easy to get your hand behind the frame mount to install the nut on the bolt.

    [​IMG]

    [​IMG]

    [​IMG]
  7. Danger4u2

    Danger4u2 KX500 is Danger4u2

    Joined:
    Mar 15, 2007
    Oddometer:
    731
    Location:
    OKC
    Are you considering it done? Or are there other items your still working on. More tweaks? May I ask why you used an 883 and didn't start with the 1200 sporty? You've done well, I like it.
  8. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    No, its close but not quite done. Here's the list of remaining tweaks / components:
    - Headlight mounting brackets - gets rid of the hose clamps-to-fork tubes mounting. On order
    - Kickstand - The one i made is from another bike and lengthened. Im making a new one from scratch now that i designed
    - Tweak the design of the front blinker brackets - so same blinkers front & rear can be used. Currently both different
    - Anodize the rear rack, tool kit plate, and skid plate - clear anodize
    - Paint the tank black w/ silver sides and top, and black scorpion logo & red letters "scorpion"
    - And lastly, a 5.5 gal gas tank - Im on the wait list to have this made, but wont be done until later this year.

    Then I will claim it "done". Im exhausted just thinking about it :stoned

    I went with the 883 because I found a good deal on a clean one. If I would have found a nice 1200 when i was looking, I would have bought it instead.
  9. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,341
    Location:
    On a set of 50,000 mile tires.
    Looking great, Jim!!!

    Add a Li Ion battery to that list and drop another 10 pounds of the bike. :deal
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    You just reminded me - I forgot to add that i just installed one today. It cranks great (much needed with the 1250 and cams) and its noticably lighter having removed those 10 lbs from up high. That, plus adding the skid plate weight down low, was a noticable change.

    There seems to be some reliability debate on these though - cold weather issues ? Maybe it was for the earlier models ? Not sure, but for a 10 lb savings, Im willing to give it a try and see how it does.

    You can see it in this picture a bit better...

    [​IMG]
  11. merc16

    merc16 Been here awhile

    Joined:
    Nov 26, 2008
    Oddometer:
    331
    Location:
    West Blocton,Alabama
    I can't wait to hear details about the kit for this.
  12. Straightedge

    Straightedge Skin Donor

    Joined:
    Aug 24, 2010
    Oddometer:
    37
    Location:
    Bluegrass, near Louisville
    Cuh-lean. Wish my bikes looked this good...
  13. JN3n

    JN3n Been here awhile

    Joined:
    Oct 20, 2011
    Oddometer:
    190
    Location:
    A Racetrack Somewhere
    Is RaceTech building your new tank ?
    I like your bike . The cool factor is way up there...
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    No, its Evan Wilcox Hand Formed Metal. He does one-off's and limited production stuff. He's at www.wilcoxmetal.com.

    Does RaceTech make tanks ???
  15. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    15,341
    Location:
    On a set of 50,000 mile tires.

    Cool!!

    I went with a Ballistic battery after hearing about all the problems with the Shorai. The battery on my BMW project was 14 pounds and I put a 2.5 pound battery back in. :wink:
  16. JN3n

    JN3n Been here awhile

    Joined:
    Oct 20, 2011
    Oddometer:
    190
    Location:
    A Racetrack Somewhere
    I met the guy who made your tank at the San Jose swap meet . Nice Guy
    RaceTec is in Oxnard and he has been making gas tanks, race car goodies etc. for along time . He makes beautiful and functional tanks flat track bikes I have built. Fred @ RaceTec 805- 486-6500
  17. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    Thanks much for the lead ! I had asked Storz who the tank fabricator was, and they "respectfully" declined to answer. I'll give him a call. Since he already has the form or whatever he uses to shape the tracker tank, it may be an easy mod to add some more volume. Im sure Evan will do a nice job though too.

    Thanks again!
  18. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    New shift lever hot of the mill. The previous one was a combination of two levers - a new machined lever + an existing spline piece pressed and pinned together. I did this since we didnt have a serration broach tool at the time.

    ..
    [​IMG]
  19. RustyStuff

    RustyStuff Been here awhile

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    Jan 14, 2012
    Oddometer:
    921
    Location:
    Crakima,Wa
    How tall is the bike?
  20. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    741
    Location:
    Sunnyvale, CA
    It has a ~35.5" seat height, and is ~33" with me on the bike. I cant flat foot it, but both feet can touch the ground without too much stretch.