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:
    750
    Location:
    Sunnyvale, CA
    Thanks for the input - very much appreciated. The new gas tank mounts like the Storz aluminum tank with a bolt attached to the backbone (either with a welded bracket or a hose clamped one like some Clarke tanks use) and also supported in the front from where the ignition coils hang - which looks like a similar hole, but towards the front.

    If I could ask - could you take another picture of the front of the backbone near the steering stem to see if that same basic mounting hole is there? Thanks in advance!
  2. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,651
    Location:
    Seven Springs NC
    Sure, I think this is what you wanted? I hope this angle is good for you?

    The first hole on left is what you use to hold the fuel tank bolt and 3rd hole from left to right is for ignite module bracket bolts.
    [​IMG]

    [​IMG]
  3. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,651
    Location:
    Seven Springs NC
    One quick question about volt regulator.. is your still in the original location? I have thought about possible of relocating it but am concerned about getting enough air flow to go through it to keep it cool, and the way the wire harness is designed, it looks like maybe relocating is not possible? Any thought?
  4. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    Thanks for the pictures. Looks promising.

    Yes, I kept the volt regulator in the same place for now. Same concern - you want to keep it well cooled. Not sure how well it will do over time there though if it gets hit by rocks or debris from coming off the front tire. Also, if you do any mud riding and it gets coated - it could be a problem. Its up fairly high, so hopefully its ok there - we shall see. If it becomes a problem, then I'd consider moving it. I did remove my horn though, which was mounted right above it. This opened up more air flow to the motor.
  5. bk brkr baker

    bk brkr baker Long timer

    Joined:
    Jul 19, 2006
    Oddometer:
    8,056
    Location:
    The Bluegrass
  6. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,651
    Location:
    Seven Springs NC
    [​IMG]

    Yo! I got 40 holes hub from local H-D Dealer for free and I was wondering where did you get your rim from? Buchananspoke.net ? Did you knew what you needed and just order it or did you had to speak with someone over there to get what you needed? I am wanting a rim that is 17" with 40 holes and the hub you have look so much like the one I have..

    [​IMG]
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    That's correct - I had the wheel built at Buchanans. I liked the Storz tracker billet alum hub (now not available - their supplier went out of biz or something like that), so I bought it from Storz and then had it shipped direct to Buchanans (theyre both in SoCal) where they laced the hub to the Sun rim with sst .156 dia spokes - 40 total. They also have Excel rims too. Check me on this, but I think they drill the spoke holes in the rims there, so # of holes can be drilled to match the hub.

    I had to call Buchanans to coordinate it and get the quote. Pretty easy to work with though and they did a great job in a short time.

    Hope that helps.
  8. Bambi

    Bambi Been here awhile

    Joined:
    May 14, 2009
    Oddometer:
    752
    Location:
    Linz upon Rhine, Germany
    Hello Jimmy,
    wanted to deny your last statement. But I'm not sure any more ...
    First: Might reach a twilight zone of my English now: I'm used to rims that offer a small recess (the English translation of our German word 'Punzung' says 'punch', but I'm not sure if this is correct this time) to the nipples of the spokes. The word 'punch' is that twilight point!
    I'm rather sure, that I never saw anything else on a rim for a motorbike. So the number of spokes that could be used on the rim is not 'dictated' by the number of holes in the hub but limited by the number of punch(e)s on the rim. Or the other way round. Even the holes in the punch(e)s must have the correct angle to line up hub, spoke and rim.
    I searched about 2 dozens of your pics to get a clear and big view to your rims. Didn't get one as good as I wanted. Tried to enlarge some of them, but with no clear result. It really looks like your rims do not have any punch(e)s and thus would enable you to marry any hub to any rim. Reminds me of the wheels of my old mountain-bike that are built that way, too. But leaves me a bit concerned about life-time-strenght of the wheel ...
    Hopefully greetings, Bambi
  9. Bambi

    Bambi Been here awhile

    Joined:
    May 14, 2009
    Oddometer:
    752
    Location:
    Linz upon Rhine, Germany
    Hello,
    just a few more words:
    the pic of the wheel on John Wesley's build-thread (page # 22) shows the recesses/punch(e) I meant! A rim like that can't be connected to any hub of your likes, it must have the same number of holes for the spokes and it has to be drilled at the correct angle to line up rim, spokes and hub.
    Kind regards, Bambi
  10. MitchG

    MitchG Iron Collector

    Joined:
    Apr 21, 2012
    Oddometer:
    606
    Location:
    Fort Simpson, NT
    Bambi, most rims can be ordered custom "dimpled" and drilled to your specifications, that includes the number, size and angle of the spoke holes(nipple seats). Hope this helps.
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA

    I think that's how Buchanans does it, but not certain - punch or drill as required to match hubs. Again, check me on this, but that's what I remembered from when I had my wheels built by them.

    Correct on the lack of punches or dimples - the Sun rims don't have them. Just drilled holes. Ive heard that Sun's aren't as strong as dimpled Excel's but not sure if that is due to the dimples or not. When I build another set, I plan to try the Excel's.
  12. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    Just got the new wind screen parts today. The polycarbonate was supposed to be grey tint, but came clear. I have a tint version on the way. Also, some bubbling occurred when doing the heat re-bending. It was bent the incorrect angle, so during the re-bend it got too hot. Anyway, prototyping is a learning process.



    [​IMG]


    [​IMG]
  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    Slowly but surely Im getting the components that I wanted to start with. Didn't have the confidence at the beginning of the conversion to commit to that kind of spending required.

    Ohlins forks and Talon front hub. Braking 32mm front brake caliper is next.


    [​IMG]
  14. WeazyBuddha

    WeazyBuddha Carbon-Based Humanoid

    Joined:
    Mar 18, 2008
    Oddometer:
    5,913
    Location:
    RGV Texas
    Awesome! Gorgeous! Fantastic! Beautiful!

    :lurk
  15. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    The new Braking 2x 32mm floating caliper received and installed. Just need a new AN3 15deg side bend brake line fitting and bleed. Once this is proved out, I'll be switching over to DOT/TUV approved crimped brake lines.

    BTW - I met the guy that owns Melvin's brake lines yesterday at the Adv Designs open house in Hayward - Nice guy & nice products made close to home. SST braided hoses, Teflon inner core, adjustable swivel banjo fittings to prevent kinks / twisted lines, and yes - DOT approved. I'll be calling him soon :deal

    Here's the Braking caliper - size of the pistons compared to the stock KTM 525 Brembo's is noticeable...

    [​IMG]
  16. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    18,984
    Location:
    Über Alles,California

    You might have the first $50,000 883 in history. :lol3

    Add in labor and you might be over $100,000. :eek1


    Sure does look good. :thumb
  17. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    Jimmy, can we get a couple more pics of that caliper and maybe a link to where you got it?

    Does it work with a stock MC or do you need a bigger one like a Sumo bike uses?
  18. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

    Joined:
    Dec 25, 2011
    Oddometer:
    1,651
    Location:
    Seven Springs NC
    JimmyTheHog,

    Suspension question- What spring rate did you had on the first shocks made by YSS (I think?) and what spring rate is on your Works' Piggyback?

    I got a good deal on HD 1200S piggyback shocks that is 13.5" long. It has a 51 lb/in which most likely is way too soft for me and the load but I am most likely going to look for used 1200C (Part # 54668-04) and replace the 1200S spring with 1200C spring because it has about ~130 lb/in spring rate and I will add some shim (spacer) so it won't be too short for the 1200S length. It would be a cheaper modification that may be equal or better vs the price of Works shocks. This is a trick that two guys who own Sportster came up as a solution to make sportster a comfortable riding bike after investing $4,000-6,000 into many different rear shocks from companies like Progressive, Works, Penske, etc.

    So I hope you don't mind me asking you the spring rate you had on first suspension and currently suspension. I am gonna ask John on his Ohlins few days later if he doesn't reply on this thread.

    Thanks!
  19. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    I'll get a few more pics soon, but you can see/buy the caliper at www.oemcycle.com

    Direct link: http://www.oemcycle.com/Item/product/900091011

    They sell the Braking 320mm rotors, adaptor brackets, and calipers. Its supposed to work with the stock KTM MC brake, but I have the stock HD MC brake, which also worked ok with the stock KTM caliper. So, it should work ok, but but I'll confirm after install and test. Still waiting on the brake line fitting. It needs a 15deg side bend fitting to keep the brake line tucked in nice and tight. I hope to get it tomorrow.
  20. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
    750
    Location:
    Sunnyvale, CA
    Yah, I think 51 lb/in will most likely be way too soft. Heres the info on the YSS and the Works Perf. For the Works, you will need to check with them on the part number as the spring rate is cryptic and I don't remember the actual (but im pretty sure its close to the YSS rates).

    Sorry for the mixed up font colors - cant seem to change them.

    BTW - Im currently spec'ing an Ohlins set of shocks which will be 15" long like the Works Perf. Im going for full adjustability on compr and rebound damping and hyd spring preload. When I know that spring rate, I'll post it too.

    YSS RZ-366 TRL Twin Shocks
    - Talk to Klaus
    - Self Adjusting Gas Emulsion
    - 15.55” Long (395mm), 4.63” stroke (TBD 120mm , 4.72”)
    - 36mm Bore, 16mm Shaft
    - Preload & Rebound 60 clicks
    - Top & Bottom 12.9 x 24
    - Black Spring: 46-25-45x260:
    -
    46 = spring ID
    - 25 = starting rate = 140 lbs
    /inch
    - 45 = ending rate = 250 lbs
    /inch
    - 260 = free length (10.24”)


    - Spec’ed for:
    * 200 lb
    Rider
    * 484 lb
    Bike
    * 50 lbs
    Luggage / Gear
    ~
    $735 / pair – OTD

    Works Performance:
    - P/N: CU-12616 (03 pr SP2 15.0 DRS D.P.211-250 BK)