JTH's HD 883 Dual Sport'ster conversion

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

  1. UnsureFooting

    UnsureFooting Title of User Here

    Joined:
    May 5, 2011
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    6,590
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    DFW, Texas
    After seeing the several of on this forum, it's one of my goals to build one.
  2. Ron Peck

    Ron Peck Been here awhile

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    May 16, 2003
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    Chico, CA
    You have raised the bar! Congrats on your podium at the Quail.:clap
  3. xlcc

    xlcc Been here awhile

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    Mar 23, 2011
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    Congradulations on your win at the Quail Bike Show Jim.That is way cool!
  4. madrider5150

    madrider5150 Adventurer

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    That is a beauty, congrats! Look forward to finding out more about the tank as well
  5. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
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    Thanks.

    The plastic tank testing is still in progress and we are making a few minor improvements. Its looking like our first production run will have tanks to us in late June 2014, then ready to ship. Colors will be Black, White, and Translucent, or special order for other colors.
  6. doggitter

    doggitter Long timer

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    Do you have a weight on the finished bike?
  7. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Last time I weighed the prototype it was 475 lbs with a weight distribution of 48% front and 52% rear.

    The configuration was with the 2:2 Supertrapp exhaust, different foot pegs, different wheels, though. The new exhaust is a bit lighter. The new WWW wheels are stronger but a bit heavier due to larger spoke gauge.

    So, its time for new weighing but I would expect it to be close to the same weight.
  8. doggitter

    doggitter Long timer

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    Thanks, and like everybodys else has said, great work on the build.

    Was there any engineering for strengths on the swingarm design or was it a cad and machine thing only?
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Yes, I did FEA structural analysis on the swingarm using Autodesk Inventor's FEA tool. The largest stress concentrations occur at/around the shock mounts so those areas were addressed with shape & generous radii on edges to minimize the stresses.

    The swingarm pivots on the frame were also strengthened by welding some gussets to the frame around the pivots that hold the swingarm. Lengthening the swingarm and moving the shock mounts forward puts a larger moment on the pivots, so I wanted to be sure over time this would be robust too.
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Feb 9, 2006
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    Got my Wolfman Enduro tank bag, tool roll, and tool bags for the rear rack and took the bike out for a nice Sunday ride up Skyline blvd and a stop at Alices to talk bikes with everyone!

    Here's a few pictures...

    [​IMG]
  11. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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  12. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
    Oddometer:
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    Location:
    Sunnyvale, CA
  13. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

    Joined:
    Feb 9, 2006
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    Sunnyvale, CA
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Sunnyvale, CA
  15. MitchG

    MitchG Iron Collector

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    Fort Simpson, NT
    Oh right........I was wondering how long it would take.......First you set the hook and now you're reeling me in............:evil
  16. theKite

    theKite Ulyssean

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    Oct 24, 2010
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    Little Mountain, Queensland
    I know that we have talked about this before Jim, but when I see that beautiful alumium tank, i still think about my equally beautiful TT500 tank from the 1970s, and I can feel my throttle hand rolling off!
    Rob
  17. xlcc

    xlcc Been here awhile

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    You certainly did a nice job on your ride,very nice.Jimmy what did you end up with your final gearing?
  18. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks. The final gears are 25/56 teeth front/rear. I went as big as I could go on the front sprocket to get the chain up over the swingarm pivot. Then picked the rear sprocket to get the ratio close to the stock gear ratio.
  19. xlcc

    xlcc Been here awhile

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    I went with 22/53 to give a little lower gearing than stock.I can still hit a hundred which is plenty fast enough for me,but I especialy like the lower 1st in the soft stuff.These engines have no equal when it comes to bottom end torque in the dirt.
  20. B.Curvin

    B.Curvin Feral Chia tamer

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    I'm sure it has been asked in this thread, but it would take far too long to find it.

    I'm not a big fan of Sportster (stock sportster) front end feel and steering. I think they VERY strongly fall into corners at parking lot speeds, and they are too stable at elevated speeds. It takes way too much counter steering pressure to initiate a turn. I think stock offset is something like 4"? Once the stock triples are replaced with something reasonable (16,18 maybe 20mm offset) does the steering become more "normal"? I'm about to get rid of my KLR and am undecided on a Sportster or a CB500X. Which ever I get, it will be the recipient of the KTM450SMR forks and Penske shock that have been hanging out in my garage for years. I had a Buell Cyclone and loved the engine, I just didn't like the rest of it.

    TIA