JW's BRP XRR Build 2012

Discussion in 'Thumpers' started by jwalters, Aug 18, 2012.

  1. jwalters

    jwalters Farkle Proliferator

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    Next I started to add the hardware to the Acerbis tank so it can be mounted to the bike. Let's just say I am very dissapointed in the quality of the hardware that came with the tank.

    Check out this bracket, the nut was welded on crooked so I couldn't even thread the bolt through.
    [​IMG]


    Fortunately, I had Hondakaguy's Tank Brace so I didn't need to use the brackets that came with the tank.
    [​IMG]

    After some trial and error, I think i figured out where the orings, bolts and spacers go on the tank. But I posted a message on the XR650R thread just to be safe. I'm calling this job done. On to some electrical work tomorrow.
    -jw
    #41
  2. Hurricane Bob

    Hurricane Bob formerly: Bomber1965

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    [​IMG]
    #42
  3. jwalters

    jwalters Farkle Proliferator

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    Of course! :rofl Thanks, i'm going to see if I can find this at the auto parts store.
    #43
  4. jwalters

    jwalters Farkle Proliferator

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    Made a bit more progress last night. I have a little fitment issue with my steel subframe. I noticed the hangar for my FMF exhaust won't reach the bolt/mount location on the sub frame because the extra support tube for the rear rack hits my exhaust. Obvioiusly, this isn't a show stopper, but it will require me to either make a bracket and use the existing hole or measure and cut a new hole in the tubing for the exhaust pipe hangar bolt.

    I'm going to think about this for a day or two before I get out the drill bits and see what other solutions might be out there. I have plenty of wiring to do in the mean time....

    [​IMG]
    #44
  5. jwalters

    jwalters Farkle Proliferator

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    I got a quick response from Globetrottin, and they confirmed some exhausts may not fit quite right with the rear rack. Great customer service! The minor tweaking is a small price to pay for the integrated rack. Knowing I wasn't doing anything glaringly wrong, I decided to just bolt the exhaust to the rack down tube.

    I'm happy with the result:
    [​IMG]
    #45
  6. Hurricane Bob

    Hurricane Bob formerly: Bomber1965

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    Did you incorporate an anti-crush sleeve in the drilled opening?:bueller

    [​IMG]
    #46
  7. jwalters

    jwalters Farkle Proliferator

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    I assume, you are talking about the hole drilled for the exhaust hangar. And the answer is no. How would you put an anti-crush sleeve on an existing piece of tubing that's welded closed on both ends?? I'm interested. But in this case, I don't know if it's needed. Seems to be pretty strong on it's own.

    #47
  8. Hurricane Bob

    Hurricane Bob formerly: Bomber1965

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    Ahh...your thinking it looks like this.....No.

    [​IMG]



    Both the bolt and anti-crush sleeve go clear through the bike rack tubing wall....and any amount of tighting the muffler to the rack will be stopped by the sleeve.

    [​IMG]

    I also assumed the rack tubing wall thickness could be thin for weight savings and add in the abuse dirt bikes hand out, an anti-crush sleeve seemed appropriate.:freaky
    #48
  9. Sean-0

    Sean-0 straya carnt

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    nice 1 bomber ....was looking for pics the help on this but you nailed it :clap

    def use a crush sleeve ..better job of it
    #49
  10. jwalters

    jwalters Farkle Proliferator

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    EDIT:

    Gotcha! I like it! Thanks for the tip. I'm off to find some small diamater steel tubing, maby some brake line at the parts store.

    PS. Yes, I was thinking of the first example you have above in PVC.

    #50
  11. jwalters

    jwalters Farkle Proliferator

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    Progress progress. I installed the new right footpeg today. I had to drill out the front hole using the 7/16th drill bit. Never like drilling into an aluminum frame, but it was an easy job. 10 minutes later, I had a stronger footpeg. Job done!
    [​IMG]
    #51
  12. jwalters

    jwalters Farkle Proliferator

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    Next on the docket was to install the new compression relief, clutch and push/pull throttle cables. These cables were ordered from Motion Pro with an extra 3 inches of length for my aftermarket triple tree and bar risers.

    Job done!
    [​IMG]
    #52
  13. jwalters

    jwalters Farkle Proliferator

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    It might be considered sacrilege by some, but I've had a Cycra front fender thrown away by the factory Yamaha super moto team at Road America about 5 years ago. Absolutely no damage to it, other than some stressed plastic markets on the edge.

    What do you think, can an XRR have a blue beak? I can already see the confusion on peoples faces....
    [​IMG]
    #53
  14. jwalters

    jwalters Farkle Proliferator

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    Cycra hand-guards installed! Unfortunately, the Yamaha front fender was not a good fit, I'd have to cut it up pretty good. I suppose I'll keep the stocker on for the time being.

    [​IMG]

    I forgot to mention I replaced all the fluids yesterday and fired the bike up. I put the Acerbis tank on and ran the bike in the yard a bit. Fired up on the 3rd kick! Not bad for completely replacing the wiring!
    #54
  15. jwalters

    jwalters Farkle Proliferator

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    More progress today. I got the Baja Designs LaPaz 8inch light installed! This sucker rocks! :clap I'm still figuring out what I want to do for the front fender....

    [​IMG]



    I also had to spend some time sanding down the throttle tube, there were some sharp bits left over after I removed the end cap so I could install the Cycra handguards. The sharp bits were causing friction in my throttle, prohibiting the carb springs from returning back to idle once you let off the throttle. Rule #1 at any tech inspection. Anyways, a little finesse and sand paper and she's smooooooth....
    #55
  16. Cumbacheech

    Cumbacheech XRated

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    Looking good!! I put a CRF fender on my XRL and I really like it. I also have a KTM fender for my sumo setup, both fenders bolted up with no real big issues...

    Cheers,

    Cumbacheech
    #56
  17. jwalters

    jwalters Farkle Proliferator

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    That's great to hear because I just ordred one of these for a CRF450:

    [​IMG]


    Thanks again for the input.
    -jw




    #57
  18. jwalters

    jwalters Farkle Proliferator

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    I spent my Saturday morning feeding the hungry wood stove and installing my Baja Designs rear tail light while it snowed outside! I spliced up some ends to feed into my brake light switches both on my front and rear brake levers. Then I wired the running light up to the 12 volt source as well. All fused of course!

    [​IMG]


    [​IMG]

    And with the completion of the rear taillight assembly, my wiring is done! :wings I'm just waiting on some sprocket bolts, then I can install my new chain and sprockets, then finally sneak in a ride before winter decides to really hit. I'll still be installing a Trail Tech speedo which I've ran 12VDC to the front of the bike already, so that will be a quick install. I also have a skid plate ready to bolt on, but I'll wait till I'm done wrenching on the BRP.
    #58
  19. rpmwfo

    rpmwfo Been here awhile

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    Do you have the part #'s for the longer motion pro compression release and clutch cables? I re-routed mine, but it would be nice to have longer cables.
    #59
  20. Honkylicious

    Honkylicious nothing to see here

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    :lurk
    #60