My ADVersys

Discussion in 'Some Assembly Required' started by kajj, Feb 23, 2012.

  1. 1reddawg

    1reddawg Long timer

    Joined:
    Aug 7, 2005
    Oddometer:
    2,292
    Location:
    Monteagle Tenn.
    Looks like alot of Fun!!Thanks fur sharing!!
    #81
  2. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    Time to mount some new stuff to the beast :evil

    Touratech radiator guard.
    [​IMG]

    This model are made for the 2009- Versys radiator but the only thing to do to make it fit my 2008 was to move the
    protection for the radiator fan to the rear radiator mountings and to bend the front mountings so that they got the same
    angle as the radiator guard.
    [​IMG]
    [​IMG]

    Machined front wheel alxe, Hel brake line (in DRZ 400 lenght), Moto-master 310mm wave brake disc. :clap
    I was looking for a OEM DL1000 left front disc but manage to find this one from Moto-master for a really good price.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
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    [​IMG]

    Things to do!

    * mount new brake line...................................................ok
    * Find a 310 mm disc.......................................................ok
    * Finish wheel axle..........................................................ok
    * fabricate brake caliper adapter
    * headlight rubbermount....................................... .........ok
    * new rally fairing
    * carbon fiber dash, relocate switches and power outlets
    * relocate turn signals
    * Weld and paint sidestand
    * Install HID lights
    * mount radiator guard..................................................ok
    * cut front fender and fabricate mount...........................ok
    * change sprockets and chain.......................................2/3 ok
    * Air filters
    * paint luggage rack
    * tighten side mirror mounts...........................................ok
    * check rear wheel/swingarm bearings...........................ok
    #82
  3. nedodjija

    nedodjija Been here awhile

    Joined:
    Nov 10, 2008
    Oddometer:
    675
    Location:
    Pocatello ID
    Love it!
    #83
  4. zandesiro

    zandesiro In rust we trust....

    Joined:
    Oct 1, 2010
    Oddometer:
    829
    Location:
    Polygyros, Greece...
    Cool...

    :clap
    #84
  5. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    Got my self a cheap impact wrench with a torque at 450 Nm. The front sprocket nut was gone in less then 10 seconds:clap
    [​IMG]
    [​IMG]

    The old front sprocket had about 25000 km on it.
    [​IMG]

    Things to do!

    * mount new brake line.............................................. .....ok
    * Find a 310 mm disc.............................................. .........ok
    * Finish wheel axle.............................................. ............ok
    * fabricate brake caliper adapter
    * headlight rubbermount....................................... .........ok
    * new rally fairing
    * carbon fiber dash, relocate switches and power outlets
    * relocate turn signals
    * Weld and paint sidestand
    * Install HID lights
    * mount radiator guard............................................. .....ok
    * cut front fender and fabricate mount...........................ok
    * change sprockets and chain.......................................3/3 ok
    * Air filters
    * paint luggage rack
    * tighten side mirror mounts...........................................o k
    * check rear wheel/swingarm bearings...........................ok
    #85
  6. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    I have found some dust that got past the OEM air filter and decided to try adding one pair of UNI pod filters to the
    intake stack. It will of course decrease air flow a bit. but I thought I should try it out and see how it works.
    [​IMG]

    I removed some material from the inside of the filters to get a better fit to the bellmouths.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    The filters do compress a little when the lid for the airbox is mounted. Should be fine thou.
    [​IMG]
    [​IMG]

    And some eye candy:evil
    [​IMG]

    Now, back to designing that brake caliper adapter.

    Things to do!

    * mount new brake line.............................................. ......ok
    * Find a 310 mm disc.............................................. ........ok
    * Finish wheel axle.............................................. ............ok
    * fabricate brake caliper adapter
    * headlight rubbermount.......................................... .........ok
    * new rally fairing
    * carbon fiber dash, relocate switches and power outlets
    * relocate turn signals
    * Weld and paint sidestand
    * Install HID lights
    * mount radiator guard............................................. .....ok
    * cut front fender and fabricate mount..............................ok
    * change sprockets and chain...................................3/3 ok
    * Air filters....................................................................ok
    * paint luggage rack
    * tighten side mirror mounts...........................................ok
    * check rear wheel/swingarm bearings............................ok
    #86
  7. Smola67

    Smola67 AdventureTard

    Joined:
    Jun 26, 2010
    Oddometer:
    230
    Location:
    Inman SC
    I think with that dl 19" and that tiny fender, you will find that water and many other things will fly off that front rubber and go straight for your helmet.
    #87
  8. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    Well I have been riding with that wheel and fender combo for about 5 month and I have not had any problems with it.
    Plenty of mud/water/sand and gravel.

    In some pics you can see I am trying out a high motard front fender. But this setup did not work that well and I had
    those problems that you described. So now I am going back to the low fender as this offered more protection for the
    radiator and the rest of the bike. Sure you get some spray on top of the front fender when going through mud but
    nothing that flings up to the headlight or higher.
    #88
  9. Smola67

    Smola67 AdventureTard

    Joined:
    Jun 26, 2010
    Oddometer:
    230
    Location:
    Inman SC
    Cool deal.
    #89
  10. aiMhi

    aiMhi Now with Titanium

    Joined:
    Sep 9, 2010
    Oddometer:
    690
    Location:
    SODE- Colorado
    Kajj - I really like how your bike is coming along man. I will shoot you some pics of my new fairing which is sick looking- hoping to have the mounting done in a couple days. Might need to work something out for you,. :lol3
    #90
  11. Murphy Slaw

    Murphy Slaw Long timer

    Joined:
    Oct 1, 2011
    Oddometer:
    1,726
    Location:
    Southern Illinois
    You're an animal......
    #91
  12. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    You got pm!
    #92
  13. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    :lol3:lol3

    :hmmmmm :huh :confused
    #93
  14. kojack

    kojack My Hardley Ableson is a POS

    Joined:
    Mar 11, 2007
    Oddometer:
    981
    Location:
    god's country, AKA. Newfoundland!
    friggin awesome buddy!....for a fairing...on ebay they were selling KTM fiberglass units for a good price, should mate up nicely to your set up....
    #94
  15. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    Thanks.

    I`ll see what I can come up with for a fairing. Will do some more research this weekend.
    #95
  16. Albin

    Albin Adventurer

    Joined:
    Feb 23, 2003
    Oddometer:
    62
    Location:
    Gothenburg, Sweden
    :clap Very interesting, my brother has a Versys (with TKC80) and I´m sure he likes your mods.....
    Have just send him a link to your tread....






    Ha Det!
    #96
  17. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    hehe, ok thanks. I will participate in Adventure days 2013. So the bike can be seen there if there is interest.
    #97
  18. Albin

    Albin Adventurer

    Joined:
    Feb 23, 2003
    Oddometer:
    62
    Location:
    Gothenburg, Sweden
    Good, I will tell my brother rightaway!
    We are going too (for the first time) :thumb

    :beer from Albin and Albin...... (Leif & Jan)
    #98
  19. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    ok, good. It will be the first time I am there to. See you there.
    #99
  20. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    Finally had some time to complete the design of the caliper adapter.
    Now I only have to check all measurements again and then fabricate it.
    [​IMG]
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    [​IMG]


    I also designed a cover plate which will cover the side of the front hub where the second brake disc was mounted.
    [​IMG]