My new wire wheeled wee......in progress

Discussion in 'Land of the Rising Sun: ADV Bikes from Japan' started by tileman, May 4, 2009.

  1. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Hi all, think I may have to start a thread for this one as its already on a couple.

    Here goes;

    I love the look of spoked wheels but didn't want the expense of a GS or KTM and the wee has such a good reputation, and it is cheap, and I owned one. So I started down the path of making the new wheels.

    Through some research and luck we (my cousin and I) found that a triumph tiger 955 front wheel was the same diameter, disc to disc width, and disc diameter as the Dl front wheel.

    After sourcing a wheel through his contacts we set about fitting it.
    First we decided to used the existing speedo drive which required making adapters as shown in the attached pic. The spacers are made out of delron similar to what is used for crash nobs, so its heaps strong enough.

    Attached Files:

    #1
  2. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    once the speedo drive was made we then needed spacers as the bearings are at different centres as the standard dl ones. The bearings were also changed to 20 ID as the spacers could then be manufactured to be captive, that is that they insert into the bearings to hold them in place to make fitment of the wheels easier.

    Attached Files:

    #2
  3. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    the spacers built...

    Attached Files:

    #3
  4. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    If anybody would like the dimensions of the spacers and speedo drive let me know and I'll send through the cad drawings....
    #4
  5. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    heres some pics of the wheel fitted....

    Attached Files:

    #5
  6. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Oh, forgot to mention, the front rim and hub were anodised/painted black and I used new front floating disks (www.metalgear.com.au).
    #6
  7. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Now to the rear;

    We used a DR650 rear hub as it came with a cush drive similar to the standard DL wheel. I then got new sprockets both front and rear from JT with gearing similar to that of the DL.

    Attached Files:

    #7
  8. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Then came the fun part of making up spacers from the rear which proved more difficult than I thought....:1drink
    #8
  9. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Rear wheel fitted, minus chain and sprockets....had a little problem with the math.......:eek1:wink::freaky

    Attached Files:

    #9
  10. Mats

    Mats Been here awhile

    Joined:
    Feb 14, 2007
    Oddometer:
    262
    Location:
    Sweden
    Nice job!! The bike looks much better with wire spoked wheels I think. Looks more dual sport!
    #10
  11. oldmanb777

    oldmanb777 Just say NO to socialism!

    Joined:
    Nov 14, 2006
    Oddometer:
    4,859
    Location:
    Centennial,Co./ Grand Lake,Co
    Love it! Much better look than the cast ones. I'm very suprised, I really didn't think it would change the look that much.
    #11
  12. caver101

    caver101 Been here awhile

    Joined:
    Jan 9, 2007
    Oddometer:
    292
    Location:
    NW GA
    Thats sharp! Sure helps the look of the DL.
    #12
  13. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Ok, I am missing a few details of the last pic;

    The rear has been raised about 1 inch over standard and the sag is decreased as I have fitted a 98 zx9r shock (had on lying around) and some shorter dogbones that my cus had built for his SV650. The zx9 shock was about the same length as the standard one but mine is stuffed after 60 k and 5k 2 up with gear.

    the rear rim is a 17 as per standard with heavy duty spokes made by a company in queensland (link i think there called???). i am also converting the chain to a 520 for 2 reasons 1. I have one 2. figure the bike isn't over powerful.

    The rear exhaust is being changed for a scorpion one that also was lying around at home.

    My cus has collected a lot of stuff over the years so I am pilfering as much as I can, this may explain the random use of parts.

    Hopefully today I can remove excess piping on the exhaust and have a go at tig welding the new pipe extension on, then make the top bracket to attach the pipe then hopefully the pipe will be done.

    Below is a list of whats coming next;

    1. exhaust fitted
    2. new undertray and side panels
    3. fitted battery in new position
    4. make the electrics all work
    5. fit new tail light etc
    6. manufacture new spacers for the front forks (bout 3 inchs) which should give about 2 inches of overall ground clearance (being 6'3", no height issues)


    then the fun parts;

    7. New front fairings similar to the KTM dakar bikes
    8. new headlights
    9. trailtech or equiv gauges
    10. mod front guard

    finally;

    hope it all works
    go riding
    weigh it!!!!!!!


    Watch this space.............
    #13
  14. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    #14
  15. Schlug

    Schlug JockeyfullofBourbon

    Joined:
    Jan 23, 2006
    Oddometer:
    8,316
    Location:
    put something on and stay in that position.
    jeexus, the bike is tits with the spoked wheels, i have to admit.

    i think, when you're all said and done, you'd have been better off with a BMW F650 GS

    but i suppose you're having a good time giving your wee a go, which is important.
    #15
  16. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    Quite possibly, but I own this one and ewan or his mate have already done a dakar gs?????? So maybe this will be a new one, I am sure someone will correct me on that.......:rofl:D
    #16
  17. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    I may have sourced a dead dual projector headlight unit to pilfer bits from so things keep falling into my lap.....yippee!!!!!
    #17
  18. azabeemerboy

    azabeemerboy Long timer

    Joined:
    Jul 23, 2003
    Oddometer:
    1,579
    Location:
    Fairhope, Alabama
    Congratulations on a very creative engineering job and a sweet looking bike as a result:clap
    #18
  19. Django Loco

    Django Loco Banned

    Joined:
    Oct 19, 2003
    Oddometer:
    3,785
    Location:
    California
    Have you thought about making the wheels tubeless by sealing the spokes?
    Couple ways to go with it. Have you looked into it?

    Changing a tubed front flat on the road isn't too bad, but a rear can be tough.
    I'd for sure do the rear wheel.

    Maybe leave the front tubed as this is a bit tricky. But I would suggest using SLIME or Ultra Seal in any case in your tubes. Even though this may not totally prevent a flat, it can slow sudden air loss.

    This is nice mid corner whilst leaned over hard at about 70 mph. :D

    Good luck .... looks good.
    #19
  20. tileman

    tileman Long timer

    Joined:
    Mar 15, 2007
    Oddometer:
    1,189
    Location:
    Melbourne, OZ
    I haven't looked at it but.........70 mph.........
    #20