Rally bike rehab

Discussion in 'Thumpers' started by neduro, Aug 16, 2008.

  1. BDKW1

    BDKW1 KL"X" not "R"

    Joined:
    Jul 24, 2006
    Oddometer:
    915
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    Easton, KS
    If your not running HID's, you can keep the lights AC with the stock regulator. With the rewound stator you can add on a second regulator/rectifier for DC power also. The Electrix Dakar dualsport kits offer options for AC and DC power as running the lights off AC makes them brighter and there is less loss.

    Personally, I would go full DC and HID's. :evil
    #61
  2. neduro

    neduro Addict Super Moderator

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    :thumb

    Good stuff.

    It's my goal to have at least one Halogen, I've seen too many HID failures and Halogen is cheap and works well. I've got more power from that stator than I need (only other thing I can think to run might be a GPS, and that can live on batteries if needed) so I'd like to have a halogen, and an HID, in the 2 openings I have.
    #62
  3. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Pickwick Lake, Tennessippi
    Everything has a beginning. I ended up going to the most basic beginning I could have.

    As simple as it can be.....disassembled to the bare frame, cleaned, some cheap rattle can paint over the raw welds, the last of the African (caustic) mud removed.....

    [​IMG]

    Note the extra structural aluminum added to the subframe...thanks Rally Management Services. :thumb

    [​IMG]

    I pressed in a fresh set of bearing cups, and decided to give y'all a close up of the upper tank brackets and the weld on damper post.

    [​IMG]

    And the steering head bracket for the lights, GPS, IMO, etc.

    [​IMG]

    Note that yellow paint stamp - that's from the Dakar Rally, and has been preserved because it's cool!

    [​IMG]

    The rear tank brackets.

    [​IMG]

    And the donor machine.......

    [​IMG]
    #63
  4. AnnieGS

    AnnieGS Namasté, bitches!

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    :lurk
    #64
  5. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    :cry :cry :cry :cry :cry
    #65
  6. gaspipe

    gaspipe Wandering Soul Super Moderator

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    It's killing me to do it. I went and rode it for an hour this morning. Too nice to be dismembered, but I think the finished product will be really fun.
    #66
  7. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    Did you pop any wheelies?
    #67
  8. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Only between gears.

    :webers
    #68
  9. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    Any of these?


    [​IMG]
    #69
  10. LiveFast

    LiveFast Been here awhile

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    Daytona Beach
    :eek2
    #70
  11. JayBo1

    JayBo1 Long timer

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    :lurk :lurk:lurk
    This is going to be a cool thread!:clap Good on ya Gaspipe for sharing with us.:bow
    #71
  12. Garthe

    Garthe ROCKS ARE YOUR FRIENDS...

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    I love motorcycles...:1drink
    #72
  13. slogger

    slogger Been here awhile

    Joined:
    Nov 18, 2005
    Oddometer:
    680
    That Dakar stamp is bitch'en!
    Keep it up, I'm enjoying this thread.
    #73
  14. nfranco

    nfranco over macho grande?

    Joined:
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    la ca
    Man! this pic stirs the moto soul!
    Thanks for keeping us posted Ned and Gas.
    #74
  15. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Now is time for some decisions.

    I think I want to run an 18mm offset on this bike, rather than the 20mm it was fitted with by the KTM factory. The 18mm will put a little more weight on the front end, which will happen anyway with all the extra weight from the fairing and fuel, etc. I have 18-22mm offsets on the pile. The 20mm might be fine? This will take some testing once the bike is running.

    I'm 235lbs - so the front forks will probably get .50kg/mm springs, and the back a 10N spring as starting points. I need to get those ordered.

    I'm still looking for an LC4 rear wheel. When I sold off the last of my LC4's, I sold off all the cush drive rear wheels I had. Now I want one for this bike. Not that it needs it for the dirt, but I plan to dual sport this bike, and pile on some miles. Any help I can give to drivetrain will probably be worth the effort.

    The front wheel is a an OE takeoff from my 950 Super Enduro - heavy duty spokes and a DirtStar wheel. It's much stronger than the original 525 front wheel.

    For the front brakes, I'm considering upsizing to a larger rotor. I have to see what I have, and mix and match caliper hangers to make it work.

    This bike was originally fitted with LC4 660 radiators, which are all but unobtainable. I will use a set of Fluidyne radiators. These add quite a bit more core area and cool the motor quite well. I've been using them on the 450 for a while now, and do not need a fan with these radiators. I'm sure I will have to fabricate some brackets to make these work.

    Lots of stuff to think about. :scratch
    #75
  16. Flood

    Flood F5lood.

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    How did I miss this?
    Go Ned and GP! :clap
    #76
  17. meat popsicle

    meat popsicle Ignostic

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    Yoyodyne!

    "Where the future starts tomorrow!"

    hard core R&D:
    <object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/d682xV0n1YY&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/d682xV0n1YY&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>
    #77
  18. Y E T I

    Y E T I Unpossible

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    So in for this!

    :lurk
    #78
  19. Seth S

    Seth S Will _____ for _____

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    buckaroo Bonzai....classic
    #79
  20. neduro

    neduro Addict Super Moderator

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    I was looking at my SE this weekend thinking that maybe I'd use that brake system. I'm going to get mine built up with stock 525 brakes, if they prove inadequate as I think they will, I think the SE parts will bolt right up and keep everything OEM.

    Agree that 18mm offset is probably the way to go.

    And I can't believe you cleaned your so nicely, I've just been bolting mine back together like a true codger. I'm going to have to deal with one issue for using it internationally- my VIN isn't particularly legible anymore. That won't do for border crossings...
    #80