Rally bike rehab

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

  1. nfranco

    nfranco over macho grande?

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    P-touch
    #81
  2. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Or maybe even an '03 640 Adventure caliper hanger and rotor. It's even bigger than the one on the SE. ??

    I'm going to play with that a bit. With as much weight as we're placing on that front wheel already with gas, fairing, etc., the 20 might be a good compromise. :dunno I guess we'll find out.

    Funny - I was worried about the legibility of the VIN, so I decided to clean it up and squirt some rattle can paint over it.

    I have tons of small bit and spacers I have to make now. It will be time consuming and slow.
    #82
  3. CodyY

    CodyY ADVenture Capitalist

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    subscribed

    :lurk
    #83
  4. gaspipe

    gaspipe Wandering Soul Super Moderator

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    I had a nice chat with Charlie from Rally Management Services - he shed a lot of light on some gray issues for me. I'm more motivated now than I have been, and this just may turn out to be the coolest bike I've built yet....I can hardly wait to ride this rig!

    Having Ned to collaborate with on the project makes it that much better. :nod His unique perspectives have gotten me to think a lot more about this than I would have alone. And for that, I thank you Ned for sharing this project with me.

    Big fun is ahead!

    I sourced out a lot of the somewhat unique parts I needed, and got the ball rolling on the suspension work.
    #84
  5. Garthe

    Garthe ROCKS ARE YOUR FRIENDS...

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    Dear Ned and Gaspipe, THANK YOU for taking on this labor of love. I have always been drawn to the "Dakar" bikes. They all seem to be like a fingerprint, each with the same purpose, however, individual and unique in their own way.

    Thank you for letting us ALL in on the fun.

    Good luck and best wishes...Jim:clap :freaky
    #85
  6. CodyY

    CodyY ADVenture Capitalist

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    Thanks for letting us in on a great project.

    Just keep it updated, don't go the way of the AntWare Alaska report. :lol3
    #86
  7. Crawdaddy

    Crawdaddy Navigate 2 Adventure

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    This project is really interesting/fun for me to follow since I own a 2002 520 RFS.......and recently picked up a ralleye replica 1998 620 EGS-E with 7.4 gallon tank.....almost as if you guys are morphing my two bikes together.....
    Keep it coming and good luck! :lurk
    #87
  8. Y E T I

    Y E T I Unpossible

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    Chris, you just got your 620. Leave it alone for a bit will ya??! :lol3
    #88
  9. team ftb

    team ftb Befuddled Adventurer

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    GP and neduro - as others have stated, bang on for undertaking this project, should be a joy even just to read, let alone when you roll the bikes out for their maiden shake down rides:clap . Good luck guys!!!

    i travel on a 525exc dualsport extensively, two week long off road trips etc. Some observations:

    Headshake with the stock 20's at speed. Hopefully carrying that much gas and equipment up front will offset some of the issue. i ended up going with 17 degree's for a much calmer ride at higher speeds. i assume you'll aalso be mounting a Scotts.

    Front brakes: The stockers are marginal for high speed work, the added issue more importantly is the bloody master cylinder allowing air into the system over time. Some people seem not to have an issue. Mine has needed bleeding on multi day rides. Inexcuseable in my eyes. I'm now using a CRF master cylinder, not any more powerful but much more reliable. No more air has gotten into the system. Great mod. One thing that may interest you gents is i also run the bike in Motard trim with a KTM motard caliper and Radial master Cylinder. Now my friends this is some stopping power!!! You can lock the front tire up at 100 MPH its soooo sttrong. Very linear and progressive feel to it. Would love this mod on your 525 that will be gaining some wieght. Only issue is the Radial mount master has a remote resoviour that is a bit vulnerable for off road usage. Though mine has survived a tumble into the tire barricade at the Go - kart track.

    Valve train - Installed Stainless Steel valves to help increase my valve adjustment interval. So far, once bedded in no adjustments needed in 3,000 miles. With only 3,000 miles its not enough to claim them as the Holy Grail but i'm hoping for the best. Leave on a 3 country (Thailand, laos, Cambodia) off road ride in a few weeks so will report back my findings.

    Oil capacity- I have used the HT cooler with no issues but you gents may want an even larger capacity. Should not be impossible to machine a larger capacity resoviour.

    Overall a great base bike to make what you guys are doing to "roll your own".
    [​IMG]

    I'm pulling up a seat to watch your build unroll and learn from your discoveries. let the good times roll and best of luck with the build.
    #89
  10. LukasM

    LukasM Long timer

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    I would use a 300mm rotor with the 2 piston Brembo caliper. With that much fuel, navigation equipment etc the stock EXC system will indeed be marginal. You just need to get a different caliper bracket which you should be able to find used very cheaply (if not let me know and I'll find you one here in Austria).

    This is also what came stock on our 690 Rallye Replica, although we have since changed the disc for a Galfer Wave one:

    [​IMG]
    #90
  11. neduro

    neduro Addict Super Moderator

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    [​IMG]
    #91
  12. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    Wooohoooo!!!!! :clap :ricky

    (squid)
    #92
  13. neduro

    neduro Addict Super Moderator

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    As I've been piecing this thing together, the number of missing parts has been dwindling. Finally, the only thing left (other than wiring) that was preventing starting it was a lack of usable midpipe and muffler mount.

    So, I decided to tackle that 2 mornings ago instead of doing what I should have been.

    First step was concept:
    [​IMG]
    Sure, that looks about right.

    Here's the stainless stock I'd use to make the missing piece:
    [​IMG]

    Next was figuring out how much angle I needed to make up:
    [​IMG]

    I'm not qualified to weld stainless, so I took the part over to Junior of Beauchamp Restoration. Here's the '57 Ferrari he's rebuilding from the ground up:

    [​IMG]

    A craftsman of the highest order, he put my pipe together in no time at all, for beer. :deal

    The finished product:
    [​IMG]

    [​IMG]

    [​IMG]

    I've skipped a ton of steps in here, so over the next couple weeks I'll go back and fill in. In the meantime, I'm over the moon with this thing- such a neat machine!
    #93
  14. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    Nice work Ned, that thing is awsome! :clap

    PS did you increase oil capacity any?
    #94
  15. gaspipe

    gaspipe Wandering Soul Super Moderator

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    I'm way, way behind you Ned - still hunting down parts before i can even start the first mockup. :cry

    My exhaust pipe was crushed - both the header and the midpipe. It is somewhere enroute to a repair firm to see if it is salvageable.

    The forks and shock are out being revalved and resprung. :thumb

    I'm sourcing some headlights, as my bike didn't come with any. Looks like I may have a solution for that worked out.

    Tons of stuff to do - but I'll work at documenting each stage as it unfolds.
    #95
  16. Gummee!

    Gummee! That's MR. Toothless

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    Hey GP!

    How'd I miss this in yer garage?

    :tb

    This is EXACTLY what I want. 640ADV was too big for my skillz, so...

    :tb

    M
    #96
  17. team ftb

    team ftb Befuddled Adventurer

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    I assume both of you gents will be thrashing these beasts on week long trips and such, prey tell, what will you be doing to address luggage carrying criterea?
    #97
  18. AndyB

    AndyB Lonely Traveler

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    :lurk definitely sum gooooood reading here! closely watching n note taking here in WV.....:thumbup
    #98
  19. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Hola ftb!

    I am going to use one of the Giant Loop rigs.

    [​IMG]
    #99
  20. joenuclear

    joenuclear Ride to eat, eat to ride... all roads lead to pie!

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    GP,

    Not to stray too far off topic but...., I'm looking at the Giant Loop also and I'm wondering what if any effect it will have on the opened up left side panel on my XR650R. Do you know if the attachment points will be on are too near the cutouts for better breathing?

    TIA