Sportster dual-sport adventure bike

Discussion in 'Some Assembly Required' started by dpetersak, Jan 14, 2013.

  1. Ben99r1

    Ben99r1 Long timer

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    I have one of those fenders on my dual sports bike. Whenever I hit mud or water it doesn't stop it from hitting my face. You should really look at another front fender. You thank yourself for it later.
    #21
  2. Krasniewski

    Krasniewski I don't ride much.

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    :drif


    Really nice job thusfar - impressive. :thumb

    I rode a little sporty for a while - I always regretted selling that thing... even moreso when I see what you are doing with yours! Live and learn, I guess...

    Keep up the good work!
    #22
  3. Ginger Beard

    Ginger Beard I have no soul

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    Digging your build man.

    I am contemplating retaining the belt drive on my dual-Sportster as well. I am curious as to how it will hold up to real off road conditions though.

    Regarding your fender, have you considered a low mount design ? Maybe something that attaches to to the fork guard mounting points ?


    I will be watching your thread with anticipation and may borrow some ideas if you don't mind. :D
    #23
  4. Bambi

    Bambi Been here awhile

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    Point one achieved: Looking super-cool on the bike ... :clap

    At the moment I think the looks of the bike are a bit out of balance. The rear end looks very massive compared to the light front. And I dislike the front-fender, too, sorry.

    But we'll see were the build will take you. Watching Jimmy's build prooves: a good custom-bike never get's finished, there's always a better idea lurking around the corner.

    Go on with your good work and keep us informed, thank you!

    Kind regards, Bambi
    #24
  5. dpetersak

    dpetersak Adventurer

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    I think the out-of-balance effect is because it still has the solid rear wheel with a 150 tire. This should change with the laced wheel and 140 mm tire. To mount the fender lower I would have to use the mounting holes for the fork guards which are waaay down by the axle and would be a very looong bracket. I'll have to see what it looks like with the fairing.
    #25
  6. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I agree that the fender looks a bit off. I think it's because the center of the arc of the fender doesn't line up with the center of the wheel. Were it me, I'd shim the fender so the front of it goes up and the back goes down - just to see how it looked. Maybe it'd work - maybe not.


    The rest of the bike looks badass though. Nice work so far.
    #26
  7. Keithert

    Keithert Been here awhile

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    Subscribed because I like Sportsters. But WAY out of my league!
    #27
  8. Barrett66

    Barrett66 n00b

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    Very cool, i like it so far.
    #28
  9. oregoncoast

    oregoncoast Racing Like a Noob

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    Very cool. Fender doesn't bother me at all. Keep up the good work! :1drink
    #29
  10. kellymac530

    kellymac530 motorcycle addict

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    The fender fit issue is because it is a Supermoto fender which are made for a 17" front wheel. Put one on a 21" wheel and they can look odd. It is fine to me.
    #30
  11. JagLite

    JagLite Long timer

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    Looking great! :D

    The forks definitely make a dramatic visual improvement in addition to the huge suspension improvement.

    Are you planning to keep the stock rear fender or go to something much lighter?

    To my eye, the low rear end with the visually "heavy" rear fender & braces makes the bike look weighed down in back.
    The 18" wheel will help for sure, as will the shocks.

    I am a fan of Dual Sportsters too and will build one before long so I enjoy reading what others are doing.
    Keep those pictures coming! :clap
    #31
  12. dpetersak

    dpetersak Adventurer

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    After getting the fork mounted, I wasn't able to get rid of the play in the steering head (I knew things had been going together to easy!). I cranked down the 27 mm bolt on top of the steering stem until the forks would barely turn and I still had play. I pulled it all apart again and examined the bearings and races and seals, etc. I discovered two things. First, the All Balls bearings I bought on ebay were stamped with a part number 99-3522, yet when I looked up the part number on the All Balls website, all KTM dirtbikes use 22-1026. All Balls lists both part numbers, although they do not have the specs for both so I don't know what the difference is. The second thing is, after I cranked down the top bolt and tried to pivot the forks, there were scrape marks on the underside of the top triple clamp where it was bottoming out on the top edge of the steering head. I filed grooves in the triple clamp to clear the head and cranked it down again. It turns freely and the play is gone, although I still ordered a set of new bearings directly from All Balls. I'm assuming that this little problem is something unique to the rubber-mount Sportster frame, since I never heard of any such problems from those who have gone before me, such as Jimmy the Hog and John Wesley. But, in case anyone else decides to do the same with a rubber-mount frame, I want this little tid-bit of information to be out there, perhaps preventing some avoidable frustration. :)

    [​IMG]
    #32
  13. MitchG

    MitchG Iron Collector

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    Crap, I just caught this. FWIW, if you where going to remove material, you should have removed it from the bottom if the steering head and not put grooves in the webs of the highly stressed triple clamp. These are huge "stress risers" you have created, watch them VERY CAREFULLY signs of cracking. Sorry I didn't see this sooner. Other than that, keep on truckin.
    #33
  14. dpetersak

    dpetersak Adventurer

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    No worries, Mitch. This is my experimental triple clamp, $22.00 on ebay. Once I get offset and other things figured out, I'll be buying a pretty triple clamp. I think then I will try a spacer of some kind between the bearing and top clamp.

    Dave
    #34
  15. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Sorry to hear it wasn't a drop in. For the hard mount 03, I used the Moose racing replacement bearings for the KTM525 which measures the same as stock KTM bearings. Sounds like the bearing race c-bores in your stem may be deeper than the 03's? or the bearing height may be less? If so, you may be able to drop in a precision machined washer that goes between the bearing top and dust cover / triple clamp to get the clearance.

    Also, if you have rubbing on the underside of the top triple clamp, sounds like the dust cover isn't installed. I used the stock Sportster dust cover with a larger drilled hole to fit the larger diameter KTM stem. It mounts between the bearing and the triple clamp.

    REF: KTM bearings from Moose Racing p/n 0410-0034
    #35
  16. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    I just looked thru some of my notes and found some dimensions I measured.

    HD 03 Stem length: 7.06"
    KTM bearing height with race: .61"
    HD 03 stem race c-bore depth: ~0.60" (this needs to be checked / confirmed)

    Next time my front end comes off, I'll take more dimensions, but as I recall, the top bearing did sit about 10-20mil about the stem top.
    #36
  17. Luke

    Luke GPoET&P

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    From what I know of All Balls Bearings:
    http://www.allballsracing.com/logos has tables of bearing sizes that you can download. IIRC the table of steering head bearings isn't totally complete. But with the KTM stem you're stuck with one size.


    99-3522-5 is a steering bearing 29 id, 50.25 od, 15 wide; this is a standard industrial bearing: L45449/L45410


    22-1026 is a complete steering bearing kit, with two bearings (can't tell what kind, presumably 99-3522-5) three seals and an o-ring.
    #37
  18. dpetersak

    dpetersak Adventurer

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    Yeah Jim, there's no dust cover on mine, although there was one with the KTM triple I bought. I'm assuming a dust cover pivots with the triple, since it's clamped between the bearing and the top triple clamp. On the rubber-mounts, the top frame rail is slightly higher than the top of the steering head, so it can't pivot. I can use a machine bushing to take up the gap, but now that I have the forks back on, the extra leverage reveals continued play in the steering head. I too wonder if perhaps the races seat further into the steering head than they do on the KTM, and the bearings are not able to seat into the race. If so, then yes, I will need to add some kind of spacer beneath the race. Thanks for helping me through the thought process. :-)

    Dave
    #38
  19. dpetersak

    dpetersak Adventurer

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    Thanks Luke. That's helpful.
    #39
  20. johnwesley

    johnwesley wanta be

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    Looking good, its nice to see a rubber being converted. Looking forward to seeing how it turns out
    :D
    #40