Sportster dual-sport adventure bike

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

  1. kellymac530

    kellymac530 motorcycle addict

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    Or possibly a washer/spacer between the lower tree and the lower bearing??? I may be misunderstanding what you fitment problem is, but it sounds as though your bearing are bottoming out on the step in the stem and not seating into the races, causing the extra play. Shiming the bottom bearing up just a bit off of the lower tree will shorten the distance between the bearings and possibly allow the proper tension on the bearings and races interface...as I said though, I may be misunderstanding your fitment problem so disregard if this is not applicable.
    #41
  2. johnwesley

    johnwesley wanta be

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    On mine I used stock steering stem and bearing which eliminated any fitment issues and made parts easy to come by.
    #42
  3. dpetersak

    dpetersak Adventurer

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    The fairing and fender are on. I spaced the fender as much as I could without interfering with travel. The fairing really seems to tie in the fender visually. The new shocks came in yesterday- 15.75" long versus the stock 11.75". I must say I am very pleased with the appearance of this bike. It still 'looks' like a Harley, but a Harley that will go places. It's still at 8.5 inches of ground clearance here, which I am happy with. My tires left Seattle on the barge, so it will be another week to ten days before they are here, not that it matters, I'm still ass deep in snow.

    I ordered another used triple clamp off ebay, this time from a 2008 SX, specifically because it has 22 mm offset and the bottom clamp bolts are on the side and not the rear. This should give me enough turning radius, but my trail will be reduced. Theoretically this will make the bike less stable in the straights but easier to lay into turns, but there are other factors. It will also extend the wheel base slightly and take weight off the front end. The bike already has a 30 degree rake and long trail. After riding that KLR for 5000 miles and then getting on the Sportster, the handling difference was very noticeable. The Sportster was sluggish to lean. So, I'm thinking the reduced trail may help. If the bike feels too 'twitchy' in the straights, I can also add a steering stabilizer. But that first ride will tell all.

    [​IMG]

    Mounting the headlight to the KTM triple clamp and a mounting bracket for the fairing.

    [​IMG]

    [​IMG]
    #43
  4. Keith

    Keith Slabbing it

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    Looking good with that fairing.
    #44
  5. Ginger Beard

    Ginger Beard I have no soul

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    How much did those shocks run you and what is the stroke ?


    By the way it looks much better with the fairing! :thumb
    #45
  6. dpetersak

    dpetersak Adventurer

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    Ginger, the shocks were a grand. I went with the pricier model because, like the WP forks, I can dial in the suspension I want. The shocks have 60 positions for rebound and 20 for compression. Also I can adjust the length and spring preload. In my neighborhood we have two kinds of roads, great and crap. The idea is, if I'm going to ride hundreds of miles on a crap road like the one pictured below, I can dial in the suspension to handle it and stiffen up the suspension when I'm on a good road. And stroke is 4.5 inches which translates to 5.5 of travel.

    [​IMG]
    #46
  7. Ginger Beard

    Ginger Beard I have no soul

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    Cool, thanks for the response. Yeah the roads up there aren't great but they sure do have great scenery! My dad lives in Homer and every time I go up there I do my best to get out a ride as much of your beautiful state as possible.
    #47
  8. dpetersak

    dpetersak Adventurer

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    Yep. I've ridden all over the U.S. and my favorite roads are still in my own backyard... the Seward Hwy towards Homer and the Richardson Hwy. out of Valdez. Motorcycle heaven.:D
    #48
  9. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Subscribed.
    #49
  10. dpetersak

    dpetersak Adventurer

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    My rear wheel is laced and ready to go. For the rear, I went with a 3.5" Excel rim laced to a hub from an 06 Dyna FXD that I picked up on Ebay for $75. Although I had researched the axle sizes for that year, this was a transitional period for Harley as they went briefly from .75" axles to 1" and then to 25mm. The 06 Dyna was supposed to be 1", but of course the hub I bought was .75". It was a nice hub and I couldn't return it, so I took it to the machine shop and had it drilled out. For tires, I decided upon Pirelli AT 90 Scorpions, which fit my intended riding style of 60-70% street and 30-40% trail. The reviews regarding street handling are excellent. Even with my shortened front forks, I still need to get the rear as high as possible to correct the chopper-like geometry of the Sportster, so I went with 18" 140/80. For the front, I kept the stock 21" KTM wheel with a tire size of 90/90.


    The both tires went on with no problems.
    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-XqjLpJP/0/M/2012_1116AA-M.jpg" title="" alt=""></a>

    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-jTBG3Cm/0/M/2012_1121AA-M.jpg" title="" alt=""></a>

    The front tread of the Pirelli is beefy but still street capable.
    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-rHXbpGW/0/M/2012_1121AB-M.jpg" title="" alt=""></a>
    #50
  11. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Edit the image links for you..

    What brake are you using on front? It looks like harley rotor? And how long is the brake rotor?
    #51
  12. dpetersak

    dpetersak Adventurer

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    With the tall suspension, the rear fender didn't look 'right'. There was too much hanging out the back with that huge taillight sticking out even further. I bought a hidden, under-the-fender tail light from Drag Specialties and chopped the fender to match it. It kind of has a dirt track look to it now.

    I didn't take a picture of the stock fender with the new shocks, but here it is in the original photo of the bike.

    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-RmCCXVW/0/M/2012_0419AB-M.jpg" title="" alt=""></a>

    The bobbed fender with the new wheel/ tire.

    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-pNrzqJ6/0/M/2012_1121AD-M.jpg" title="" alt=""></a>

    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-bW7WXXG/0/M/2012_1121AG-M.jpg" title="" alt=""></a>

    <a href="" title=""><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-bGFpb9q/0/M/2012_1121AH-M.jpg" title="" alt=""></a>
    #52
  13. dpetersak

    dpetersak Adventurer

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    Because I am obsessed with weight, the new rear wheel shaved off another 9 pounds of weight (unsprung) when compared to the stock wheel. The front wheel with the Pirelli tire is 7 pounds lighter.
    #53
  14. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Its looking good! It will be interesting to see what the finished weight comes in at. Not sure your doing this, but the Shorai or other L-I batteries can shave up to 10 lbs off. I went with the Shorai and so far, so good.
    #54
  15. kellymac530

    kellymac530 motorcycle addict

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    Definately looking better with the laced wheel and cut fender. Nice stuff.
    #55
  16. dpetersak

    dpetersak Adventurer

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    Everything on the front end is KTM. The front rotor is an oversized supermoto rotor, which comes with an adapter bracket to step the caliper out further. The only thing still Harley is the brake line, and Harley and KTM use different style bolts. I think I can marry the Harley line to the KTM caliper though, and I'll be working on that riddle this week, so more to come soon.
    #56
  17. Trane Francks

    Trane Francks Been here awhile

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    Subscribing: This is looking really good! :lurk
    #57
  18. dpetersak

    dpetersak Adventurer

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    A few weeks back I was unable to get rid of the play in the front end, even after cranking down on the top bolt as much as I dared. After looking at it further, it seemed that the bottom seal was hitting the edge of the steering head before the bearing seated in the race. I decided to try a spacer on top of the race. I used the old seal as the spacer by grinding off the lip, honing and beveling the inside, and then filing off the burrs. The race seated nicely in the steering head and the bearing seated in the race with no play. Another problem solved :clap

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404552861&k=hpVdmbj&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-hpVdmbj/0/M/2012_1111AA-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404564834&k=PcXVpgd&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-PcXVpgd/0/M/2012_1122AB-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>
    #58
  19. dpetersak

    dpetersak Adventurer

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    I cut-out, bent, and drilled some aluminum plate to create a skid plate.

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404552781&k=ncQVWRL&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-ncQVWRL/0/M/2012_1124AA-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404553811&k=mDJz4rZ&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-mDJz4rZ/0/M/2012_1125AA-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>

    I also added some mini crash bars. They're off a 79 Yamaha 1100. The bottom is bolted to one of the bolt holes for the forward pegs and for the top I welded a tab to the frame.

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404553865&k=TvmmQtc&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-TvmmQtc/0/M/2012_1125AB-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>

    <a href="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/27242605_QsJxjX#!i=2404554486&k=FZsDpt4&lb=1&s=A" title="Photo & Video Sharing by SmugMug"><img src="http://akulsp01.smugmug.com/Motorcycles/Sportster-Build/i-FZsDpt4/0/M/2012_1125AC-M.jpg" title="Photo & Video Sharing by SmugMug" alt="Photo & Video Sharing by SmugMug"></a>
    #59
  20. WhicheverAnyWayCan

    WhicheverAnyWayCan Deaf Biker

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    Looking good!! Your skid plate is really simple! :thumb

    I am curious to see what your plan is for the kickstand. I like JimmyTheHog's but I think his might be a bit too tall for mine. Or are you gonna stay with what you have?
    #60