the project that shouldn't be

Discussion in 'Some Assembly Required' started by johnwesley, Feb 19, 2011.

  1. johnwesley

    johnwesley wanta be

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    Projects come and go mentally, I contemplate them and then research. The start of it is in the mind as one considers the options and work that maybe need to finish it, and then, is it worth the effort? This project is one that I have put through the mental stages many times and have always come to the conclusion that it is not worth the effort. There are better bikes to build, better performance, better handling, and less weight. Logic has won out time after time, but this time I have to build it. I have to get the idea out of my head so that I can go on. If it flops then that fine, at least I have it out of my head and can move on. So now that this is solved next up is what model would work best? This takes lots of research and time. It is a bike that I am not familiar with so I start from scratch. Joining forums and reading all I can absorb. This studying lead me to the xl1200s, basically is is Harley's Screaming Eagle edition. Dual plug lighting heads, 10:1 compression and single fire ignition. In the suspension department we have fully adjustable forks and shocks, with dual disk brakes and twin piston calipers. None of that maters thought because it just good ebay stuff because we are going to change this out for MX suspension.

    Now that the introduction is done here is where we start

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    the thing that causes me the most concern is the rear suspension. It is stock with dual shocks and moves in a 1.14:1 ratio. Not ideal if you want a suspension that is matched front to rear with lots of travel. So out comes the math and the mock up for travel with different shock placements.

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    after a lot of work I come up with a workable 1.73:1 ratio and a single shock mount with possibilities of 2:1 and a little longer swingarm. Shock placement ala ATK. It works for me and frees up room.

    Next up is drawing up a steering stem to mount the forks triples with and use stock HD bearings.

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    The stem drawings are sent off to the machine shop and the swingarm to BTRmoto. Wheels are at woody's and I am in a holding pattern waiting on parts

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    #1
  2. (none)

    (none) poser

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    I'm gonna be watching this. Very nice.
    #2
  3. johnwesley

    johnwesley wanta be

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    this one is inspirational

    [​IMG]
    #3
  4. Czechsix

    Czechsix Slower than you....

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    In on one...subbed

    Attached Files:

    #4
  5. eternalRider

    eternalRider Ride to Live!

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    Looks good what what are your plans for it? I'll be watching:clap
    #5
  6. jdrocks

    jdrocks Gravel Runner

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    lordy, you must be dreamin' of some travels.

    did you happen to see the photo of the desert race prepped HD that was on the forum? got a plan for fuel? what's the target weight?

    i like that screw jack holding up the bike, in the best tradition of garage bike builders...use what ya have at hand. i have a few of those old jacks myself.
    #6
  7. johnwesley

    johnwesley wanta be

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    right now the fuel plan is to build a cell that goes between the fender struts an just behind the drivers seat. Hope to get 4 gallons from it which will give 7.3 total. I want to try and keep the peanut tank as I like the look of it.

    I have seen the other builds for the true off-road bikes. here are two that come to mind

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    [​IMG]

    this one from Australia is what shows me I may be able to build one and the reason to throw out logic and just do it

    [​IMG]

    then a forum member built this one with minor modds, just wheel and shocks. Don't let the tank fool ya it has to many plug wires :deal

    [​IMG]


    JD from weight stand point I'd be happy to keep it under 500. It will be no fly weight like the V649HP. If someone likes to see results from weight reduction efforts this is the bike. Everything on it is heavy, all thick wall steel. even the fenders weight several pounds. Easy to get the weight down
    below is the stock specs with this build the ground clearance goes up to 5"+/- as does the seat height

    Length 88.5 in.
    Weight 501 lbs.
    Ground Clearance 6.7 in.
    Wheelbase 60.2 in.
    Seat Height 28.0 in.

    In stock form this bike isn't bad a s a adv bike along the lines of a scrambler type bike as it has 6.1" of travel and 6.7" clearance with a 19" front wheel.


    the 650r was a bike I considered strongly, but just never found that deal I wanted. I found this bike for about what the 650 is going for here
    #7
  8. SamM

    SamM Jeep Overlander

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    johnwesley,
    I've thought seriously about doing something similar but using the Blast engine instead of the V-twin. The 500cc engine can be pushed out to 625cc's fairly easily.

    Cool build. Can't wait to see what you come up with.

    SamM
    #8
  9. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Hey John - Looks like we share the same insanity :evil
    Im trying to get these ideas out of my head too.

    Im still trying to figure out the rear shock mount locations and so far, the best I can see looks like what you said - ATK style. I have a 13.2" lg shock, 2.7" travel, and gives ~ 2.57:1 ratio at the mounting points I picked. I'll post them soon.

    Looking forward to your rear fuel cell - Nice posts :clap
    #9
  10. johnwesley

    johnwesley wanta be

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    yea that doesn't give us a good travel. try mounting the shock 90degrees from level and use the factory top mount

    EDIT:I do not have my swingarm any more or I would go look at it and see
    #10
  11. johnwesley

    johnwesley wanta be

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    just for fun i weighed a few things to see what kind of weight may be possible to loose. with just front wheel brakes and rear wheel we have a reduction of 40 lbs which brings the wet weight of the sporty to 486. I'm sure you can get another 15-20lbs off. the thick steel fenders are heavy, as most things on American iron. It will be interesting to see what the weight will end up at
    #11
  12. madeouttaglass

    madeouttaglass The AntiHarley

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    #12
  13. P7HVN

    P7HVN Been here awhile

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    What are you going to do with those shocks you took off, and how long are they? Looking for replacements for my stock XR1200 shocks....
    #13
  14. johnwesley

    johnwesley wanta be

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    I'm going to sell them. I am in Nicaragua right now and will measure them when I get home
    #14
  15. johnwesley

    johnwesley wanta be

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    They are 13" from eye center to eye center.
    #15
  16. johnwesley

    johnwesley wanta be

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    I have a few parts in, but still waiting on the main pieces before we can really start back together with the build.

    I like the ss2r exhaust for the sound level (quiet) and for the high exit. I looked at more scrambler styled pipes but was concerned about heat and bike width in the standing position. this seem to work out well. With the single shock I will be able to keep the muffler in tight and the bike narrow.

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    woody's did a great job on the wheels. They powder coated the front hub and did the super lace and over sized spokes w/ss nipples. It makes a very strong wheel as I can attest to the abuse the klr wheels have taken.

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    #16
  17. johnwesley

    johnwesley wanta be

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    got a new toy to help with the build :D

    sale at harbor freight

    [​IMG]





    Waiting on parts is getting old, I'd like to move forward a little on the build. Hope something comes, in time to get work done before I leave for South Africa
    #17
  18. tragerbon

    tragerbon Been here awhile

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    #18
  19. johnwesley

    johnwesley wanta be

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    yea I saw that one. interesting concept. counting mine there are 3 builds going on on adv
    #19
  20. ohiofathead

    ohiofathead Been here awhile

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    John,
    I've thought about doing something like this, and I'm glad you're giving it a stab. :clap

    Can't wait to see how it turns out.
    #20