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Birth of a rallye bike

Discussion in 'Some Assembly Required' started by Mudguts, Oct 30, 2008.

  1. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia
    Birth of a Rally bike
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    <o:p></o:p>
    Stage 1, sourcing a bike,
    <o:p></o:p>
    Well with lot of research, I decided on a KTM 525 maybe not the best bike for long haul rallies, but the best I could afford, the bike I purchase was a second hand
    2005 KTM 525 with 4500km on the lock
    <o:p></o:p>
    <o:p></o:p>
    The first to do is to rip into to and check everything is in good working order, drain all oils fields and give my baby new blood
    <o:p></o:p>
    While I was doing this a quick valve gap check and in section for damage
    After this I pulled the forks apart for a clean & service and too drop in .48 springs
    To suit my weight better .While the fork are out I&#8217;ve cleaned the head stem bearings
    And applied fresh grease.
    <o:p></o:p>
    Next is the rear shock a quick clean and swap out the spring for a new better suited for my weight again while the shock was out I&#8217;ve pull the swing arm off for a clean and fresh grease. I discovered the rebound adjuster needle was broken no big deal as it needed a service any way, and a common issue,
    <o:p></o:p>
    The first Ride was just day trip in the local area Toolangi, bike performed well only one issue that was the water pump seal, $20 and fifteen minutes all fixed.
    <o:p></o:p>
    Stage 2
    <o:p></o:p>
    Spending lots of cash
    <o:p></o:p>
    With a bit of internet research, I ordered the flowing parts
    <o:p></o:p>
    16l safari tank
    Stealth sprockets 15 /50t
    DID vmx 250 chain
    Full set wheel bearing and spacers
    RS concept rallye faring & nav cluster
    Thumper racing 570 big bore kit
    Stage 2 cam
    Touratech road book,
    Ohlin steering damper.
    EVS neck brace
    09 Shift recon pant and jersey
    <o:p></o:p>
    And now I have run out of money (for Now), and waiting on all the parts to turn up
    To my door.
    After waiting near on three months I finally had the cash to pay the freight from <?xml:namespace prefix = st1 ns = "urn:schemas-microsoft-com:eek:ffice:smarttags" /><st1:place w:st="on"><st1:country-region w:st="on">France</st1:country-region></st1:place> a whooping $886Aud for a whole 6kg (30kg cubic) was actually more the fairings. These things had better be good!!!
    <o:p></o:p>
    I also was assured the my 570 big bore kit would be delivered in the same week
    About bloody time.
    <o:p></o:p>
    The only thing now I have changed my mind, Oh well I just sell the kit locally
    To one of my brother mate for there KTM Motard

    Stage 3 the fun part , opening boxes and pulling apart bikes .

    An Artist impression of finished project
    <o:p></o:p>
    <o:p>
    <o:p></o:p>
    <?xml:namespace prefix = v ns = "urn:schemas-microsoft-com:vml" /><v:shapetype id=_x0000_t75 stroked="f" filled="f" path="m@4@5l@4@11@9@11@9@5xe" o:preferrelative="t" o:spt="75" coordsize="21600,21600"><v:stroke joinstyle="miter"></v:stroke><v:formulas><v:f eqn="if lineDrawn pixelLineWidth 0"></v:f><v:f eqn="sum @0 1 0"></v:f><v:f eqn="sum 0 0 @1"></v:f><v:f eqn="prod @2 1 2"></v:f><v:f eqn="prod @3 21600 pixelWidth"></v:f><v:f eqn="prod @3 21600 pixelHeight"></v:f><v:f eqn="sum @0 0 1"></v:f><v:f eqn="prod @6 1 2"></v:f><v:f eqn="prod @7 21600 pixelWidth"></v:f><v:f eqn="sum @8 21600 0"></v:f><v:f eqn="prod @7 21600 pixelHeight"></v:f><v:f eqn="sum @10 21600 0"></v:f></v:formulas><v:path o:connecttype="rect" gradientshapeok="t" o:extrusionok="f"></v:path><o:lock aspectratio="t" v:ext="edit"></o:lock></v:shapetype><v:shape id=_x0000_i1025 style="WIDTH: 237pt; HEIGHT: 198pt" type="#_x0000_t75"><v:imagedata o:title="fondprepaktm2" src="file:///C:\DOCUME~1\10120023\LOCALS~1\Temp\msohtml1\01\clip_image001.jpg"></v:imagedata></v:shape>
    </o:p>
    #1
  2. craig525

    craig525 Ktm nut

    Joined:
    Apr 16, 2008
    Oddometer:
    1,596
    Location:
    Lilydale
    you forgot the most important mod cush hub
    #2
  3. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia
    No , i thought my rear wheel of the 950 would fit , but does not ,

    Not real big deal ATM as will only doing short day ride and testing loading on the ute for now any way .

    But i will be building another set of wheels with cush rear hub ,
    #3
  4. MymoJoe

    MymoJoe Ride Ride Ride

    Joined:
    Sep 30, 2005
    Oddometer:
    3,525
    Location:
    Fernvale QLD not close enough to the desert
    very nice little project..

    :lurk
    #4
  5. jtb

    jtb Long timer

    Joined:
    Dec 4, 2003
    Oddometer:
    2,495
    Location:
    Hawkesbury NSW Australia
    Great! You'll have to keep us posted with pics... :clap :clap
    #5
  6. rhino_343

    rhino_343 Southern Explorer

    Joined:
    Mar 29, 2007
    Oddometer:
    2,137
    Location:
    Yallingup Western Australia
    What's the story with the bash plate in the photo??
    #6
  7. Richard M

    Richard M Doesntplaywellwithothers

    Joined:
    Apr 24, 2006
    Oddometer:
    587
    Location:
    Brisbane,Australia
    I've just sold my 525 from last years safari & have all the rally gear for sale including 16l tank pm me or call mobile.

    cheers
    Richard
    0411853810
    #7
  8. ChrisCrossed

    ChrisCrossed Now sans KLX...

    Joined:
    Feb 14, 2006
    Oddometer:
    1,889
    Location:
    Lake Macquarie NSW Oz.
    you forgot the most important mod learning to navigate

    Looks good. Condo will be an ADV benefit this year, wonderful stuff!
    #8
  9. M.R.

    M.R. Been here awhile

    Joined:
    Jan 27, 2008
    Oddometer:
    885
    Location:
    Vic
    Looks like the water cell on the far side. the water you have to carry but hope to never use:evil:evil
    #9
  10. ranui rocket

    ranui rocket Adventurer

    Joined:
    Aug 29, 2008
    Oddometer:
    52
    mudguts how much for the rs concepts screen and cluster cheers
    #10
  11. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia
    Cost too much try $2100, mind you 885 of that was freight ,

    Checked the tracking on the freight sent on friday in melbourne on sunday delivery later today i hope , not bad from france
    #11
  12. macuser

    macuser Been here awhile

    Joined:
    Jan 8, 2008
    Oddometer:
    452
    Location:
    Calgary, Alberta Canada
    Anxiously waiting on the pictures :)

    Love this kind of stuff...
    #12
  13. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia

    Anxiosly waiting to for company Gift vouchers buy a new camera .

    Might Do some thing about it this week.
    #13
  14. jtb

    jtb Long timer

    Joined:
    Dec 4, 2003
    Oddometer:
    2,495
    Location:
    Hawkesbury NSW Australia
    Me too!:clap :lol3
    #14
  15. macuser

    macuser Been here awhile

    Joined:
    Jan 8, 2008
    Oddometer:
    452
    Location:
    Calgary, Alberta Canada
    What's the "RS concept rallye faring & nav cluster" worth?
    I have a 2007 KTM 450EXC and I'm curious what it'd cost to 'fix' it up. $11,500 for the full conversion kit, but I'm interested in the fairing costs.
    #15
  16. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia
    I did not get the full kit as you can save heap buy shopping around

    the fairing cost a whooping $1485 no joke the freight was $885 alone
    the fairing was $600 .

    I'm off to today to get quote for a modified copy ,


    I'll be back ....
    #16
  17. kiwipeet

    kiwipeet Uber Cyber Loafer

    Joined:
    Oct 12, 2005
    Oddometer:
    3,058
    Location:
    Gizboooooring
    :lurk

    And... can I ask... how did you decide on the 525 as your bike of choice? Was it the best starting point?

    Were there any other serious contenders? XR650?
    #17
  18. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,686
    Location:
    Some were in , lostralia
    Well took the day off work and headed out to valleyforce Husaberg

    the fairing almost fits like a glove on the stock 09 450 a couple little trims hear and there, Now i must state the berg did not have a large tank , i believe Gary ( sarfari berg ) is getting them made . After that i drop the fairing of the the fairing joint to be quoted ,
    to be continued
    #18
  19. SafariBerg

    SafariBerg Oz Safari Addict

    Joined:
    Mar 11, 2007
    Oddometer:
    3,167
    Location:
    Perth Australia
    cool, got the mobile photo looks good, give me a call once you have a price. Cheers
    #19
  20. atgreg

    atgreg Africatwinarama

    Joined:
    Mar 10, 2003
    Oddometer:
    10,043
    Location:
    Sydney Australia