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tileman 05-04-2009 10:38 PM

Spoked wheels, new fairings, exhaust, its all happening
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Hi all, think I may have to start a thread for this one as its already on a couple.

Here goes;

I love the look of spoked wheels but didn't want the expense of a GS or KTM and the wee has such a good reputation, and it is cheap, and I owned one. So I started down the path of making the new wheels.

Through some research and luck we (my cousin and I) found that a triumph tiger 955 front wheel was the same diameter, disc to disc width, and disc diameter as the Dl front wheel.

After sourcing a wheel through his contacts we set about fitting it.
First we decided to used the existing speedo drive which required making adapters as shown in the attached pic. The spacers are made out of delron similar to what is used for crash nobs, so its heaps strong enough.

tileman 05-04-2009 10:41 PM

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once the speedo drive was made we then needed spacers as the bearings are at different centres as the standard dl ones. The bearings were also changed to 20 ID as the spacers could then be manufactured to be captive, that is that they insert into the bearings to hold them in place to make fitment of the wheels easier.

tileman 05-04-2009 10:42 PM

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the spacers built...

tileman 05-04-2009 10:45 PM

If anybody would like the dimensions of the spacers and speedo drive let me know and I'll send through the cad drawings....

tileman 05-04-2009 10:46 PM

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heres some pics of the wheel fitted....

tileman 05-04-2009 10:54 PM

Oh, forgot to mention, the front rim and hub were anodised/painted black and I used new front floating disks (

tileman 05-04-2009 11:00 PM

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Now to the rear;

We used a DR650 rear hub as it came with a cush drive similar to the standard DL wheel. I then got new sprockets both front and rear from JT with gearing similar to that of the DL.

tileman 05-04-2009 11:19 PM

Then came the fun part of making up spacers from the rear which proved more difficult than I thought....:1drink

tileman 05-04-2009 11:27 PM

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Rear wheel fitted, minus chain and sprockets....had a little problem with the math.......:eek1:wink::freaky

Mats 05-04-2009 11:52 PM

Nice job!! The bike looks much better with wire spoked wheels I think. Looks more dual sport!

oldmanb777 05-05-2009 05:40 AM

Love it! Much better look than the cast ones. I'm very suprised, I really didn't think it would change the look that much.

caver101 05-05-2009 05:42 AM

Thats sharp! Sure helps the look of the DL.

tileman 05-05-2009 06:24 PM

Ok, I am missing a few details of the last pic;

The rear has been raised about 1 inch over standard and the sag is decreased as I have fitted a 98 zx9r shock (had on lying around) and some shorter dogbones that my cus had built for his SV650. The zx9 shock was about the same length as the standard one but mine is stuffed after 60 k and 5k 2 up with gear.

the rear rim is a 17 as per standard with heavy duty spokes made by a company in queensland (link i think there called???). i am also converting the chain to a 520 for 2 reasons 1. I have one 2. figure the bike isn't over powerful.

The rear exhaust is being changed for a scorpion one that also was lying around at home.

My cus has collected a lot of stuff over the years so I am pilfering as much as I can, this may explain the random use of parts.

Hopefully today I can remove excess piping on the exhaust and have a go at tig welding the new pipe extension on, then make the top bracket to attach the pipe then hopefully the pipe will be done.

Below is a list of whats coming next;

1. exhaust fitted
2. new undertray and side panels
3. fitted battery in new position
4. make the electrics all work
5. fit new tail light etc
6. manufacture new spacers for the front forks (bout 3 inchs) which should give about 2 inches of overall ground clearance (being 6'3", no height issues)

then the fun parts;

7. New front fairings similar to the KTM dakar bikes
8. new headlights
9. trailtech or equiv gauges
10. mod front guard


hope it all works
go riding
weigh it!!!!!!!

Watch this space.............

tileman 05-05-2009 06:26 PM

Heres a photobucket album for some more pics, I'll add as I go.....

Schlug 05-05-2009 11:51 PM

jeexus, the bike is tits with the spoked wheels, i have to admit.

i think, when you're all said and done, you'd have been better off with a BMW F650 GS

but i suppose you're having a good time giving your wee a go, which is important.

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