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madeouttaglass 08-12-2010 08:13 AM

Another DualSportster
I've envied some of the enduro Harleys I've seen online and always thought that I'd like to build one someday. Last week my buddy Dan emailed me a link to a cheap Sportster in PA. I had him go right out and buy it for me. (We've done these things to each other before.) A couple days ago I drove the 4 hours down to his house to pick up my new toy. In the meantime Dan had me pick up an old Kawasaki G4 that I found here in upstate NY. Much to his wife's delight, I brought that down for his kids. The exchange was made and I got my ass out of there before Myra got home from work.
Two nights ago I picked up and old YZ490 chassis to steal parts off of. I've ordered a few nice orange and black plastic bits off ebay that I think will go nicely with the stock tank and rear fender. Unlike some of the more radical versions I've seen on ADVRider, mine will be more of a low budget build. If I can find a decent width 16 Knobbie I can keep the stock wheels and have this thing together in short order. Any suggestions? My goal is to have it out for some nice fall rides.
Pics to follow shortly.

Kawidad 08-13-2010 07:15 AM

I would suggest looking around for spoke wheels and then re-lace them to a 21/18 pattern. 21" fronts are common, so no lacing required, but an 18" or even a 17" rear hoop will give you much better tire selections and don't require any re-engineering of the bike itself.

Money, skill, tools, and imagination are your only limitations. :freaky

madeouttaglass 09-08-2010 03:30 PM

Here's a picture of the almost finished product:

madeouttaglass 09-08-2010 03:31 PM

Here's the other side:

WooPig 09-08-2010 03:58 PM

That's cool. How does it work?

madeouttaglass 09-08-2010 04:03 PM

This is just the alpha test. I'm going to register it in a week or so to feel it out. I've only ridden it on our acreage for about 2 miles total. I need to find a 14-15 tooth front sprocket. It has a 22T and I've only been able to find 21T. That won't cut it. I also need to build a kick stand and possibly lower the pegs a bunch. I'll have to fab up some sort of rearset shifter linkage to do that this winter.

madeouttaglass 09-08-2010 04:04 PM


Originally Posted by WooPig
That's cool. How does it work?

In a nutshell- like a Harley (not too good.:D )

Big Mistake onWheels 09-08-2010 04:07 PM

Harley dual sports? Hear me roar? In the BACK COUNTRY? Dark Age deepens.

madeouttaglass 09-08-2010 04:11 PM

Here's the engine a few days ago. What a technological marvel! (for 1903)

AustinJake 09-08-2010 04:27 PM

More ideas here

madeouttaglass 09-08-2010 04:43 PM

That bike is one of two Sportsters that inspired me. I saw a picture of that one in Alaska. The other one has more suspension and is all orange. Both probably better bikes than mine currently is.

johnwesley 09-08-2010 06:02 PM

this one is cool

madeouttaglass 09-08-2010 07:06 PM

No question. Too expensive for me though.
I need to use his shifter link idea when I lower the pegs. Looks like good engineering.

Murf2 09-09-2010 06:30 AM

MOG, What is that rear tire your using? Is it tubeless? Very cool bike!


madeouttaglass 09-09-2010 06:34 AM


Originally Posted by Murf2
MOG, What is that rear tire your using? Is it tubeless? Very cool bike!


The back tire is a Duro median. It is the ONLY semi off road or off road tire that I could find in a 16 inch diameter. I tore up our field with it pretty good last evening.
It took me a week to find a supplier that actually had stock. Most are on indefinate back order.
It said tube type, but I run sealer and it's held pressure for over a week.

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