Show us your TransAlp modifications!

Hey Guys & Gals,
Well after about 6 months of fooling around in the shed and getting help from a few people, the next phase of my TransAlp’s customisation is almost complete. I mentioned last year I was keen to extend the fuel range of the TA, particularly for the long distances between outback fuel stops. In the process of doing this, I was interested in trying to turn this bike into a twin exhaust – upswept, Rally style!
<?xml:namespace prefix = o ns = "urn:schemas-microsoft-comfficeffice" /><o></o>
I had purchased a USA made KTM 950 AdvTank , with the intention of fitting one of these to both the LH & RH side of the bike. The tank arrived – and whilst making some clever brackets, it could be made fit the LH side, the RH side was not going to work. Disappointingly, the AdvTank went onto the flea market.
Another option was the Boano AT650 / AT750 (RD04), 17 Litre rear fuel tanks & panels. Further investigation revealed two drawbacks:
- I would need to source & fit the rear frame and mudguard section from an AT650 or AT750 (ok);
- Jarno Boano advised that their rear rack was only rated to carry top load maximum of 7kg (problem).


<o></o>


SYDADVGS, suggested contacting KTM Matt, as he had been making a couple of aluminum rear tanks for some orange machines (640’s, etc). I sent a few details to Matt, and it all seemed ‘do-able’.
<o></o>
EXHAUST SYSTEM<o></o>
<o></o>
During this time I had been researching exhaust system components and options. Some Arrow headers were sourced from Italy. After talking to a few people, someone (can’t remember who???) suggested Foran Exhausts in Gosford (near Sydney). I went to visit Denis with the headers and some pictures of rally bikes (KTM 660RR & 690RR’s). Denis advised he could manufacture replica mufflers (measurements via Johnno 950 – thanks!) and the mid pipe – but to keep the costs a bit lower, he advised sourcing mufflers from overseas. After scouting around, the closest thing I could find was some SP Engineering units:


<o></o>
**Link: http://www.spengineering.co.uk/product-1-stainless-big-bore-xls-exhaust.html
<o></o>
They are 2” ID straight through cans, approx 100mm OD, 300mm long. Tips are 2 ½” dia !!!!
The mufflers are mounted to the original blinker mounting brackets, with some black nylon spacers made up to space out the mufflers:
<o></o>

<o></o>
The spacer dimensions are: 8mm ID, 30mm OD, 30mm length.
Mounting hardware:<o></o>
2 x 94050-08000 Nut – Flange M8 (Honda Part)
2 x 95701-0805000 Bolt – Flange M8 x 50 (Honda Part)
2 x 90535-KB9-000 Washers – M8, Large OD (Honda Part)
<o></o>
<o></o>
The rear blinkers were repositioned to the rear carry rack:


<o></o>
The Arrow header pipes received an M8 exhaust gas test point approx 6” from the header ports.
The bike was then taken to Denis for him to work his magic. The exhaust system is effectively 2 – 1 – 2, where by the scavenging / extracting function of the headers is retained.
<o></o>
After the intermediate pipe was completed (less fuel tanks mount points...), the bike came home. There were a few things that needed attention. The side stand was fouling on the LHS rear pipe:


<o></o>
<o></o>
<o></o>
<o>(Sorry about these 2 x pics being a bit blurry..)</o>
<o></o>
The mounting bracket was cut through the weld on both sides (not cut completely through). The side stand mounting plate was bent outwards approx 5-10 degrees. This took a couple of attempts to get correct. The side stand was then rebuilt, using a new section of pipe with a bend to curl the stand back towards the bike. The bend is 22 degrees:
<o></o>

<o></o>
The mid-pipe needs supporting where the pipe splits to the twin section. The following hardware was used:
1 x 5L-4804 Clip (P Type) (Caterpillar Part)
1 x 9L-6331 Bracket (Caterpillar Part)
1 x 90535-KB9-000 Washers – M8, Large OD (Honda Part)
1 x 94050-08000 Nut – Flange M8 (Honda Part)
1 x 95701-0802500 Bolt – Flange M8 x 25 (Honda Part)
<o></o>
NOTE: the 9L-6331 Cat Bracket was mounted to the Pro-Link U-Section mounting point:
<o></o>

<o></o>
The next item to address was the need for a heat shield on the RHS rear pipe:
<o></o>

<o></o>
(NOTE: the Side Stand shields left leg from the LHS rear pipe)
<o></o>
I tried to find a straight exhaust shield from a Honda bike, but could not find anything. After scouring the internet, I found that the heat shield from a 1997 Yamaha TT600E Belgarde would fit nicely. The following parts were utilised:
1 x 5CHE4-62800 Protector (Yamaha Part)
2 x 90164-06017 Screw (need to shorten) (Yamaha Part)
2 x 90206-06090 Washer – Wave (Yamaha Part)
4 x 4BD-14760-00 Washer – Protector (Yamaha Part)
2 x N/A Nut – M6 Stainless (Hardware Store)
<o></o>
The M6 Stainless nuts need to be TIG welded to the RHS rear pipe.
<o></o>
TANKS<o></o>
Next up the TA was taken to KTM Matt for him to fabricate the tanks & inner mounting brackets.
The upper, rear mounts:
<o></o>

<o></o>
Replace the inner rear mudguard / fender bolt with a longer M8 x 50mm Flange Head Bolt (95701-0805000). The tank is retained with a 94050-08000 Flange Nut. Hardware for both sides combined:
2 x 94050-08000 Nut – Flange M8 (Honda Part)
2 x 95701-0805000 Bolt – Flange M8 x 50 (Honda Part)
<o></o>
The upper, front mounts:
<o></o>
<o></o>
<o></o>
<o></o>
<o></o>
The tanks are bolted to the mount assemblies with 1 x M8 x 16mm Bolt on each side:
2 x 95701-0801600 Bolt – Flange M8 x 16 (Honda Part)
<o></o>
The lower, front mounts:
<o></o>


First up, the pillion foot pegs were removed. The tanks bolt up, using two M8 x 20mm bolts on each side. Hardware as follows:
4 x 95701-0802500 Bolt – Flange M8 x 25 (Honda Part)
<o></o>
Other progress photos of the tanks’ construction:
<o></o>



<o></o>
After painting, the fuel tank filler necks were fitted and sealed with 3 Bond. The ‘Grey’ 3 Bond variety has a greater resilience to Petrol – so go with it, not the white.
<o></o>
FUEL PUMP, TAPS, and LINES<o></o>
The fuel pump and its mounting bracket were purchased through Boano. This allowed the Fuel Pump to be mounted above the Starter Motor. I adjusted the orientation of the mounting plate on the pump, as the fuel lines would have been running next to the LH Rear Spark Plug Lead.
<o></o>
1 x Mikuni DF52-82 Fuel Pump (Sourced – Boano)
1 x N/A Mounting Bracket (Sourced – Boano)
<o></o>
I wanted to be able to switch fuel supply between the Front (Original Honda Tank) and the Rear Auxiliary Tanks. After a bit of looking around, I found this little 3-Way sucker:
<o></o>

<o></o>
<o>(Yes I know the clamp is loose...)</o>
<o></o>
I sourced it through a local Husky / Toro ride on lawn mower dealer. Basically, ask them for an equivalent on any of their duel tanked ride on mowers. Details:
1 x 745-059 Fuel Tap – 3 Way (Hustler) (Mower Dealer)
1 x N/A Mounting Bracket (Flat Bar Aluminum)
<o></o>
Main Tank Fuel Tap – with the fuel pump being vacuum operated, I had a problem / dilemma with what to do with the main front tank fuel tap. The problem being it is vacuum opened. With a Scott Oiler running off the front cylinder vacuum port, and the fuel pump running off the rear cylinder – there wasn’t many options. The fitting on the main tank is a peculiar size – I even sourced a second hand Honda NTV650 fuel tap (non-vac) – but the thread was different. So, having a bit of a ‘thought’ – why couldn’t I make the tap normally open, instead of normally closed:
<o></o>



<o></o>
Disassemble the fuel valve, switch the spring to the other side, and reassemble. Now holds in the open position. NOTE: the spring sits nicely over the inner casting:
<o></o>

<o></o>
For the Fuel Lines, parts breakdown:
3 x Metres 6mm or ¼” Fuel Line (Auto Store)
1 x 16958-MB0-000 Tee Piece – 6mm Hose (Honda Part)
10 x 95002-4120008 Hose Clamp (Honda Part)
0.2 x Metres 19mm Heat Shrink (Electrical Store)
3 x 4K-8864 0.50” P Clamps – Vinyl Coated (Caterpillar Part)
NOTE: The heat shrink was used on certain areas of the fuel line to provide better mechanical protection – if there was a chance the line may rub on adjacent parts.
<o></o>
Fuel Taps – Rear Tanks, were supplied with the tanks via KTM Matt. They’re a KTM type fuel tap (aftermarket version).
<o></o>
The fuel tank breather lines are simply some left over 4mm clear tube. Each tank was supplied with a M4 grease nipple (centre valve removed). Whilst these would work fine to connect the tube to, I had some left over brass M4 barb fittings from the Scott Oiler kit.
<o></o>
SIDE PLATES<o></o>
With the removal of the original side plates to accommodate the fuel tanks, I wanted to have some sort of panel / cover over the air filter housing and battery. So I knocked up some cardboard versions:
<o></o>

<o></o>
Then, trace and cut out from 2mm Aluminum sheet:
<o></o>



<o></o>
Finally, the aluminum versions were used by a local composite company as moulds to make fiberglass versions.
<o></o>
COMING TOGETHER – Bits n Pieces<o></o>
As the bike came together, two things needed to be addressed. The first was protecting the cross over section of the exhaust pipe. It was exposed & vulnerable. So KTM Matt built up a new bash plate with a lowered section at the rear to protect the pipe. The base is 5mm aluminum, so I’ve taken to it with a hole saw to reduce its weight.
The other item was the rear exhaust pipe mounting supports. Once the tanks were built, the bike went back to Denis so he could TIG some brackets to the pipe. This would allow them to be supported by the tank:
<o></o>

<o></o>
The following hardware was used:
2 x 94050-08000 Nut – Flange M8 (Honda Part)
2 x 95701-0802500 Bolt – Flange M8 x 25 (Honda Part)
2 x N/A Washers – Black Plastic (Made at Home)
<o></o>
The intent of the 8.5mm x 25mm x 3mm black plastic washers is to reduce heat transfer from the pipes into the fuel tanks.
<o></o>
There was a whole heap of other work carried out during this period including:
<o></o>
- Fitment of Sena SR10 UHF Bluetooth Adapter;
- Fitment of GME TX3100 UHF and Antenna;
- Valve Adjustment done;
- Fitment of Mitas E09 Dakar 140/80-17 rear tyre;
- Fitment of 82 Deg C Thermo Fan Switch; &
- Fitment of TA650 Carburettors.
<o></o>
With radical change in exhaust and different carburettors, the bike went back onto the dyno to check out the fuelling. Both cylinders were running rich on the main, while rear also needed leaning off on the needle. The rear went back from a #128 to a #125, plus lowering the needle 1 x position. The front was a #125. A #122 was ordered and fitted, though has not been retested.
Disappointingly, the Hp figures were down significantly (43hp versus 48hp previous), though hopefully the rich mixture it the culprit.
<o></o>
HERE SHE IS<o></o>
<o></o>

Here are a few pics of the end result:
<o></o>



<o></o>
<o></o>
<o></o>
<o></o>
<o></o>
<o> </o>
<o></o><o></o>
VERDICT<o></o>
The LH Tank is 10L. The RH Tanks is 11L. That plus the original 18L up works out to 39L all up. Test run yesterday up to Armidale (fully fuelled, plus additional 10L fuel in Jerry Can, plus 10L of water, plus loaded saddles, plus camping gear, & tank bag – fully loaded!!!) saw an overall figure of 597km. That works out to 15.3km / Litre. All the while, running up the New England range at anywhere between 100km/h to $1.20 / hr.
<o></o>
The exhaust sounds awesome, but it is very, very loud. I think I’ll need to be careful not to draw too much unwanted attention from Mr. Policeman…
<o></o>
The problem at the moment is an intermittent fuel starvation problem when running off the rear tanks. Sometimes this has occurred in either slow traffic (low fuel demand) or say, cracking up Moombi range with the throttle on the stop. Normal running at 80 – 110km / h seems fine. It is quite possibly the pump playing up. Further diagnosis required. :huh KTM Matt has kindly lent me (with option to buy) a Mikuni DF52-44 to try and see if that resolves the problem.

The only other item I need to sort out is the seat bolts are not accessible with the tanks fitted. I'm still working on a solution to this problem - but I suspect a strap with release clips might be involved. At the moment the UHF radio antenna bracket is keeping the seat from jumping off.

<o></o>
Anyway, my dream bike is getting closer to reality. The next step will be to get that little v-twin banging a bit harder. But that will have to wait a while...


Cheers,

Dan.

Fantastic work as always, well done.

One word....WOW!

Well I finally finished doing some maintenance on the Transalp. Here's what I did:
-Chain and sprockets
-valve adjustment
-carburetor float adjustment
-install 38 idle jets
-carb sync
-new plugs (stock)
-repack Supertrapp Muffler and install 8 or 10 (I forgot already) discs
-repainted header and fixed the leak at the header/muffler joint
-a few small cosmetic things

So now the bike seems pretty starved for power. It runs okay around the yard, but on the road it feels as though it will die trying to go up hills.

I have come to terms with the fact that I need to go back through what I've done, including rechecking the valve clearances and carburetors. Is there anything specific I should look for?

Curiously, the muffler seems even louder now that I've repacked it. I was a little worried that maybe I'd overpacked the muffler, but I really don't know.

When I first fixed up my old CB500/4, I had the carbs off four or five times before I got it right, so I know it may take a couple of tries to get the Transalp running right and I'm okay with that.

<a href="http://tinypic.com?ref=rtgtuh" target="_blank"><img src="http://i41.tinypic.com/rtgtuh.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

Holy crap,Dan. Fantanstic vision, and great work. You got you an outback bike now.

<a href="http://tinypic.com?ref=35izlzk" target="_blank"><img src="http://i43.tinypic.com/35izlzk.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=4u8kfl" target="_blank"><img src="http://i41.tinypic.com/4u8kfl.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

Dan, awesome job.

Galba, nice bike.

Nice bike Galba. Which headlights are those? I've been thinking of doing the same with something like Buell XB lights.

Wow

I go away for a week and you guys all build new bikes.

Welcome Galba,

Nicely done modifications with the dual headlights, AT bachplate etc. I think yours is the first "Cigarette Transalp" I've seen. Reminiscent of the 90s Dakar bikes.

Dan,

What a wonderful job and a great write-up also. Thanks for letting us in on all those secrets and writing it so anyone can follow your lead.

You've really built the Transalp Valdez supertanker. Perfect bike for the your way outback.

For fuel starvation you might check tank venting. I recently read an article where the rear aux tanks fitted to a GSXR would not flow because the low pressure area behind the rider would not allow the tanks to vent. This was only at speed though and doesn't work with starvation at idle....just a thought.

As for me, I've been working on car stuff (yeah, I know) My best friend is building a sports car FROM THE GROUND UP. He's a race car mechanic and great with engines and suspension design. Frame is all chrome moly tubing. Engine is a period GMC 6 cylinder. Suspension corners are aluminium bits from a Corvette.

We've been working on building a hand formed body out of aluminium sheet. He bought an english wheel and has been teaching himself the rather arcane science of rolling and bending sheet metal. I'm trying to keep up but it's one part engineering and two parts black magic.

Just spent a week doing the left side of the car so I can appreciate all the work that goes into building the side tanks on the TA.





The left rear grew so large we had to jack up the wheel to fit it through.

This week........back to motorcycles Whew.

That's talent there. See if he'll build you new fairing pieces.

Dan,

I always liked your bike, but now..WOW... it looks unbelievable, bet it sounds great too; how about letting us all hear it?

Cheers
Potski

<a href="http://tinypic.com?ref=50qmiu" target="_blank"><img src="http://i40.tinypic.com/50qmiu.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=4ifwbl" target="_blank"><img src="http://i41.tinypic.com/4ifwbl.jpg" border="0" alt="Image and video hosting by TinyPic"></a>




<a href="http://tinypic.com?ref=34e6qef" target="_blank"><img src="http://i41.tinypic.com/34e6qef.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

Nice work guys, thanks for the inspiration!!!



I am giving the Flea-Market another attempt, my 4th I believe....


http://advrider.com/forums/showthread.php?t=883063


All humor has been removed and I think I am only braking one rule but I believe that a link to my 100 photos is better than posting them all.....we'll see.

<a href="http://tinypic.com?ref=zl7y2b" target="_blank"><img src="http://i40.tinypic.com/zl7y2b.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=otk8zk" target="_blank"><img src="http://i41.tinypic.com/otk8zk.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=yj4wp" target="_blank"><img src="http://i39.tinypic.com/yj4wp.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

<a href="http://tinypic.com?ref=5l4ges" target="_blank"><img src="http://i43.tinypic.com/5l4ges.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=x4rz37" target="_blank"><img src="http://i41.tinypic.com/x4rz37.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=34yqs5s" target="_blank"><img src="http://i39.tinypic.com/34yqs5s.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

http://www.dirtbikerider.us/index.cfm?P=ShowPicture&Picture_ID=46007



<a href="http://tinypic.com?ref=2jh00g" target="_blank"><img src="http://i44.tinypic.com/2jh00g.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=174rq0" target="_blank"><img src="http://i41.tinypic.com/174rq0.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=o60m75" target="_blank"><img src="http://i39.tinypic.com/o60m75.jpg" border="0" alt="Image and video hosting by TinyPic"></a>




<a href="http://tinypic.com?ref=2qjvqj4" target="_blank"><img src="http://i43.tinypic.com/2qjvqj4.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=17bx2q" target="_blank"><img src="http://i39.tinypic.com/17bx2q.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=20zxz08" target="_blank"><img src="http://i44.tinypic.com/20zxz08.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

<a href="http://tinypic.com?ref=svhv81" target="_blank"><img src="http://i44.tinypic.com/svhv81.jpg" border="0" alt="Image and video hosting by TinyPic"></a>


<a href="http://tinypic.com?ref=2z55742" target="_blank"><img src="http://i42.tinypic.com/2z55742.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=2sal0r8" target="_blank"><img src="http://i44.tinypic.com/2sal0r8.jpg" border="0" alt="Image and video hosting by TinyPic"></a>



<a href="http://tinypic.com?ref=jg3b6v" target="_blank"><img src="http://i44.tinypic.com/jg3b6v.jpg" border="0" alt="Image and video hosting by TinyPic"></a>

Are those AT lights? They look like they're smaller but maybe it's just because it's a different fairing.

[QUOTEAre those AT lights? They look like they're smaller but maybe it's just because it's a different fairing.][/QUOTE]

are not AT,but Aprilia Rally,

http://www.dirtbikerider.us/index.cfm?P=ShowPicture&Picture_ID=46007