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Old 12-21-2010, 12:01 AM   #16
a1fa
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Very nice bike!
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Old 12-21-2010, 12:02 AM   #17
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Old 12-21-2010, 12:28 AM   #18
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Originally Posted by a1fa View Post
Very nice bike!
Thanks, they are a fun thing, but its got 2 wheels and an engine, so by definition....
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Old 12-21-2010, 12:50 AM   #19
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Nice bike Steve! Looking forward to seeing the rest of the build.
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Old 12-21-2010, 12:55 AM   #20
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What I tried to do with the fork adaption was not to cannabalise anything so that where I used the stock parts, they are untouched. I also wanted to minimise the expense, so kept the stock instruments etc. The only thing that was too hard was getting the steering lock to line up. I could get it to work but would never be able to remove the key because of the bar mounts being further forward on the KTM triple clamps.

I trusted LukasM http://www.advrider.com/forums/showthread.php?t=239519 on his advice re the steering head bearings, and it works so far, ie keep the Suzuki cups in the steering head and the KTM races will line up. the bearings are sized differently, ie 29 x 50.25 x 15 KTM vs 30 x 52 x 16 Suzi but it seems to work OK. The rollers are in full contact with the cup. A couple of shim washers to lift the top clamp to clear the damper post mount and we shall monitor durability. May end up fitting a sleeve to the KTM shaft and just use the Suzi bearings, dunno.

EDIT, the steering head bearings failed, read on.


$AU costs for the front end conversion:
$520 KTM 08 SXF forks and triple clamp, with bearings - ebay
$30 Husky guard - local wrecker
$105 DRZ400 SM headlight mounts - local wrecker
$32 KTM white fork shrouds - ebay
$8 Suzuki stickers - ebay
$142 MSC KTM submount for damper - MSC

I also got 2 sets of head bearings, just in case, but as yet unused from ebay for about $100

I also had some scrap steel and bar stock for making adaptors etc and an axle and lock nut in the shed, and miscellaneous bolts, so no direct cost as such.

Steve
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Old 12-21-2010, 01:14 AM   #21
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Still to come is the Ohlins, a new bash plate from KTMatt and some pannier frames.

I've also fitted a Brembo master cylinder to the front brake for improved control, a definite improvement. TM do it, so it must be good, although the other way around!

And I ordered a 39 mm FCR today too I can't help myself but my perfectly set up Bergs create a benchmark


Steve
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Old 12-21-2010, 01:16 AM   #22
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Quote:
Originally Posted by LukasM View Post
Nice bike Steve! Looking forward to seeing the rest of the build.
Hey, thanks. You, Mezo, and Snowy got me thinking At least I have someone to blame when the wife looks at the bills

Steve
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Old 12-22-2010, 02:38 PM   #23
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Top chain roller torn out. I repaired it, relocating it abit, and adding a strap to the frame crossmember from under the bolt head. So far, so good.

If you look closely, you can see a crack in the top middle of the chain guard. Its stuffed too. I replaced it with a Kawasaki GPX250 one, a bit taller.
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Old 12-22-2010, 02:41 PM   #24
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The stock chain guide is fragile. A replacement from Procycle and I added a brace on the inside too. Bolted to the inside of the swingarm with nutserts.
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Old 12-22-2010, 02:43 PM   #25
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The FMF header makes a difference.

Fastway pegs I like, and the mount is cut down and rearset.
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Old 12-22-2010, 02:44 PM   #26
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The seat is stock with a Yamaha XT600 foam added in, and the sheepskin too. Better for my bum and dodgy old knees.
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Old 12-22-2010, 02:45 PM   #27
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The Megacycle muffler
The racks are work in progress.
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Old 12-22-2010, 02:48 PM   #28
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The main rack is an old Ventura that I've adapted.
The toolbag is a Kelly
The lower rack is from the wife's KLX250 and replaces the stock tailight. The replacement tailight and guard extension is Berg one I had lying about.
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Old 12-22-2010, 02:50 PM   #29
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OK, so I seem to have the picture thing working now. Enjoy.
More to come, I might have the shock tomorrow.

Steve
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Old 12-22-2010, 02:56 PM   #30
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very nice

it looks like you sail around the horn with that front end
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