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Old 05-16-2008, 07:23 PM   #61
Pumpkinhead
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Ok. It's been a couple of months. Anything new on the DR?


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Old 07-07-2008, 11:56 AM   #62
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?!?!?

soooo... more man more..
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Old 07-07-2008, 12:39 PM   #63
LukasM OP
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Guys,

I would love to post an update on this thread. I got the bike running last year and even took it for a week-long trip through the Alps in November (ride report coming up as well).

Unfortunately I have been living/working in Spain the last few months and didn't bring any of the pictures I took so far. However, I will be going back to Austria in August. Good news is that there are a ton of parts waiting for me, so the build will go on and the bike will be even better than I had first planned. Lots of cool mods (some unique) coming up!

Here is a preview pic of the Winter-Alps-Tour that my cousin sent me:
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Old 08-20-2008, 06:20 PM   #64
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Back in business!

Boys and girls,

I finally got home from Spain for my vacation and have started working on the bike again!!!

I'll try and continue the thread where I left off last year, even though I have changed some things since then. But more on that later, you'll see as we move along.



With the wiring out of the way (mostly), the next step was suspension, wheels, etc.

The 17" Supermoto wheel fit in with no problems now that I had the right triple clamps (29cm center spacing for the fork tubes). I also decided to replace the stock jello bars with some very strong 1 1/8" Pro Tapers. A bit blingy but I got them new for less than half price:




Then the post guy showed up and brought me my new KTM style fender. Since the OEM/Acerbis part is only available in orange, silver and black I had to order a special part from Italy to match my blue color theme. The company is called Cemoto and quality appears to be good, about on par with Acerbis.

I also got some UFO handguards, with an aluminum bar insert of course. At some point I will put on some Acerbis Multiplo (very strong plus they have a nice curved bar for hand side exit) with the big Touring shields.

The color (Yamaha blue) is a decent match for the Suzuki blue IMS gallon which I also trial fitted in this picture:

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Old 08-20-2008, 06:34 PM   #65
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So with the bike a roller, I thought it would be nice to finally have some front brakes. I didn't get a brake line with the caliper/master cylinder setup I got of Ebay, so I took some measurements and headed to a local motorcycle brake specialist to get some nice stainless steel lines made up. I had worked with him on my R6 track bike and was very happy, this time was no different:

Again, I just HAD to spend an extra $10 to get the blingy gold anodized fittings:

Brembo MC (adapted the brake light cables to plug into the DR harness), UFO handguards:



Switched back to the 21" Excel wheel since my Brembo 2 piston caliper only works with a 300mm disc and not the 320mm that will go on the 17" wheel. You can also see the new white lower fork guards:




And here is the overall front look with the KTM style front light. I really like these because they attach with two quick-release rubber straps and can be undone in 2 seconds to access the wiring. Plus it weighs about 1/3 of the Suzuki light:

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Old 08-20-2008, 07:06 PM   #66
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One thing that had been bothering me since the beginning was a slight leak right above the shifter shaft. The plate seemed to have had a bunch of liquid metal gooped on to it, so I figured there was probably a crack somewhere:




We had just done an oil change, so Alex (that's him in the picture) had the brilliant idea to lay the bike on the side before taking the plate off. With me riding it will just be a matter of time (minutes?!? ) until I crash I, so I wasn't exactly concerned with scratches.




Upon taking the plate off, I found the culprit of the oil leak - there was indeed a badly patched crack in the cover. I was going to try to fix it with some more epoxy until I found the following (fast forward a few days until I got in the new parts that are laid out next to the old ones for comparison):

So which one should I put on the bike..... (btw isn't that the part that Max Kool broke during an offroad trip to France?):


Don't have to do a patch job after all, plus it saves me some clean-up work:


Got all the crud out that fell in when we took the cover off:


New gasket in place:


Buttoned up and ready to go!




Of course no solution without creating another problem..

While we had the bike on the side, the new oil temp gauge that I screwed into the oil filler hole touched the ground. Maybe it is because the Suzuki skid plate that I have on there now doesn't have "ears" like the Utah Sports one, but for now I won't recommend it for offroad riding (where the bike will likely rest on its side at some point):

Cracked one day after installing, didn't even get to test it once:
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Old 08-20-2008, 07:17 PM   #67
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Old 08-21-2008, 01:06 AM   #68
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You going to lower the footpeg mounts on the beast?
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Old 08-21-2008, 04:40 AM   #69
macdesign
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[Switched back to the 21" Excel wheel since my Brembo 2 piston caliper only works with a 300mm disc and not the 320mm that will go on the 17" wheel. You can also see the new white lower fork guards:




[/quote]
Lukas, as a matter of interest what didn't fit with the 17" wheel/320mm disc/Brembo 2 piston caliper combo?
I ask because I have a KTM front end (like yours) that I am about to marry to a F650GS hub/Excel 17" rim combo (ebay special that I couldn't resist!). No disc as yet.
I haven't bothered measuring anything up yet but a few spacers and some appropriate size (F650GS OD / KTM ID) bearings should do the trick. As far as the disc goes, we have a disc manufacturer here in Oz that will make any size you want off an AutoCad drawing.
Thus the reason for my original question.
To use a 320mm disc I imagine that all one needs to do is replace the bracket which "ties" the caliper to the fork leg with one, machined out of stainless or 6XX or 7XX series heat treated aluminium, that places the caliper 10mm further out.
Finally, as always thanks a million for taking the time to share your innovation and work with us. Cheers
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Old 08-21-2008, 09:25 AM   #70
LukasM OP
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Quote:
Originally Posted by NordieBoy
You going to lower the footpeg mounts on the beast?
I have a set of Fastway pegs in the low setting on my bench that I will put on this weekend. I am going to check how that works, but it is likely that I will cut and weld them about 1/2" lower or so like Max did.



Quote:
Originally Posted by macdesign


Lukas, as a matter of interest what didn't fit with the 17" wheel/320mm disc/Brembo 2 piston caliper combo?
I ask because I have a KTM front end (like yours) that I am about to marry to a F650GS hub/Excel 17" rim combo (ebay special that I couldn't resist!). No disc as yet.
I haven't bothered measuring anything up yet but a few spacers and some appropriate size (F650GS OD / KTM ID) bearings should do the trick. As far as the disc goes, we have a disc manufacturer here in Oz that will make any size you want off an AutoCad drawing.
Thus the reason for my original question.
To use a 320mm disc I imagine that all one needs to do is replace the bracket which "ties" the caliper to the fork leg with one, machined out of stainless or 6XX or 7XX series heat treated aluminium, that places the caliper 10mm further out.
Finally, as always thanks a million for taking the time to share your innovation and work with us. Cheers

The only reason why it didn't work is because I didn't have the appropriate caliper bracket for the 320mm disc. Actually I had one (it is a factory KTM part stock on some of the older LC4 Supermotos) but I decided to sell it as I will use the Brembo 4 piston caliper with my Supermoto setup.

By the way, the one in the picture is the wrong one as I has 65mm spacing for the bolts - KTM Duke and new LC4 Supermotos have a different fork leg that doesn't require an intermediate bracket. EXC and some LC4 need a bracket and the 40mm spacing caliper. Don't ask me how I know...





Your plan should work no problem. What size is the axle on your BMW hub and what size is the KTM fork leg? If your wheel bearings are larger than the axle it is indeed very easy to just have some bushings turned with the smaller ID as I did earlier. The other way it not so easy as you either need a custom axle that is thinner in the middle or use a 17mm KTM axle and have some slotted (so that they can still be clamped down) bushings machined to fit the smaller axle into the larger fork legs.

When you have some measurements from the front brake disc, get back to me. Amongst my piles and piles of parts I have a new Spiegler 320mm brake disc for a buddies F650 Rallye project that never got off the ground. I was supposed to sell it for him a while ago, maybe we can work something out.

It's floated, cadmium plated, anodized center ring etc. Serious piece of kit from a German racing company:

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Old 08-22-2008, 05:37 PM   #71
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When I was working on the next few things unfortunately I did not get to take too many pictures. I was supposed to leave on a trip through Switzerland, Italy and Austria the following day. Had a 36h marathon in the garage (shocking how long those little things that you thought would be done in a few hours can take) getting the bike ready.

For the trip, I had to fit some sort of luggage system. I thought I wanted to go with Gobi hard cases so I ordered the SW-Motech side racks. I also found a Hepco & Becker top rack on Ebay. Mounting was fairly easy, although I managed to strip a bolt and took forever to rig something up as there was no way to get a replacement in time.

Rack mounted, since I removed the stock sub-fender there is still something missing for the rear mounting. The stock white fender was spray painted blue with plastic paint - it doesn't hold up well at all.



Alex and my buddy Norb working feverishly on MY bike while I stand around taking pictures...



We ended up fabbing a plate holder out of 1mm aluminum plate, with the bend located so it would bolt to the rear of the luggage rack. This bad picture shows it after one year of use, including many crashes. It survived ok but since it has a crask I am going with a 3mm alum. plate next time:

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Old 08-22-2008, 06:29 PM   #72
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Since this trip was taking place at the beginning of November last year, we knew it was going to be cold. Even here in Vienna slightly above sea level early mornings and evenings were not feeling good in my Gore-tex gloves, so it would be much worse up in the mountains. After lots of reading on ADVrider I decided to get a set of Symtec (also sold by Dual Star) heated grips.





The install is fairly easy if you follow the instructions, here are a few additional tips:

Use some sort of tape to reflect the heat, otherwise the bar will soak it up and your grips will not get very warm. I used 2 layers of electrical tape which held up fine (this picture was taken after 1 year of use):




On the throttle side, the constant movement can weaken the connection of the cable with the pad so it will eventually break off. To avoid this, I made a hole through the side of the grip. Then I looped the cable through it from the outside so that the pull is on the wire/grip point and not the wire/heat connection. Kind of hard to explain so maybe the pictures will help.




Finished throttle side with my new Progrip 714 grips - very thick but quite comfy:


Finished clutch side, Touratech holder for my Garmin 60 CSX also shown:






After I buttoned up the wiring, I put the plastics and the seat back on and started packing. Gobi cases did not arrive in time, so I got some soft Ortlieb dry side and top bags.

Here she is loaded up and ready to roll, 6am of our departure day:

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Old 08-25-2008, 07:34 PM   #73
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If I ever finish this thread (these pictures are all from last year - bike is currently ompletely in pieces again!) I will post a proper ride report. Until then, here are some pics from the trip we took right after finishing the rebuild (version 1.0). I'll try to keep them DR-specific.

View from the rear that shows the luggage setup:





The first mountain pass we had to cross on our way from Vienna to Zurich - near Innsbruck, Austria:






The Fluela pass in Switzerland, only a few km from the boarding school my rebelious little brother has been exiled to:





Getting a bit cold on the Paso Tre Croce (spelling?) in Südtirol, Italy:






That's what I got for showing my cousin how the DR can run circles around his GS:





Riding on the snow sucked with our tires, so when it got dark we decided to stop - Colfoco, Italy:





Just pitched the tent in a big emtpy parking lot, freezing pretty badly by now:




Next morning:



View from the tent:





With clear skies the snow is quite enjoyable and makes for great views:



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Old 08-25-2008, 07:50 PM   #74
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In a gas station we picked up a motorcycle magazine and read about this mysterious pass near our current location. Supposedly it had been closed for a while because of an avalanche. We decided to check it out and found this:





Young, reckless and quite stupid we waited until the work crew left for their lunch break. Then we snuck through the barriers:







We expected a torn up road with mud all over, instead we found this - no cars, great tarmac and LOTS of switchbacks:





From here on it was mostly a decent, with the weather getting nicer and warmer all the time. Definitely more of a late fall scenery than the first part of the trip!









Back home after a VERY enjoyable week - and the Zook performed great:

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Old 08-25-2008, 08:22 PM   #75
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