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Old 06-13-2009, 07:47 PM   #16
LukasM
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Man, I absolutely LOVE these kind of projects. I think it was reading Pyndon's rebuild that inspired me to buy an old DR and do my own here on Advrider.

And I can absolutely relate to the mission creep thing. I have 2 R6's that are completely in pieces because I wanted to have their frames powdercoated and then got somehow held up. Been occupying a very big storage rack ever since.

But all the new bits are looking sweet, you will definitely rediscover your love for the bike once she is back together.

I'll be watching with lots of interest!

Lukas
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Old 06-13-2009, 08:12 PM   #17
RogerDe
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That's a good refinishin job your doin on your Adv, Look forward to more pic's as your rebuild project continues ..Then you can...Ride On...
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Old 06-13-2009, 08:49 PM   #18
Flanny
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Right-on dude! Glad to see you jump-in!

I'm in a similar boat right now...The damn bike is half apart in the basement, and all I wanted to do was change the airfilter after this weekend's dusty ride...

So, I took the airbox apart, and while that was apart I figured I should install my K&N (Pyndon)Pre-Filter Mod...
...but before I could do that, I had to re-locate my Glove-box Fuse-Panel to the upper fairing....
...and since I was doing that, I thought I should do my HID and Driving Lamp install at the same time...
..and while I was doing that, I figured I might as well do the Battery-Terminal extension...
...And while my skid-plate is off and battery box apart, I figured I should install my Mikuni Fuel Pump....
...and since the bike is going to be apart for a couple of weeks, I might as well paint it with the "RR" colours I've been meaning to do...

Mission Creep sucks!
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Old 06-13-2009, 09:16 PM   #19
sakurama OP
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Well you've been an inspiration. The trick is how could I possibly do something different and just as nice? I saw today that you powdercoated the pegs and brake and I've been on the fence about that but it looked nice. I'm trying to decide between full on black out (my usual and favorite) or mostly black with some touches of silver. I'm hunting for a set of carbon cans on ebay right now and am seriously thinking about the exhaust but summer is ticking. If only I was as smart and did these things in the winter - oh, right I was broke and moving...
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Old 06-13-2009, 11:44 PM   #20
Qwik
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Sakurama, If you had anything to do with the Team Incomplete BMW Then i have no doubt your KTM will be amazing when its finished. I lived in the Roaring fork valley for almost 14 years and Followed the build on that bike. I even Spoke to the guy who rides it (You?) via Email a few times. Love That BMW

Tim
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Old 06-14-2009, 04:02 AM   #21
Autostream
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Quote:
Originally Posted by sakurama
... I'm trying to decide between full on black out (my usual and favorite) or mostly black with some touches of silver. I'm hunting for a set of carbon cans on ebay right now and am seriously thinking about the exhaust but summer is ticking....
As a stop gap you may consider de-badging and reversing the Wings so the rivets are on the inside, then and get them polished, they come up looking like something quite different.

Mine are semi polished, but you could almost get chrome like if you had a good polisher (I have short attention span so good enough was close enough)...

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Old 06-14-2009, 04:26 AM   #22
poepol
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What front mudguard are you using Sukurama?Looks carbon fibre.Good luck with the build,looks sweet already.Are you thinking about spraying the plastic too?
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Old 06-14-2009, 04:46 AM   #23
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Hi Tim,

Yeah, same guy. Of course there's also stuff I never finished on that bike (like a sidestand!) and that Rickman behind has been like that for two years - brand new engine just waiting to go. So my record is hit and miss.

This project has reaffirmed how important time in the shop is for me - it's my sanity to come out to our space and just work on bikes. It makes me feel like tackling that Rickman next.

As for the pipes I like that idea but I've dented them so I have to see if that will work. I also have a bid in on a set on ebay and many projects start from winning a casual auction. If I win it I have to figure out a way to do something different with the exhaust and Flanny has me thinking about an underseat tank and K2M has done such a stunning job on his that it makes me think I could tackle it.

Paint has yet to be decided.
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Old 06-14-2009, 08:06 PM   #24
Flanny
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Quote:
Originally Posted by sakurama
If I win it I have to figure out a way to do something different with the exhaust and Flanny has me thinking about an underseat tank and K2M has done such a stunning job on his that it makes me think I could tackle it.
Feel free to PM me...I can give you the run-down on all of the pros (mostly) and cons (very few) of the low exhaust from my vantage-point...
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Old 06-26-2009, 10:41 AM   #25
Pax
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How's it going?

Just checking in to see how this is coming along?

I was sufficiently horrified by the tear down that I'm anxiously awaiting the build-up.


-Pax
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Old 06-26-2009, 01:06 PM   #26
Yellow Pig
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Great Refresh, can't wait to see how it turns out!

Get creative w/ the paintjob.

Thanks for documenting it.

Dan
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Old 06-26-2009, 02:24 PM   #27
sakurama OP
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Quote:
Originally Posted by Pax
I was sufficiently horrified by the tear down that I'm anxiously awaiting the build-up.
Yeah, me too. If I'd known it was going to be so extensive I'd have taken better notes. I got hung up by backordered swingarm bushings and steering head bearings. I could have gotten them somewhere else but didn't think of it at the time but the rest of the bearings are coming from Bearings Direct. The worst is the bearing in the sprocket carrier - $98 from KTM and $4.95 from Bearings Direct.

Anyway, I got the frame on and I'm pulling the other systems together and I'll update more next week. The goal is end of next week since I've got a week with the GF on vacation so it's extended shop time.

No paint - Revit wants me to document our trip to Labrador for the 2010 catalog so the bike can't have too crazy a paint job. That's a relief actually.

So more photos soon.
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Old 06-26-2009, 11:09 PM   #28
Mark950
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I'm in for the rebuild.
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Old 06-27-2009, 08:47 PM   #29
sakurama OP
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Judiaann is in Portland for a week so I'm a bachelor which means today was a big day at the shop. I've had trouble getting over there to work as the five miles can take 2 hours if the traffic is bad - of course if I had a motorcycle it would take 15 minutes...

I wanted to put in a solid day and actually see some progress to encourage me. Earlier in the week I'd put the frame on the engine after putting in new steering head bearings:



This was good. The bike is finally sitting on it's own shiny new center stand. Today I thought I needed to make it look more like a bike so I'd feel like I had the beginnings of a motorcycle. I started with the swingarm which got new guards and bearings:



I then mounted that and started work on the quagmire at the front of the bike; the battery box, relays, and the oil tank. Of course after I mounted the battery box I remembered I had a new fuel pump - two actually as I'd gotten a Facet too but it looked like a hassle to mount and rewire and I decided to put that off for another day and keep the momentum and just replace it with the new stock one I had on the shelf. Then I saw I had a new pushrod for the clutch and thought I'd look into that. The great part of this board is that I don't really use shop manuals any more I just search the archives - in this case Pyndon's thread. I'm glad I replaced this - it's crazy how much it's worn:



From Pyndon's thread to Cyborg's on sealing the rims. I'd used silicon for years but hated how thick it had to be and was excited to try Cyborgs method as I'm always glad to see an improvement to an idea. Here's his method: Here's the link to Cyborg's rim sealing.

So I went back and forth all day from the rim to the parts. Here's the first nipple sealed with the Seal All - looks good:



I did two coats but the stuff seams to bubble up as it dries which is strange but Cyborg mentions small bubbles are okay - I hope so:



By this time I'd done the whole wheel so I'm going to hope for the best and add the GOOP tomorrow and then let it sit for a day or so and by then my new Conti Attack will be here and I'll see if it worked. I'm looking forward to getting a 170/60-17 on that new rim.



So I got the radiator and subframe mounted as well and I'm beginning to run out of clean parts but that's okay because this is now starting to look like a very clean new bike - the basic shape is there:



This is important in these sort of projects and partly why my Rickman has been so neglected - it's just a pile of parts which is too overwhelming to deal with so you put it off. While there's a ton left to do I can now see it all coming together and it's looking good:



I'm hoping to have it together by the end of the week but that might be unrealistic as there are some backordered parts I'm waiting on and there's a lot still to clean. The wiring harness might take a day to sort, clean and reinstall and I'm not looking forward to it but that's okay because I almost have a motorcycle again.



I just need a rear tire and another day and I'll have a roller! Once I get stalled I'll clean up the mess but today was all about making some progress.

sakurama screwed with this post 09-19-2012 at 11:28 AM
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Old 06-27-2009, 10:20 PM   #30
Yellow Pig
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Sweet! Keep it up.
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