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Old 07-31-2012, 10:22 PM   #106
150ron
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Very nice, you did a great job on all those parts, and i think the bike looks much better and cleaner now with the white and black and all those stickers removed, good going!!
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Old 08-01-2012, 03:59 AM   #107
Joe Watson OP
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nah, I am not setup for alloy welding unfortunately. I have to get a mate to do it for me.

The bike is a little wider in the knees, but not overly bad. If I was just using it for single track and that sort of riding, I would leave it with the stock tank. But because I do all the different riding on here, I like the big tank. Not too bad for the tight stuff, just don't fill it right up.

Thanks for the kind comments. There will be some big changes in the coming weeks! Excited!!

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Old 09-04-2012, 02:05 PM   #108
SpeedStar
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Hey Joe, I was reading through your WRR build thread and was watching your Monofail vid and noticed I was hearing Hilltop Hoods as a double-play. I was playing them on my iPod while watching your vid that has them in the background. Small world - looks as if we have similar taste in music too.
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Old 09-04-2012, 08:18 PM   #109
simonpig
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I had the same experience as you when I tested out the 4.75. The vacuum fuel pump wasn't picking up the fuel from wings. Sent the tank to IMS and they gave me some crap about tank foam getting clogged and in the fuel filter. I'm no mechanical god, but I could see that as soon as some air got into the line, the fuel line pressure dropped enough so that it wasn't pulling the fuel up. Decided I didn't like the tank anyway, so I sold it. Just my experience. I bought the 3.1 instead. Others have said they could use the fuel to the last drop?

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Everything was where it should be, checked the piping for the vacuum pump and all was well there. I tried blow/sucking on the line to make the vacuum pump work and it kinda did, but it would not work when connected to the bike....... So e-mailed IMS about it and the leaking bungs in the wings which I had to fix like four times. They said they would see what they could do about it.
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Old 09-05-2012, 03:33 AM   #110
Joe Watson OP
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Speedstar: Yeah mate, they are a local Aussie hip-hop group who I love! I should really update my Mono-Fail vid one day cause I can mono reasonably well now!

Simonpig: Yeah, my second big IMS tank is a little better, but is still does not use every drop, I was riding today with about 2L or so left and it was cutting out a bit.
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Old 10-10-2012, 07:12 AM   #111
Rapid Dog
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Question

....you the chap that had the Staintune for sale over at the WR Forum?...
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Old 10-11-2012, 02:52 AM   #112
Joe Watson OP
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Yeah mate, that sold a long time ago.
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Old 11-06-2012, 01:18 AM   #113
Joe Watson OP
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Been a long time since I have updated here, so here goes with all the stuff over the last few months:

Started the big changes with going all white plastics:



KTM front guard:





Some gold rim tape for a bit of bling:



Some new folding levers, much shorter, really quite good:





Lack of adjustment on the brake master cyclinder though:



New front guard fitted:





New levers:





Low guard.........nah:





Setup of the new tail with foam tape where factory put it:



All new white plastics (Except headlight, not needed for future fairing)












So then continued on with my rally bash plate making:









Fitted a rear rim lock as, due to lack of care and attention, let the rear go so flat I ripped the valve stem!!



Took a bit of balancing!!





Heading off for an overnighter:



New front braided brake line and new brake fluid front and rear:







Bash plate all welded up (THANKS DRJOE!!!!!!) My welder is not set up for alloy unfortunately!





Making the lids:







Fitted:









Beginning to sand and polish everything:



Latches for bash plate mounting:



Cleaning down all welds:



Inside:



Sealed with silicone just in case:





My buffing setup, cheap, but very very effective!!















ITS A MONSTER!!!!!













Nope, that is going to rattle around WAY too much!!



Winner:



Now onto the bloody pesty leaking fork seals!!















This was such and easy and enjoyable job, I would NEVER pay anyone to do it ever!!

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Old 11-06-2012, 01:43 AM   #114
Joe Watson OP
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So it was now time to get onto the serious job of doing a full fairing and nav tower, not a minor job to undertake by any means!

Sourced some decent headlights:



Fit like a bloody charm! Also some indicators fitted too:



Cad drawings........computer modelling......CNC machines..... Nope!!! Some old steel, set square, tape measure and pencil and paper mate!! It's the Aussie way!!



Head gear all removed:



Removing the ignition barrel:









Now for Nav tower mounting:





Yup, real mans stuff!!












The scariest part of the whole job!!! PLEASE BE IN THE RIGHT SPOT!!!













Bugger, not enough length on the outward prongs, start again!!



Sealing up to make sure no dust or water works its way into the headstem:











Thought I should replace the plug while I had the bike apart too, lucky I did check it!!



So now with the Nav tower mount on, the bike can go back together:



Started making the side fairing mounts:























Got a suitable sticker made up for the bash plate:











Quite easily fit this in just one side of the bash plate:




Ok, so it was now onto the Nav Tower plates:











Light mounting:









Getting there!!

















Front mountings for the fairing:









Trimming the fairing to suit the lines of the bike/fuel tank:















Relocating the OEM instrument panel:









GPS mount/Roadbook mount:









Wiring and heated grip switch mounting:



12V outlet mounting:





Painting fairing:














So, the fairing is mounted from four simple screw head bolts, so it is easy to take on and off. I own a van, so it has to come off each time for transport.

It's maiden voyage!









Then it was time for a bit of stickering up to make it look the part:











Then it was off for 3000+ kilometres to test it all out. Performed flawlessley. Man I LOVE this bike!!!!










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Old 11-06-2012, 01:45 AM   #115
Cruz
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Nice work Joe.

What are you going to work on next?
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Old 11-06-2012, 01:53 AM   #116
DRjoe
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Well done joe.

No why the bloody hell are you trying to sell it.
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Old 11-06-2012, 03:47 AM   #117
Joe Watson OP
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Joe: Just bored I guess LOL. Happens far too often with me. I finish something, get bored and move on to the next thing.

Cruz: So far I am thinking KTM530, Berg 570 or the new WR450F.

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Nice work Joe.

What are you going to work on next?
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Well done joe.

No why the bloody hell are you trying to sell it.
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Old 11-06-2012, 11:47 AM   #118
Tomdog
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Love your work Joe (and your workshop).
Well done.
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