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Old 09-19-2012, 06:19 PM   #46
RuggedExposure OP
wandering the desert
 
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Joined: Apr 2011
Location: Hermanas, NM (on the US/Mex border past BFE)
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Here is what I ended up with:



Instead of installing a 10x24 bolt, I decided to JB Weld a stud in place and see if that works. If it doesn't I've found a source for a new TM33 for less than $220.

First I removed the head off of the bolt and filed it down to a flat surface:




I then place the newly made stud into what remained of the threads to see what it looked like:


It turns out that that there were enough threads left that the stud will actually sit in place and hold somewhat of a load.
I then installed the lever and spring to assess the situation again.
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Old 09-19-2012, 06:24 PM   #47
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I wanted to check the clearance with the cam that the cable ends attach to:


Turns out it barely touches, so I filed off a little more and checked it again:


I wanted to make sure I could install all of the pieces correctly with this stud permanently in its new home:


Here is everything in place, and the stud is holding its own in the remaining threads. This is a good sign


I removed the pumper lever and spring, mixed a small amount of JB Weld and positioned the stud in the threads:


Now to let it cure over night and see how it works tomorrow...
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Old 09-20-2012, 11:34 AM   #48
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Love me some two part mix.

http://mrpulldown.blogspot.com/2009/02/epoxy-night.html
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Old 09-20-2012, 06:15 PM   #49
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I handle the legislative work for our state off road organization here in Ohio. I get several calls per year from people who started to convert a bike to street legal and were stopped dead in their tracks by employees at the BMV or title office (separate in Ohio) telling them it can't be done, or telling them the WRONG procedures. I then call the office they are having trouble with, tell them what form they need to provide the owner, re-educate them, and if that fails I have a contact in the main BMV office for our state that I bring in. Whatever state you are in, contact your state off road association for help when this happens! The staff at the AMA also has good info, and in some states ABATE will also be able to help. There is almost always a way to do it rather easily, although I have no experience with NM.
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Old 09-25-2012, 09:06 PM   #50
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Quote:
Originally Posted by muddyrabbit View Post
I handle the legislative work for our state off road organization here in Ohio. I get several calls per year from people who started to convert a bike to street legal and were stopped dead in their tracks by employees at the BMV or title office (separate in Ohio) telling them it can't be done, or telling them the WRONG procedures. I then call the office they are having trouble with, tell them what form they need to provide the owner, re-educate them, and if that fails I have a contact in the main BMV office for our state that I bring in. Whatever state you are in, contact your state off road association for help when this happens! The staff at the AMA also has good info, and in some states ABATE will also be able to help. There is almost always a way to do it rather easily, although I have no experience with NM.
Unfortunately New Mexico has put an end to the days when one could easily make a dirt bike street legal. They have included a specific clause stating that if the title, MCO or any sticker on the motorcycle says 'offroad', or if it has ever been registered as an Off Highway Vehicle, if can NEVER be made street legal. Even if the owner or a shop makes the necessary mods to make it conform.

You will have to register it in another state or take the route I did to get it street legal in NM.
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Old 09-25-2012, 09:14 PM   #51
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Joined: Apr 2011
Location: Hermanas, NM (on the US/Mex border past BFE)
Oddometer: 1,211
I got the carb back together, and had to take it apart several times to adjust the tuning. I opened up the airbox during the rebuild with a 3"x3" hole and assumed it would have to be a tad richer. So I put the needle clip in the 4th postion from the top and the bike ended up having a bogging problem at throttle tip in.

So I moved the clip back to stock position. It ran a little better, but still had a slight bog at cruising speed. I finally moved it to the 2nd position from the top and the bike runs great now.

I also put in a new airfilter, some Shinko 244's, and some Moose bark busters with the metal band.






If you notice in the right side of the last pic you'll see the old rear knobby tire... It was so old and hard as a rock that I could not get it off with tire irons or a pry bar. So I ended up cutting it with a saw. Sometimes you don't have time to mess around with crap.
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Border Road 100 Border Road Rally Raid
'13 Husky Terra 650, '08 Kawasaki Meanstreak 1600, '95 DR350S
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Old 09-25-2012, 09:28 PM   #52
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Quote:
Originally Posted by RuggedExposure View Post
Sometimes you don't have time to mess around with crap.
Well said!

Bike's lookin sweet man. Envious of that headlight. And nice work with the DMV issues. It's very easy here in Michigan, a homicide detective inspected mine

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Old 10-02-2012, 06:33 PM   #53
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Location: Hermanas, NM (on the US/Mex border past BFE)
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Since this bike will soon be used for commuting about 100 miles/day (30 miles rough road), I have been looking at pannier racks. I wanted something along this line:


But didn't like the price tag. So I made my own:


Solid steel tubing, pretty stout material but not too heavy.


Here it is with the ammo cans attached. these cans are a little bigger than .50 cal cans


I have no explanation for the random corgie chasing my dog in the background.



I was going to weld on some extra supports for the ammo cans in case of a fall, but got to thinking that I'd rather have the cans collapse or the bracket than the sub frame. They are getting painted black as I post this.

The cool thing about my design is is the cans get trashed, I can always bolt another set right on. Or if I want smaller/larger ones, I can change it up easily.
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The fear and dread of you will fall on all the beasts of the earth

Border Road 100 Border Road Rally Raid
'13 Husky Terra 650, '08 Kawasaki Meanstreak 1600, '95 DR350S
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Old 10-04-2012, 12:55 AM   #54
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Location: Hermanas, NM (on the US/Mex border past BFE)
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Waited for the paint to dry, put them on and gave them hell around town and on crappy roads today. Everything seems fine.


Then I loaded the bike down with 5 days worth of camp gear. Clothing, food, water, sleeping bag, etc and gave it hell. Made it 70 miles in the dark in one piece.
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Border Road 100 Border Road Rally Raid
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Old 11-14-2012, 07:57 PM   #55
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Great story.
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Old 11-15-2012, 01:42 AM   #56
Sierra Thumper
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This is one of those stories where he fought the law, and HE won I've never saw anybody so determined to get a dirt bike street legal.....I think he's going to savor his victory
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Old 11-15-2012, 01:56 AM   #57
orangebear
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in the uk as long as its over 10 years old and you can get paper work to prove the age then you just make it road legal and then grind off any thing that saids off road only.
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Old 11-15-2012, 02:56 PM   #58
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Location: Hermanas, NM (on the US/Mex border past BFE)
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Quote:
Originally Posted by Sierra Thumper View Post
This is one of those stories where he fought the law, and HE won I've never saw anybody so determined to get a dirt bike street legal.....I think he's going to savor his victory

and savor I did

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The fear and dread of you will fall on all the beasts of the earth

Border Road 100 Border Road Rally Raid
'13 Husky Terra 650, '08 Kawasaki Meanstreak 1600, '95 DR350S
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Old 11-15-2012, 03:08 PM   #59
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and savor I did

Dude.......thats amazing.
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Old 11-15-2012, 03:50 PM   #60
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and savor I did

Nice!
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