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I am rebuilding the old dual sportster and making some tweaks along the way. here it is before the crash. It worked out very well and has been to the end of the road in InuviK NWT Canada and in Deadhorse, AK. I love the motor, and ended up ADVing around the nation for about two years before I had a major crash on it which destroyed the frame among other parts and I spent a few days in the hospital. So what we begin with here is a destroyed ADVsporter and a 95 XLH with a blown motor. I do not believe the rebuild will be anything like the old bike, but we'll see how it turns out. This time around funds are very limited so the build will be on a tight budget. Just as a refresher here are a few pics of the last version
dual sport mode
adventure mode
I was glad to find a complete bike just in case I needed some parts. When swapping a sport motor over you have to change wiring harness as well so after several hours I had the harness swapped. It needed several connectors repined as I was working with the 95 lights and controls.
I had to pull the blown motor out and now I have a spare in case I need parts or want to build a stroker
I have replaced the awful buck-horn handle bars and changed out the hideous seat, tossed the sissy bar and have done a little cut and weld on the exhaust. The thunder header I have been running is striaght and they do not offer one that is angled up at the muffler and I thought that they should, so I did it for them. Not much just enough to add some clearance and and style
just want to throw this pic in as she has made it in a few magazines not as an article just as a shot from a event I went to. Take what ya can get
I took the bike on a 400 mile test run to make sure the motor is still working well and my wiring holds up. All worked well and the engine is still in good shape last travel pic of it in a semi stock shape
. The rear of the bike has now been striped.
I cleaned up the extended swing arm and got it ready for mock up. I am looking at balancing this bike out from a suspension movement stand point and not focusing so much on maximum travel. So with that in mind I set out to get some swing arm angle numbers and playing with travel numbers from the shorter stroke.
here we are with the set up as I had it pre crash. We are at 18* angle at full extension. and 10.5" of travel
So the plan is to get the angle closer to 10* If I shorten the shock up 1" then I come up with a 12* angle at full extension. Not bad:deal
As you look deeper into the whole swing arm travel you will find a good balance of travel and I have it here. From full extension to full compression I end up with 12* of swing arm angle in both cases. That is as balanced as it gets. Now when I factor in the suspension sag I end up with 8* angle when riding and we have a great set up with no chain rub. with this I still have 8.75" of travel which is a respectable number and I have lowered the seat height 1.5" which is also good.
dual sport mode
adventure mode
I was glad to find a complete bike just in case I needed some parts. When swapping a sport motor over you have to change wiring harness as well so after several hours I had the harness swapped. It needed several connectors repined as I was working with the 95 lights and controls.
I had to pull the blown motor out and now I have a spare in case I need parts or want to build a stroker
I have replaced the awful buck-horn handle bars and changed out the hideous seat, tossed the sissy bar and have done a little cut and weld on the exhaust. The thunder header I have been running is striaght and they do not offer one that is angled up at the muffler and I thought that they should, so I did it for them. Not much just enough to add some clearance and and style
just want to throw this pic in as she has made it in a few magazines not as an article just as a shot from a event I went to. Take what ya can get
I took the bike on a 400 mile test run to make sure the motor is still working well and my wiring holds up. All worked well and the engine is still in good shape last travel pic of it in a semi stock shape
. The rear of the bike has now been striped.
I cleaned up the extended swing arm and got it ready for mock up. I am looking at balancing this bike out from a suspension movement stand point and not focusing so much on maximum travel. So with that in mind I set out to get some swing arm angle numbers and playing with travel numbers from the shorter stroke.
here we are with the set up as I had it pre crash. We are at 18* angle at full extension. and 10.5" of travel
So the plan is to get the angle closer to 10* If I shorten the shock up 1" then I come up with a 12* angle at full extension. Not bad:deal
As you look deeper into the whole swing arm travel you will find a good balance of travel and I have it here. From full extension to full compression I end up with 12* of swing arm angle in both cases. That is as balanced as it gets. Now when I factor in the suspension sag I end up with 8* angle when riding and we have a great set up with no chain rub. with this I still have 8.75" of travel which is a respectable number and I have lowered the seat height 1.5" which is also good.
My secret spot in the woods, not accessible by cars.
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