Project 525EXC Dualsport

[joker650]

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Island Hopper wrote:

You've most likely had this move planned for quite some time as you seem to have everything covered. Has it got a keyed ignition? Down around where you live it would seem you would have to worry more about security than up this way. It's always nice to not have to worry about your bike being stolen if you leave it for a few minutes to go for a coffee or something. Only bike I had stolen was in the dealers possesion at the time, thieves broke in and moved 30 bikes to steal mine.

Knowing Paul ..this bike will have all the options plus a few extras installed.

Last year on a ride out in the midle of nowhere, Paul sent my son some e-mails of how the ride was going!.................... what a GEEK....but a kool GEEK!:tup:

 

[ktmken]

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Looks good, can't wait to see the end product, all "adventurized"

KTMKen

 

[640in604]

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Island Hopper wrote:

Has it got a keyed ignition?

Not as stock in North America. But there is provision for a hidden kill switch and you would need to keep a disc-lock handy I think. Or maybe "the club" hehe.. It is a different story for sure, compared to being 350+lb with locked steering you don't worry so much.

Island Hopper wrote:

Only bike I had stolen was in the dealers possesion at the time, thieves broke in and moved 30 bikes to steal mine.

Mean people suck.

 

[640in604]

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ktmken wrote:

Looks good, can't wait to see the end product, all "adventurized"

KTMKen

OK, after much therapy I'm willing to admit that I'm not just "dualsporting" the 525, I'm "adventurizing" it as Ken pointed out.

I know I must seem like amental deficienttaking a dirt bike and making a "KTM 525 Adventure" out of it. Why sell the 640 Adventure in the first place?:shoot:

It takes about 2 minutes to swap gas tanks back to the stock small one. The wiring harness is designed such that the signals, horn, headlight, etc... all unplug in a matter of minutes from the main wiring harness if you wanna go "MX Woods Racer Commando" and be back around 250lb again. I couldn't do that on my 640 Adventure, and for about 10 rides a year I wished I could.

The 525 Adventure will not be close to the Adventure bike the 640 is, but that's the trade off for being able to convert it into a dirt bike when needed.

My therapist says I'm making excellent progress, the first step was admitting I have a dualsport problem. The next step is "actualization": build that Mutha &^$#@! and ride her like I rented her!! :wi:

I'm expected to make a full recovery.:tuplenty of medication though :hb:

-Paul

 

[640in604]

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I'm even looking at the Cee Bailey dualsport windscreen for long rides like Mexico

Again, removeable in 5 minutes to stick with my program.

-Paul

 

[640in604]

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joker650 wrote:

Knowing Paul ..this bike will have all the options plus a few extras installed.

what a GEEK

How about an TAZER hooked up to the safety wire on my handgrips for anti-theft? Someone with bare hands that tries to roll my bike away without disabling the Tazer gets barbequed!!!!:wi: Mmmm barbeque.....:tup:

 

[HeadinSouth]

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Can I get some more info, if you have any, on the DRZ in that pic? Looks like someone set up a DRZ SuperMoto for touring.

 

[640in604]

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Sorry, I just nabbed that pic from Cee Baileys website.

 

[HeadinSouth]

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Thanks.

 

[Hooligan]

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So Paul,


Couple questions:
That 25L tank, what did you pay for that ifI may ask?:shock:
Do you have to replace the stock seat with that tank?


I just bouth the 13L KTM tank....for a whopping $450incl. my "prefered client discount".......:tup:......and I have a new seat coming....

Looks good,Imight do this to the 450 at some point......I however feelmy bikes should never overlap in functionor purpose.....that would be possible grounds for selling one...:shock:...

:hb:

 

[640in604]

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The stock seat works fine with this tank, it is designed for the EXC (I'm told). The tank retails for $419 CAD I believe, so I got a little discount from that. My Enduro Engineering Tall/Soft New Saddle was only $129 US, and seems pretty nice. My brother has the Corbin which is super nice too.

 

[640in604]

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Sort of light day at work today, so I had a chance to play in the garage a little. I got to work on the tail end. First I drilled 2 holes for the rear signals wiring harness to feed through to the underside of the fender. This pic is looking at the underside, the little hole in the middle is to drain trapped water from the taillight access area on the other side.

There is a reinforced portion on the edge of the fender where the turn signals should mount to.

I used these as a guide for drilling my holes.

The big hole on the right is for the threaded portion of the signal post, and the smaller keyhole to the left is so the signal won't rotate on you.

The end of the signal matches, see?

Matched up to the holes, and assembled using the supplied washer, nut and lock washer. Notice the post is hollow? That's where the wiring goes - duh.

Repeat for the other side, then test fit the sub fender.

Lookin good so far. I just have to remove the signal lense covers and lenses, feed the wires through the hollow posts and attach the connectors. While I'm at it, I'll seal the 2 piece lense holder where mud/water can ingress.

See this one on the 640? I just figured out how it is getting in there, and I'll advise the new owner on how to seal them up when he takes them apart to clean them.

All that mess is on the INSIDE of the lens cover, not the outside. The cover is clear on the 640, with an orange cover over the white bulb...

The turn signal post with the lens holder removed.

The new "duct tape"

Re-assemble the two pieces.

That's a little gooey lookin, so I'll just remove the excess. It's no piano.

But it'll do. Reassemble the signal completely, the remount the rear fender.

That is one sexy rear end!!:mb:

I don't think I've seen a nicer tail... well, you know where I'm goin with that...

Next up, get the handlebar switch mounted for signals/lights/horn etc...

 

[Island Hopper]

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Light day at work,yeah right! Any excuse to get back to tinkering with the 525. It's funny how a new bike can occupy so much of your thoughts through the day, my bikes already been around for a while and it's still the focus of some daydreaming. Keep her coming I'm interested to see whats next for the orange one.

 

[joker650]

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joker650 wrote:

Island Hopper wrote:

You've most likely had this move planned for quite some time as you seem to have everything covered. Has it got a keyed ignition? Down around where you live it would seem you would have to worry more about security than up this way. It's always nice to not have to worry about your bike being stolen if you leave it for a few minutes to go for a coffee or something. Only bike I had stolen was in the dealers possesion at the time, thieves broke in and moved 30 bikes to steal mine.

Knowing Paul ..this bike will have all the options plus a few extras installed.

Last year on a ride out in the midle of nowhere, Paul sent my son some e-mails of how the ride was going!.................... what a GEEK....but a kool GEEK!:tup:

It was bound to show up Paul.

Your ultimate add-on:tup:

 

[Hooligan]

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or a525RALLY ? :tup:

 

[640in604]

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Hooligan wrote:

or a525RALLY ? :tup:

Pretty much w/o adapting the frame for the 660 Rallye tanks and front fairing.

 

[640in604]

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Beautiful sunny day Saturday, everyones out enjoying themselves on the bikes, and I'm still sidelined with an injury... so...

On with the show. Get this bike dualsported already!! The basic "dualsporting" will come first, then will come the "adventurizing". I have the back brake switch, lights, and signals. I am getting anxious to try the switches and lamps out to make sure I haven't made any wiring errors. I can't really re-assemble the rear end properly until I know I haven't fugged it up somehow.

Front brake switch, is this cute tiny little switch that has a cool sealed plunger meachanism. The switch has a couple little posts on the side, why?

Well, I'd say this is why. Cool! Take off the brake lever dust boot, and behold!!! Two little holes there.

The little sealed switch just snaps right in, then reinstall the dust boot and viola! The lever when pulled releases the switch and it's normally closed contact should cause the rear brake lamp to light. The switch is normally depressed (plunger held in) by the brake lever when it is released. The reach of the lever is adjustable however, and I'll have to see if the plunger is being "plunged"? enough to keep the brake lamp off...

After removing the existing "kill" button and it's wiring harness I grabbed the multifunction switch pieces. Admittedly the multifunction switch: horn, kill, hi/low/off beams, turn signals - was a bit confusing to assemble. There was a couple pieces, and I hadn't realised one of the pieces of the puzzle was still sitting in a plastic bag in the box - whoops

. I managed to solve the puzzle before I picked up the phone and had a hissy-fit all over the kind Cyclezone people. It was just a "hard-of-thinking" moment...

Not enough lager I suppose.

:

Crisis averted, I finally got to start adding the first of several pounds of wire ty wraps. I would love to get some black nylon spiralwrap to cover the various wiring harnesses properly. I had used the regular clear/white spiral wrap on my Adventure wiring harness to protect it from vibration abrasion and pinches. So I got the cables all under control and tied down where they can't vibrate and catch on anything. Also, aesthetics is EVERYTHING lol.

Under the one fastener for the speedo mounts the flasher relay, and it has its own corresdponding connector on the harness.

Time to mount the little lenses for the turn signal and high beam idiot lights. Insert the TINY little bulbs and then bung up the lenses with the bulb holders. Everything is a snap, click fit, which is nice and simple. Keep the tools in the toolbox, I say.

Another couple pounds of ty wraps and we'll put this baby to bed.

 

[640in604]

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I'm serious about going mental with ty wraps, once I get started I can't control myself. I probably added 4 lbs of plastic in ty wraps

I'll just ty wrap that fan connector out of the way until I'm ready to mount the fan (1st service - or maybe I'll just do it next).

I set the tank on temporarily, connected the fuel line, pulled out the choke and pressed the starter. Nuthin. Cripes!!

What have I done??

Oh yeah, forgot to connect the ground lead on the battery

Press starter, and she fires right up!

So I quickly test the signals and horn, kill switch, high beam etc... Was I surprised when I found that there is an OFF position for the headlamps (shhh don't tell anyone, that's my stealth mode).

Got the rest of the body work put on and she's ready for action (as soon as I get a mirror or two and mount the plate). I took her for a quick spin around the neighbourhood, the exhaust is stock and terrifyingly loud in the suburbs. I love it! All the signals worked, turns out I had to adjust the brake lever so the brake light wasn't lit all the time.

The 640 Adventure in the background was picked up by the new owner today - I need a moment...

: and a tumbler full of Glenmorangie. Talk amongst yourselves. Congrats on your new bike sagot, enjoy!

The "END" of the dualsport section, more mods to follow

 

[joker650]

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Paul there is a pic of all the plug-ins behind the #(er... headlight)plate. Did you happen to use dielectric grease on any of the connections? I find it helps eliminate bad connections due to corrosion over time. It keeps all the moisture out.

Nice job buddy:tup:

 

[ktmken]

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That is going to be one sweet adventure bike, Keep them pictures coming.

KTMKen