Project 525EXC Dualsport

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ElChupacabra

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Continuing....

On the right side the horn is the first obstacle. I removed the fan mounting bracket hoping that maybe I could feed it through the rad guards or maybe something...

525DS4Rad10.jpg


No dice, there wasn't a good way to fit the bracket through so I had a sudden brain-flash. Why not just take the speed nut off of the bracket and mount it on the rad guard. Why not? Too perfect!! Just big enough slots.

525DS4Rad11.jpg


That done, I could mount the rad guard. I was really pleased overall how quickly these guards mounted up, and how sturdy they are.

525DS4Rad12.jpg


The next fly in the ointment is the cooling fan. The EXC does not come with a fan, and they will boil the coolant out if you are stopped behind other riders on a tight trail or just plain 'ol stopped in traffic. The cooling fan is about a $86 option if ya buy it from Munnracing.com or a $156 option if ya buy it from your local dealer you bought the bike from. Guess which one mine is? You can't see it in the photo but mine is the one that comes with the 24k gold bearings that is autographed by Johnny Carson.
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My brother needed one too, so I ordered him the $86 one. Thanks Chip!

525DS4Rad13.jpg


I removed the fasteners, and placed the rad roughly into place and marked the place where the rad cross brace interferes with the fan shroud.

525DS4Rad14.jpg


What? You don't like my Spongebob pencil? What can I say, I have 2 little kids.
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525DS4Rad15.jpg


Some well placed cuts with the saw, and snap the pieces of plastic out with a pair of pliers. Test fit, trim a little more, then mount in place.

525DS4Rad16.jpg


Here it is with wires attached, ready for the heat!

525DS4Rad17.jpg


Hornall mounted up to the speed nut on the rad guard - super cool. ( as cool as those :ymca lookin horns are)

525DS4Rad18.jpg


View from the pilot's seat

525DS4Rad20.jpg


All ready for a good old fashioned drop on some boulders.

525DS4Rad19.jpg


Not necessarily next, but will be coming soon:

525DS4MarkerPrev.jpg

(deja vu!)

Just ran out of gas (figuratively) last night, and couldn't finish the rad post. It took as much time to post as it did to install everything. From start to finish it was about a 90 minute project, although I had some interruptions. Not too bad considering. Next time (my brother's bringing his 450EXC for the same surgery) it should be about 45 minutes or less.

Post done, for now, time for my reward.
Guinness03sm.jpg
 

joker650

Active member
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Nice post Paul......Did you have to update the charging system to allow for the fan?
 

Hooligan

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.....and soon afteryour brothers450EXC, will I bring my 450EXC around for your attention....:tup:...I got my new larger tank this week.

BTW,

Have you got any idea how much weight you added with all the goodies?

:hb:
 

Island Hopper

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It's starting to look congested under your tank, just like the Adventure. Those rad guards look pretty slick, lots better than the plastic ones.
 
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ElChupacabra

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joker650 wrote:
Nice post Paul......Did you have to update the charging system to allow for the fan?
No, there's enough for the fan. I do plan on upgrading it though:ted:so I can run my electric vest and maybe some heated grips in the future...

Trailtech flywheel with stronger magnets and maybe rewind the stator myself. Boy do I have time to kill...
 
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ElChupacabra

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Hooligan wrote:
I got my new larger tank this week.


Nice, is that the KTM MXC tank & seat? Or aftermarket?

Hooligan wrote:
Have you got any idea how much weight you added with all the goodies?

Valid question.Answer: No idea.

But!I haven't increased the "unsprung weight" at all yet. (Wheels, tires, swingarm, hubs). So the only increase in weight has been sprung weight (Frame, motor, skidplate, etc... and of course the biggest sprung weight factor: RIDER!!)

I have managed to shed ~10 lbs since late November so I could bolt more shit onto my bike!! Woohooo !! It's all part of my fiendish plan. So NET I have probably only addedless than apound to the EXC.

Hehe:mb:smartass.

Simply put: need more kit for your bike, have less pints, eatmorefruits & veggies, and go for a 5k run every other day.:tup:

I will weight the bike without fuel when done and compare to the delivery weight of 247? lbs.

FWIW, my 640 Adventure never felt heavy unless I was picking it up off the ground:?. It's a power to weight thing.

Cheers!
 

HeadinSouth

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When the tank gets thrown on and the beer holder that thing is gonna be a beaut.

Looking good.
 
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ElChupacabra

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HeadinSouth wrote:
When the tank gets thrown on and the beer holder that thing is gonna be a beaut.

Looking good.
Well, I'm pretty sure it's getting a ProMoto Billet rear rack - but I haven't seen their beer cooler add-on yet. There's one for a chainsaw! But what about dem suds?
 
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ElChupacabra

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kitchencabinet wrote:
nice thread. where in abby did you find the grease that your using?
k.
Canadian Tire, in the grease aisle!I tried Lordco &KMS - no dice. Its where all the fuel additives are located. They use it for boat trailer bearing packing because of its higher water resistance than normal lithium based grease.
 

skidmark43

Administrator / BFF in the blue jacket
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ElChupacabra wrote:
kitchencabinet wrote:
nice thread. where in abby did you find the grease that your using?
k.
Canadian Tire, in the grease aisle!I tried Lordco &KMS - no dice. Its where all the fuel additives are located. They use it for boat trailer bearing packing because of its higher water resistance than normal lithium based grease.
At Lordco, you have to ask a counter person to get the good grease out of the stock-room. "Red Ram A-Complex with Paratac". This stuff is the sh!t - Beyond boat trailer applications it is designed for low maintenance, wet & dirty conditions - the grease of choice for marine, logging & drillingequipment, as well as highway rigs, agricultureetc. "Aluminum complex-based grease with exceptional tackiness; it will not wash or hammer out".

I recall it was less than $10 at Lordco after our club (thanks Chris!) discount.
 
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ElChupacabra

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skidmark43 wrote:
At Lordco, you have to ask a counter person to get the good grease out of the stock-room. "Red Ram A-Complex with Paratac". This stuff is the sh!t - Beyond boat trailer applications it is designed for low maintenance, wet & dirty conditions - the grease of choice for marine, logging & drillingequipment, as well as highway rigs, agricultureetc. "Aluminum complex-based grease with exceptional tackiness; it will not wash or hammer out".

I recall it was less than $10 at Lordco after our club (thanks Chris!) discount.
:?I did ask at the counter, and they showed me to the shelf where they had 1 kind of plain jane lithium grease.:(

But now that I know exactly what to get, I will be good and specific next time.

Awesome, thanks skidmark!!:clap:

Paul
 
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ElChupacabra

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busboy wrote:
Good Morning Paul:525 looks great! Time to ride
"...I wanna ride, I wanna ride, I wanna riiiiiide - I want to ride!..." 10 days and I'll be road riding, 3-4 weeks till I'm offroading. Hopefully. You have no idea the amount of restraint it took not to throw a leg over the bike today after I installed the new G2 Ergonomics billet throttle tube and throttle cam...
 
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ElChupacabra

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HeadinSouth wrote:
Tank yet? You ready to sell me your bike yet?
:dr:
What??? I really haven't ridden it yet!! No, the tank's not here yet...:( Couple weeks it should be here, which should coincide with me being physically able to ride again!:tup: Better, stronger, faster! Sell it? I'm gonna ride it like I stole it!
 
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