Yet another WR450... Rebuild. - Page 2
Page 2 of 2 FirstFirst 12
Results 51 to 90 of 90

Thread: Yet another WR450... Rebuild.

  1. #51
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Oh yeah, a friend of mine bought a GasGas EC300 that is street plated, maybe one day he will be making a thread in here He rides in the forest a lot though.

    Got it from the same dealer I got my Seat Concepts from.

    He's coming from a 1993 XT350, should be a little bit of an upgrade Haha.
    Attached Images Attached Images

  2.  
    Advertisement
  3. #52
    Join Date
    Jul 2008
    Location
    chicago area
    Posts
    273

    Default

    it will be 100x easier to find the correct clutch lever than to try to make a cable work with the wrong one

  4. #53
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    I ordered a cable spacer.

    Clutch lever works fine.
    Attached Images Attached Images
    Last edited by Borg; 01-16-2017 at 02:33 PM.

  5. Remove Advertisements
    SuperMotoJunkie.com
    Advertisements
     

  6. #54
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    So I ordered a brake fluid reservoir from China for $20...


    Laughed my ass off when I opened the box.
    Attached Images Attached Images

  7. #55
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Got some Axle and Bar End sliders from Mr.Bellamy here on SMJ.

    Might need to get some peg sliders now.
    Attached Images Attached Images

  8. #56
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    So I bought an adapter for my caliper.

    This project is ending up costing way too much

    Gonna try and get some bolts and washers to get the brake all setup tonight.
    Attached Images Attached Images

  9. #57
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Attached Images Attached Images

  10. #58
    Join Date
    Apr 2015
    Location
    Gordon's Bay South Africa
    Posts
    56

    Default

    Nothing better than the right parts for the job.
    TM Racing....

  11. #59
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    I've had this threaded bar end kit sitting around for a while now... decided I should install it finally.

    The inserts don't fit as tight as I had hoped, tons of slop in the threads, but I used epoxy when I installed them, so they should be good forever regardless.
    Attached Images Attached Images

  12. #60
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Finally picked up the right hand guard mounting kit... they sent one for 7/8" bars for some reason, even though I asked for 1 1/8"

    Also, anyone have any better ideas for mounting the brake line? If I mount it up into the fork guard, it sticks up REALLY high and looks stupid.

    I made a little tab thing to hold the line inboard for safety, but not sure if this will be final routing or not.
    Attached Images Attached Images

  13. #61
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Thumbs up New

    I am new to supermoto but to me it looks like you are doing a great job......These post really help with building mine....Thanks
    Jack

  14. #62
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    No problem, good luck on your build.

  15. #63
    Join Date
    Jun 2016
    Posts
    43

    Default

    Great build! Keep it up!

  16. #64
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    So I finally got my dye tank setup.

    55 Gallon oil drum, cut the top off of it, drilled 2 holes for a water heater element, and hooked it up directly to 220v power.

    For some unknown reason the fender, and rad shrouds didn't turn out very well.. but the gas tank did, so I guess it's a win.


    I gave up and ordered black shrouds, side panels, and rear fender... I don't want my bike to look all purpley after this much effort.

    Can't for the life of me figure out why the gas tank turned out so well, oh well, that was the important bit anyways.
    Attached Images Attached Images

  17. #65
    Join Date
    Jul 2005
    Location
    Chicago
    Posts
    1,269

    Default

    If I send you a tank do you mind coloring mine black? Mine is clear right now. I will pay you to do it and cover shipping costs. I am in Chicago. BTW the build looks great.
    2014 KTM 1290R SuperDuke
    2012 KTM 500 Sumo

  18. #66
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Not interested, because I can't guarantee that colour tank will turn out black.

    Contact Aljo, or get RIT Proline Disperse dye.

    Worse case it doesn't go completely black... and MAYBE adding more dye and dying it multiple times will make it black.

    I dyed 3 different colour items with a 1/2 oz sample.

    White turned grey.
    Natural colour turned mostly black.
    Blue turned black with a factory look, except the fender and rad shrouds I tried it on failed. But my first sample fender piece turned out perfect.

    If you have access to a very large cook pot and a gas burner, you can just dye the tank on one end and then flip it and dye the other end, it will turn out all the same most likely.
    Attached Images Attached Images

  19. #67
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    I polished the dyed tank a bit, I honestly can't figure out why the tank turned out so well, but the other bits looks like crap.
    Attached Images Attached Images

  20. #68
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Anyone have ideas on trimming the number plates to make the bike look more modern? I put all the plastics back on and was thinking about it.

    I have black number plates coming in the mail though.

    Was also thinking of leaving the white ones on and getting very bold 666 numbers to put on just for fun.
    Attached Images Attached Images

  21. #69
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Well it's nearly done.

    Gotta bleed the front brake, and tidy up a few things, and install the muffler.

    Definitely getting new tires sooner rather than later.
    Attached Images Attached Images
    Last edited by Borg; 02-24-2017 at 05:47 PM.

  22. #70
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Thumbs up Nice

    Looking good..............................................

  23. #71
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    It started snowing again here...

    I pointed the exhaust out the back door and started the bike up, you know.. to make sure all the wiring mods I did work...

    Man I miss that thumper sound!

  24. #72
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    So I had the ignition cylinder zip tied to the handguard mount...

    Decided I need to make a nice aluminium plate to hold in instead.

    Dremel, drill, tap, and about 30 minutes later, I came up with this.

    Really happy I did it, looks so much better than when I had it zip tied, Haha.

    To top it off, it's quite solid, feels proper to me.
    Attached Images Attached Images

  25. #73
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Bled the front brake finally.

    Did it without any fancy tools, just a piece of tubing with a zip tie on it, an 8mm and 7mm wrench.

    Lever feel is similar to the FTE master, this is a Brembo 16mm master from an R6, with Chinesium Pazzo Knockoff levers.
    Attached Images Attached Images

  26. #74
    Join Date
    Oct 2014
    Posts
    1,972

    Default

    Alright already get that exhaust pointed out the back door. Get her up to speed and do a stoppie in the den. Video is mandatory. style points for grabbing a donut with your teeth off the dining room table. BMX helmet might help there.

  27. #75
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Better wait till the wife isn't home for that one, might need a camera man for that.

  28. #76
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Maiden voyage was good till I went to leave my friends house.

    No spark...

    Somehow the bike made it to his place, then the soldering job I did broke while the bike was sitting.

    Pulled the stator out when I got home, yep, broken solder joint.

    Re-soldered it, with a crimp connection in place, fired right up.

    The bike rides so much better with the suspension more leveled out.

    That front brake... wow... I didn't do any stoppies, but damn, it's got nice one finger power.
    Attached Images Attached Images

  29. #77
    Join Date
    Oct 2014
    Posts
    1,972

    Default

    Borg, didn't you ever learn the golden rule of motocross racing? Make sure it makes smoke before loading it up. It most likely broke from the vibration sitting at the back of the bus.

    Those "Rizoma" brake bits doubled the braking forces.

  30. #78
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Quote Originally Posted by lloydstrans View Post
    Borg, didn't you ever learn the golden rule of motocross racing? Make sure it makes smoke before loading it up. It most likely broke from the vibration sitting at the back of the bus.

    Those "Rizoma" brake bits doubled the braking forces.
    Haha.

    How does it smoke if it won't even run?

    It broke before I loaded it up on the van.

    I still can't believe I ordered that reservoir from China for $20, it's quite well made.

    Can't wait to take some new pictures of the bike all finished in some fancy places again.
    Attached Images Attached Images

  31. #79
    Join Date
    Oct 2014
    Posts
    1,972

    Default

    The thing is just prior to loading it up, fire it up and make sure it runs. Better than getting to the track, setting up your pit, and then find out it won't run just prior to first practice.

    Yeah, I got some killer looking stuff from China and some real crap too.

  32. #80
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    I think you missed the point, I rode the bike to my friends house.

  33. #81
    Join Date
    Oct 2014
    Posts
    1,972

    Default

    Aah, thought you had it on the back of the truck. So your wiring lasted only a couple heat cycles?

  34. #82
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    Quote Originally Posted by lloydstrans View Post
    Aah, thought you had it on the back of the truck. So your wiring lasted only a couple heat cycles?
    2 heat cycles Haha.

    I used the crimp that Baja Designs provides, and filled it with solder this time.

    Rather than soldering the 2 wires together and just heat shrinking.

  35. #83
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    The more I look at this exhaust, the more I wish I didn't buy it, and just bought an FMF.

    Why did you do this Leo Vince? Why must I modify it to not look ridiculous?!?!

    Game plan..

    Drill rivets out
    Flip the silencer around so the mounting bracket is closer to the rear of the system
    Shorten mid pipe
    Cut off excess silencer to that it lines up with the mid pipe
    Weld nuts to the inside of the end cap for easy re-packing
    Re-assemble and not look ridiculous
    Attached Images Attached Images

  36. #84
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Thumbs up Pipe

    Pipe is a little long, but bike looks nice. Get those tires yet?
    Jack

  37. #85
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    They're supposed to ship at the end of the month.

    Then I'll hopefully make a video destroying the Diablo Rosso tire on there now Haha.

  38. #86
    Join Date
    Aug 2011
    Location
    Fergus, Ontario
    Posts
    352

    Default

    So my tires are apparently 2 weeks delayed... thanks Michelin.

    Went out for a proper ride today.

    Swapped in a YZ rear shock for the firmer damping, feels very equal now front and rear.

    2006 Pirelli tires are super sketchy in the cold... was pushing it a bit keeping up with a guy on a DRZ400, and ended up 2 wheel drifting a bit, puckered pretty hard when that happened.

    Overall very happy with how the bike turned out, the front brake is phenomenal! If I ever sell this bike, that front brake is coming with me to the next bike 100%
    Attached Images Attached Images

  39. #87
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Thumbs down Nice...................

    Nice...........................

  40. #88
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Default ??????

    Not sure how the thumb down showed up.....It was to go the other way .....LOL
    Jack

  41. #89
    Join Date
    Jan 2015
    Posts
    12

    Default

    NICE job! love the WR400'S. Aside from that exhaust looking really long.... the bike looks killer!

  42. #90
    Join Date
    Jan 2012
    Location
    Valley Springs, Ca.
    Posts
    104

    Default Nice

    Bike looks really nice.....Look even nicer with some Michelin power rs tires........LOL.....Those tires should be good. Again your bike looks really nice.
    Jack

  43.  
    Advertisement
Page 2 of 2 FirstFirst 12

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •