BMW K75gs RTW bike build
 

BMW K75gsa......


This thread is about my vision to design and build a Travel Bike using the three cylinder 750cc bmw K75 engine. It's a long term project and the end goal will be a touring bike for two to go off on a RTW trip, a motorcycle that has been custom built with its primary objective being overlanding with a no compromise approach....


Feel free to comment with advice, constructive criticism or general banter...





Cheers MEZ :scooter:

There is a vast amount on the web about the K100/75 motors/clutches/gearboxes on the web. Lots.

Chief failings - motor ...
Water pump. By now I suspect they all have the stainless steel shafts.
Monkey nuts. Rubber drive to the alternator, they ware out.

Clutch .. easiest thing to do is replace it and you know where you are.

The K75 motor is a sweet runner. Pity they did not take it to a 4 valve. And put motronic rather than jetronic EFI on it. Someone put the DIY EFI on one ... megasquirt IIRC.

Warin nice one mate, exactly what I need, info..!! I could also beam trawl the net but personnel input always better..!!
The alternator anomaly again in detail plz...???


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There have been several attempts by various people to create a K75GS which may be the sort of thing you are looking for. The only photo I can lay my hands on at the moment is this:

Hi Magnon, yes there are lots of pics on goog-im, I know the set up of the bike I'm building just haven't ridden a K75 or more unforgiving have dismissed them over the years...!! I'm after the weak points so I can iron them out from people who have owned ridden experienced...!!!

Mez


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K100 and didn't have it long but you are welcome to the info here:


https://sites.google.com/site/yorksh...rogues-gallery


Weakpoints? Can't think of many. The fact they are all ancient and honestly not made of the best materials can be an issue, but that's just a bike thing. I'd move the fuel filter to an external position if likely to become blocked and make sure the previous owner had greased the drive shaft. The wiring includes some mad features like a brake light test which just add complexity and result in failed annual inspections in the UK.


If you get one with a rectangular air snorkel the later round one will fit. This can be fitted with a pod filter, thus you can bin the BMW air filter and not need to remove the engine on service day or employ child labour to get the telephone directory sized lump of paper out through the rock-drummer auto-biography sized gap between the frame and airbox half.


Andy

Check out this old thread:
http://www.horizonsunlimited.com/hub...0-1200-a-29697

Starts out as a R bike thread ... but ends up as a K75 thread.

Old K75's are super cheap here in the USA ... even ones in really good shape.
Like $2500 to $4000 usd range. I always liked the motor, know nothing about it.

Seems to me it's too heavy for an off road travel bike? :confused1:
Obviously ... it can be done (above threads prove that) but will you be happy? :innocent: Riding a heavy bike in tough conditions is NO FUN. But some need to learn everything the hard way .... and they always know best! :rofl:

Go ride one. They are not light. They are smooth. Can be economical fuel wise.

You want the details .. google bmw k bike technical .. leads you to BMW K-Bike Motorcycle Tech Page

I forgot about the fan .. fit an over ride switch .. operate it a minute or two before you stop the bike ... that exercises the fan, cools the motor so it reduces the heat soak when you stop.

The photo shows a Paul Rooney special.

Seems to me it's too heavy for an off road travel bike? :confused1:
Obviously ... it can be done (above threads prove that) but will you be happy? :innocent: Riding a heavy bike in tough conditions is NO FUN. But some need to learn everything the hard way .... and they always know best! :rofl:[/QUOTE]

The weight isn't an issue here, I've put a fully loaded gs12adv in places that some wouldn't dream of hence my choice and disregard, thanks for the other stuff mind..!!

The learning curve is the engine, keep it coming gents, big thanks cus just like Tesco's, "Every Little Helps"...!!!!!!

Yea ... your right! You are, of course "always right!". Ride on mate! bier
Far as places I wouldn't dream of ... I think I saw you there! I even got a pic!
https://lh5.googleusercontent.com/-n..._AUqeC-M-1.jpg

https://lh3.googleusercontent.com/-x...enR1200GSA.jpg

https://lh3.googleusercontent.com/-2..._KntQM-L-1.jpg

https://lh3.googleusercontent.com/-P..._UKmns-O-1.jpg
So convenient ... with "easy pivot" cylinder for easy 180º rotation!
:thumbup1:

https://lh5.googleusercontent.com/-1...26_XKBCH-L.jpg
This will be the 5th pick up today dude! you owe me big time!

Mol old bean, you need to stop being a penis seriously, find a different site bud ok... I can only assume by your geographical misfortune that you are judging GS riders by your own BMI & offroad incapabilities so keep your trigger happy friendly fire mouth for someone who gives a f#@k...!!
Apologies to others on here for this garbage...!!! ;~]


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Mez-o, as it happens.......! That comment I made will no doubt cause a stir but truth is ( if were gonna turn this into a GS war ) I love my 12adv to bits, it's a hooligan tool with slight off piste capabilities. I also love my XL600 and no doubt will love these K's to bits..!!
I would imagine quite a high number of GS owners would back your comment up mind, big old debate always on simmer.. ;~]


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Gentlemen please. If we are going to go all ADV rider at least start a thread about Britney Spears wardrobe and Dunkin donuts.

The K100 is an odd combination of Japanese 4 Peugeot buzz box revvyness and BMW ride. Not very R bike like IMHO, so definitely try before you get into all the work.

Andy

I ran K100 for a couple of years commuting covering some 70k miles with only one rear shock failure. I've ridden a couple of 75s which are smoother and buzzier but a bit weak by comparison.

I would say that a k75 suitably adapted would make a good rtw bike if it's ridden with a rtw attitude. If you are looking for a bike for extreme off road then as you say it will be much too heavy - no matter how much of an off road god you are.

Well I for one hope that this thread stays vaguely on topic rather than ending up as a slanging match with people flouncing out because I'd be interested to see what Mezo comes up with.

I know a K75GS has elements of silk purse and sows ear about it but trying to make it work as a project has been one of my if "I had more time and a better workshop" ideas. People have RTW'd on the most unlikely bikes - a 75GS seems like one of the better constructs.

Andy your so right..!!! Britney Spears naked & smuthered in donut icing riding a bespoke RTW K75gs offroad over the woopydoo's section....... We digress, nah I'll be fine mate, riding the bike isn't the issue, ultra reliability is what I'm seeking plus the engineering challenge that lies ahead..!!


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Backofbeyond, is this the very same B-of-B I met at the 2013 Elephantreffon Rally, you pootled up on a B120 ..???


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Mezo I think B-o-B meant Mez not Mezo....!!!!!!!


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Wow, ur Pops knew his stuff then, I like the old stuff also but can't get away from the fact that the GS is a fantastic bike. I bought my '06 GSA from new & will never sell her. Don't like any of the models after '07/08 ?!?!
I'm shipping one of the bikes to OZ eventually as part of the master plan but as we all know plans can go to rat shit yeah..!!!


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Small world isn't it!

This bring back any memories -

http://i145.photobucket.com/albums/r...psa30755d3.jpg


Latest project on the B120 - thinking ahead to next winter and trying to make a set of ex Land Rover snow chains fit.

http://i145.photobucket.com/albums/r...psf1a08ed3.jpg

Yes indeed...!!

We owe you an inertube also...!!! (Mark does anyhow..!! XL600..??)

So your fancying the same build..?? I had one bike back then, I now have two, doing a side by side build in prep for 'the big trip' some time in the near future. There will be plenty of pics posted on the build so keep em peeled..!!!

Mez

Yes, it's always amazed me that the tube held out. If you can blow them up that much and they survive I'll just pack some bicycle tubes for the bloop in the future:thumbup1: :rofl:

I was all set to go to the Alt-Elephant at the Nurburgring this year on the Suzuki but we had a DIY crisis at our flat in France so I went down to the Alps instead. I've applied for a place on next year's TaurenTreffen which is what the snow chains are for.

Re the 75GS, post up your work in progress - the good, the bad and especially the ugly. :eek3: :rolleyes2: After the XLs if anyone can make this work you can!

Lol...!!! Yes indeed, thanks. Ironically I played that video clip you took on utube last night, I've built a few specials in my time but these 'K' bikes are really getting my juices flowing I can tell you..!!
Always in your debt, Mez...!!!!


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Wait a minute, nobody told me I couldn't take a GS around the world!! Otherwise I wouldn't have done it!!

And I feel like I'm missing out of the big boys gang because my rear drive hasn't failed.........or anything else.

It's so unfair. I'm always the last to know :blushing: I might as well give up riding and become a forum "expert"

No wait a minute I'll go for another ride across Russia. Now which one to use? The GS, no the rear drive will fail. The "83 Tenere? no that's too old and won't make it. The XT660z Tenere no apparently that's underpowered and too heavy too.

Oh god it's all too depressing jeiger

Now back on topic. I loved my K75C but in this order

The fuel pump went (well was gone when I bought it)
The water pump shaft and seals went.
and the tank rotted through at the lowest point (damned condensation in FNQ tropics)

But apart from that the engine just kept on going, and was so smooth.

I did see one in Elizabeth Street in Melbourne once that had been modified to go off road. Looked a bit funny but it was covered in mud so the guy that owned it must have thought it worked.

Good luck with the build and let us know how you get on.

Chris

Hi Chris, I both squirmed & pissed myself there, that was a cracking retort & oh so fkn true..! I'm on all 3 sides of the fence here, again it's a statistic thing but I'm glad you made us all choke on our own words..!!
What I'm doing is a contradiction in terms really, why leave a GS12 and zoom off on a home brew jobbie when not only you but an awful lot of others also have done the same ?? God knows..??!!!!
Don't care really, I love building bikes, check out Doug Wothke's Harley off-roader ?!!!! For me it's all about the building of the bike & I reckon I've chose the best engine/doner bike to kick off.. As for wieght of the thing, I reckon yourself Chris can also vouch about chucking a 12 around the loose stuff, tyres are the all saving grace here.
Thanks for the snippit of info, another 'tesco' moment...!


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To condense, run with what you've got and have a complete blast doing it:thumbup1::thumbup1:

TM1-SS, correct attitude cheers bud..!!

First hurdle for the early stages yesterday, the KTM (50mm) yolks don't have enough 'offset' for the frame. Gutted, can't use them and no way round it, found some Apprilia Caponord 1000 50mm yolks that should surfice, there's a whole front end up for grabs but want to run with the KTM 50mm extreme forks...!! I'm sure this will be just one of many hiccups in proceedings if past experience is anything to go by...!!!! :oops2:

It starts to take shape here with some very rough draughting going on..!! Tubes are being cut n bent and some ally sheet folding too...!!!

Looking good Mez!!:thumbup1:

Beautiful start! :thumbup1: Keep it UP! bier

Sort of reminds me of this custom bike:
https://lh3.googleusercontent.com/-v...0/IMG_0034.jpg

K75s
 

Hi I put over 70,000 miles on my one, in its first year.

Eventually the Drive shaft failed (sheared)- but gave me about 200 miles notice, I just wasn't listening.
You should replace it regardless, motobins sold me a welded one for less than £100 fixed in 30 mins.
The Pinion joint is considerable more expensive - check it out to establish what condition it is in as this is one of the deal breakers on the bike, if its in any way imperfect, buy a different K75.

The "weak" points are:
1) The (very old bike's) indicators electrical contacts inside the handle bar housings worked intermittently.
2) The Engine Oil cap has a habit of not being replaced and if you don't put a piece of string on it, you may loose the cap, but its surprising how far you get before noticing, and the cap remains on the engine, where you left it...
3) The exhaust is bloody heavy, and low, and an absolute pig to keep clean.
4) The Tank isn't really ideal and you get rattles, when your knees are in contact with it at certain rev's.
5) The Disk rotor's, rust (if you buy the cheap ones)
6) Initially it may appear intimidating to work on, but this is rapidly overcome as you realise the simplicity of it.
7) Most of the plastic screw attachment points will have become useless and need rebuilding. These body plastics screws will have rusted too.
8) the Brake lines are very old and as with the Hydraulic brakes will require a sound service

Its an awesome bike, considerably superior to the K100 range. But it will be old and though an advanced bike for its age, you really will feel the age compared to a modern bike.
It would be a labour of love to make one into an adventure bike, when in reality you are better off just getting an XT

As a power plant, the Engine is inconveniently heavy for your kind of project, and reliant on and efficient water cooling system. There is fairly good reason why BMW themselves have not made a K series GS.

If I remember correctly the engine itself becomes an integral part of the chassis - or am I getting confused with the big Triumph? Not sure this is a great option for a bike you plan chucking around bad roads on.

The weight will be fairly high, and very thin so righting the bike with a raised suspension will be... well I'm not going to help you.

If you are looking for a rock solid mile munching winter bike, I couldn't recommend a k75 more. I sold mine with over 137,000 miles on it, and in all honestly it will easily do another 100,000 miles.

K75gsa
 

This guy is a frame specialist and this is his first attempt at a tank, done rather well i'd of said.......

That tank should be Really Cool looking when it's all faired and smoothed!

Find an R65gs and get the 50bhp upgrade, then spend a bit of TLC on the suspension... I've seen people do interesting things on these machines, so why even bother spending fortunes on improving on something which can never be made to work.

....

Because I don't want a boxer engine :)


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Great project.

I agree with TM1-SS that the tank is looking really good.

Glad to see people working for their own vision even if it's not the well-worn path.

"Never made to work"....:nono:
Watch this space my friend, the fabrication guy who I'm working with is ingenious and will create exactly the bike I'm after.....

In the meantime has anyone dealt with Gletter.de quite recently..?? Herbert isn't responding to emails and I need one of these....

Gletter is not very good at e-mails. Fax(!) or phone works better doh

Very interesting project:thumbup1:

MEZ, I called in down the workshop the other day to see Colin, saw your bike again - its certainly different a bit mad really but very cool in other ways and its coming on well. I'm not so sure on your pannier ideas personally, but hey ho we all go our own way - and I am sure you will be very happy as one things for sure you will get what you want - no matter what other peoples views may be and that sir is very much at the heart of a build like this. I hope you can sort out the Gletter shaft extension - I had mentioned it to Colin a few weeks ago when I first saw your bike - but was not sure if he does the extension for the K series as the shaft is different. If not no doubt Col will make one. When I done the HPN project (at Colin's place) I allowed myself to have a few changes - to fit in with other peoples ideas - namely the rack area on the rear sub frame - and that was one area that never quite worked for me - so stick with what you want then if it does not work you can only point the finger one way. By the way the new owner of my HPN rates it as the best bike he has ever owned - so that speaks a bit for the strength of fabrication and quality of build done down on the hill. I will maybe bump into you down there one day as I often call in for a cuppa with Col and rob.
Tchus Jake.

Hi Jake, thanks for those words, we will indeed bump into each other no doubt down at Colins. As for your words of wisdom and encouragement, thanks..!! Colin will indeed deliver exactly what I want in a very high quality format wether right or drastically wrong, the pannier system I have envisaged will indeed come in for some drastic critism but tbh I dont give a flying fcuk what other people think or say. I've built several specials in the past, none of them have been based on compromise or basic idea's. I'm just so glad that I went down the 'Hill' and started asking around who was capable at my engineering demands..!!
Looking forward to meeting you and chating about your adventures Jake, in the meantime lets have a snapshot of your HPN rep on this thread yeah..?!!!

MEZbier:scooter:

Here are a couple of pics of the HPN rep built from my old r80gs I sold it due to a major spine injury now a year post surgery I am back riding (gently) and have just restored an Elefant from a crashed non running pile of shite to a great handling and fun to ride machine. I will be staying on the road now though the back cant take any big falls and I fall off a lot on the dirt.
The BMW starting point http://i1244.photobucket.com/albums/...psc76b1642.jpg
the finished project - there were a lot of bits in between the fabrication was done mainly by rob in colins workshop colin worked out some of the frame build physics and did the paintwork along with some other bits and bobs. [=http://s1244.photobucket.com/user/rallyejake/media/P5140131-1.jpg.html]http://i1244.photobucket.com/albums/...P5140131-1.jpg[/URL]
The elefant starting point stripped and in the corner (I had at this photo stage rebuilt the heads and barrels were ready for the engine build)http://i1244.photobucket.com/albums/...ps3e105639.jpg almost finished http://i1244.photobucket.com/albums/...ps961d36fe.jpg and done a great little rider over the moon with herhttp://i1244.photobucket.com/albums/...ps5e6610e9.jpg Tchus jake

I also just refitted the original seat after recovering it - bugger of a shape but it turned out well after a bit of sweating, pulling and stretching to get that material into place. http://i1244.photobucket.com/albums/...psb3e6371c.jpg Jake.

The REP looks bloody nice mate have to say, who built the rear sub-frame..??

Mez, rob built the rear sub frame (Rob lives in colin's rented flat ) he is often in the workshop, The rear rack was removable by sliding out of the frame. The sub frame like the chassis was very very strong and the sub frame with the double braced side struts was very stable even side to side it would not move so a good basis for heavy panniers if needed, the seat locked on perfectly with a seat lock, and it had a massive toolbox underneath (see photo) but for me was the one area in the bike that went too modern away from my idea of how the whole package should have ended up - I have very classical slant towards the way bikes look. Some pics:
Making the sub frame and fabricating the underseat storage http://i1244.photobucket.com/albums/...ps4d24685d.jpg and the finished box powder coated (without its lid on which was a waterproof lid, the box acted as the rear stone / mudguard to protect the batter box area and worked very well it was nice and secure under the seat. It was 10 inches deep about 6 long and 5 wide, so very handy - ye gads I regret selling that bike now ! (even if the paintwork was a tarts handbag) - it would soon have battered down to a nice used finish.http://i1244.photobucket.com/albums/...psfa5340b6.jpg The new owner has about 10 bikes and classic cars - he rates this as the finest of his bike collection, and has used it in a few classic trials !!!, the engine on the bike was superb for a gs, I had it rebuilt in germany at motoren israel at the time it cost quite a bit but the payoff wasthat it was very smooth, produced most of its torque from 2000 revs It has a lightened and balanced crank, Balanced con rods (balanced over entire length to each other, steel lined oil pump, 296 enduro camshaft with a bronze bushed bearing,1000cc piston upgrade (siebenrock), gas flowed and twin plugged cylinder heads,2 twin tower dyna coils, one piece rocker/valve gear, deep oil sump, nissan starter motor, K and N air filter, SGS high torque exhaust, Endurolast alternator and twin spark electronic ignition, heavy duty clutch. The gearbox has High top gear and lower first. The engine puts out about 65 bhp and has 73nm torque measured at the back wheel at 2000revs.

Jake, yeah have met Rob and purchased some GS bits off him that will be grafted onto my project bike, 'The Hill' and Colins w/s is a great find for me, itching to get back onshore now...!!!! To make you feel good I have to say I don't think I've seen a better looking Airhead Special than yours, giving the HPN camp a run for there money there bud...!!!!!
I'm at that very earl stage of 'Dry Build' , things tacked together and loads of offering up, sucking through teeth and scratching of chins etc etc...
I need to source a local T & W electroplater....????

Mez

Hey MEZ whats happening with the special - I have not been to newcastle for quite some time and have lost track with your bike I will try to call down next weekend - 20th sept. By the way your Yamaha build was also superb i take it you shipped that home with you. Jake.

K75gsa
 

Hello Jake, been offshore with no wifi, its a killer tell thee....!! Yes the project is coming on slow but sure, Colin is very thorough in his approach to work, the drive shaft extension issues have been sorted & we have a direction now. It will drift into next year I feel...!!! The Yamaha project you were looking at is a Honda...!!! Sorry, couldn't resist that one...!!! Not sure what to do with that bike yet..!!

Sorry Mez - Oop's must have had a brain meltdown I thought xt600z Tenere's were Yamaha' s !! and the badges on the engine and fairing - Yamaha - disguise the Honda input very very well - But then again its all japanese to me. :confused1: Jake.

Which bike was that..?? Think that was Mezo from OZ, a Brit Mez that chipped in this thread earlier on so your eyes weren't deceiving you..!! I thought you were on about my XL600 bike down Colin's workshop ??


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K75s
 

You might like to look at Paul Rooney's website. rooneycycle.wordpress.com
He has built a few RTW bikes with a K75s engine. He recommends the 75s for it's weight and power. I was going to have him build one for me but health problems intervened.

Progress
 

Some progress has been made. The all important rear wheel issue has been resolved with just the CNC stainless rear calipar bracket to pick up from the machine shop. Tank is also 90% finished. Out of tank fuel system buttoned up bar the auxiliary fuel pod. Engine will be tackled when the frame goes to paint. Wheels are out of this world have to say, very pleased with the finished product. Swingarm/driveshaft has successfully been extended by 50mm, please don't ask how much the 4 titanium studs cost me ok...
Now it's the turn for the whole front end to be fabbed. Iv'e gone for some radical thinking here so more pics in several weeks time.


MEZ

Here is a K75 (GS) I saw in OZ:


https://lh5.googleusercontent.com/-4...0/OZ_1-022.jpg

More Progress
 

Slow but sure progress being made. Electrics are causing a few challenges but getting there....!!!

That's looking good Mez...:thumbup1:

Fuel/electrics pod now in place.

Hi everyone, I'm Robert from Poland. I'm building BMW K75GS now and I have a question to MEZ. How did you solve a problem with rear wheel? The oryginal one is centered on the motorbike but 1150gs rear wheel is moved to the left side of bike. Thanks

:-)

I need three posts to send a message :-)

Used to be 5, perhaps still is.

Mez...don't sweat the paranoia.

The K has flaws like any other bike...and some have been covered on here but the following are worth repeating...

Final Drive(check the splines), tank(check the bottom front corners for weakness/rust), fuel pump(they go, carry a spare), fuel pump wiring disconnect(crappy connector-replace it before it gets flaky and kills your pump), fairing bracket connector to frame(re-enforce it), rear shock(upgrade your shock and a stiffer spring), lower weight fork oil on the front, and Metzeler ME 88 Marathon on the rear, with ME 880 on the front.

The rest you can figure out.

edde

Road tested and very happy with weight distribution aspects especialy front end, only issue was seat height was too high but overall very pleased..!!

Wow! That's quite a beast.

K75 Adventure Bike
 

Been busy and it's starting to look usefull..!!

So its been a while.....
 

Getting somewhere now, integrated luggage system starting to take shape. Rear cubby box is my favourite piece of engineering so far, love it...

:D:D:D
Excellent work! Beauty! Love the boxes:thumbup1:

But I still worry if your K75 is ever taken into rough country, riding over corrugations (washboard) or worse. Not only will be hard to handle once fully loaded, but Stuff can shake apart, crack, or other wise fail.

I just ran my Ducati Hyperstrada over 15 miles rough dirt roads .... it is now dead. Not sure what or why, but suspect failed fuel pump. It's a street bike and I should never, ever have set foot on dirt with it. Now, what is the K75?
And what does it weigh fully loaded for travel?

Heavy street bikes get even heavier when loaded up with metal boxes, luggage and whatever else you strap on there to travel (kitchen sink perhaps :smartass:

And, if you look at the long iist of potential failure items MotoEdde has listed below, well, IMO, it's quite daunting and Edde would know. (RTW on a K75)

For me? My "new to me" Ducati is up for sale. This was my first longish ride on it ... and it crapped out. Done.

My DR650 has over 60K miles of very harsh dirt roads/two track, Desert rocks and lots of high speed road road work at 75 mph as well. Not ONE ISSUE beyond normal, basic maintenance.

Review again what Edde wrote way back when:
I think for a road based ADV bike your K75 will be tits. But I would not take it too far from home or off road. But that's just me ... spoiled by Japanese long term reliability. :D

Hello AGAIN Mr Mollydog, your thinking way too offroady here, I am taking the wife with me on the journey and in no way will I be skimming the wash board tops and certainly not anything at great speed. I will however be doing logging roads, off the beaten tracks when it feels right, off the main road river locations etc etc you know the score but the sort of stuff you wrecked your Duke on ???? No thanks not on a RTW trip...
As for the panniers , you would have to pick one up to realise just how surprisingly light they really are.
With reference to MotoEddie's post, my bike is so far removed from a standard K75 its only the engine issues that relate and final drive.
Anyhow, there's a new build i'm starting that would get your juices flowing and again it involves fabrication intervention. It's a cracker and only 3 of them exist so far, 2 in the states and 1 in the UK..... Watch this Space..!!

Can't' wait to see what you come up with! :thumbup1:

BTW, my Duc WAS on a forest service road! :w00t: Granted, it was in bad condition, even the paved sections were brutal. I could not avoid one the millions of Sharp edged Pot Holes (in shade) and nailed it at 40 MPH. BAM!!

Thought I'd broken my spine! ... or at very least bent a wheel or cracked the frame. No damage (except to me!)

You've probably done more RTW travel than I have ... but in my mostly USA/Mexico/Centl America experience I find that the dirt road that can start out nice and easy can somehow transform into a nasty nightmare.

Bad corrugations can happen anywhere there are UP HILL sections, not so much when flat. California is ALL Mountains. UP DOWN UP DOWN ... all day.

Water Crossings? Deep Sand? Rocky Tracks? These conditions are everywhere and can sometimes get tough and sometimes can't be avoided if you want to go off road.

And what about Mud? Sometimes you can't avoid it either ... even on roads that are normally in good shape. I struggle in mud on my DR650 and could not make some on my former VStrom 1000. (mud jammed front mud guard ... wheel would not turn and jammed up around hugger/swingarm too. Once free, I had to turn round.

Your new boxes are works of art :D and I'm sure as light as you say. Problem is
once you LOAD THEM UP! :oops2: Now add on a tail box, tank bag.

One Baja ride years ago a couple of KLR guys were over packed, using Alu Boxes. They really struggled even in relatively easy sections. On that one Baja ride we had a Chase Vehicle following along or taking alternate near by tracks.

On DAY 2 of this 14 day ride BOTH KLR guys off loaded their Boxes into Chase truck. Lucky for them the Chase truck showed up each night at our motel. Even KLR's get heavy and I'm thinking that K75 Brick is no light weight power plant.

In EU perhaps off road Forest tracks may be maintained. In much of USA and
for sure California ... they can be a bit nasty on a street bike.

Going slow helps of course but sometimes it's good to maintain some momentum, depending on your gearing and terrain.

My Ducati has such HIGH gearing that doing super steep up hill 90 degree switchbacks on super loose dirt I nearly stalled it. Slipping the clutch not easy on this super grabby clutch with about 1/2" of engagement range.

I did not fall ... only solution was to speed up hope I don't tuck the front. Don't think I could have managed it TWO UP. Low gearing a BIG plus for any UPS and DOWNS of any consequence. We rode on 9% grade yesterday and the Duke Hyperstrada (and me) suffered. Lets see the new bike when you can! bier

CRF500L Dual Sport Hybrid......
 

This should be in the Honda section but just answering your intrigue here....


Basically been itching to get back to off-roading and have for some time fancied a midrange parallel twin engine instead of a 'Thumper'. Went on ADVR and found my answer.... Honda CRF500L


I have bought a 2016 CRF250L donor bike with light rear end damage and also a brand new CB500F flood damaged bike to source all bits for conversion (Water level never reached engine so fine).


This project is getting fast tracked because I need IT in my life

So with the luggage system over half way finished I thought i'd pop the seat and tank back on to get a rough idea of the finished look....

Beautiful colors!
But man, that Ray Gun thingy poking through the screen is really gonna hurt if you're launched over the front and it catches you between the legs! :rofl:

YOUCH!

Should be a good Sport Touring set up! bier

:thumbup1:

Is the deathray an eye-level light, raised air intake or actually something to melt David Essex impersonators while Richard Burton does the commentary?

Andy

Haha..... Nice try, actually it's the intake for the butterfly valve but also works with moths when night time riding....!!

time for glitter...!!!
 

Ok, renewed mojo in place I got round to finishing the loom to 95%, the frames final welding, linnishing and quality control, its off to the powder coaters for some colour. While that's being done the engine gets a little tlc, water/oil pump recon, valve clearance check, clutch spec checked, new swingarm bearings fitted, final drive checked. lots and lots of small final tweaking jobs done to get bike on a realistic platform for a test trip somewhere sunny next year.
Oh, I nearly forgot, I weighed all of the bike as I stripped it down and yes it's quite some lump but not as bad as I feared... 280kg

Picking up your parts from the powder coaters is indescribable, especially when you have blatant disregard for brand colour loyalty...!!!

Slow but sure progress being made and sure beats being at work..!!



One thing I've noticed about posting attachment photo's, you cant see them when you preview your post to check picture orientation, it's a complete lottery as to wether they turn out sideways on or upright..!!

Rebuiling
 

Wheels on to balance the Orange.…!!! Slow but positive progress....

Back in the day

Almost standard R70/6, tank bag, simple panniers, rear rack and rack over cylinders. 2 up.

http://i46.photobucket.com/albums/f1...psaa3037cf.jpg


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The unnecessary absolute badassery of this is inspiring! Can't wait to see the final result.

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What was effect of the panniers / frame over the engine on the riding position or didn’t it affect it particularly?

https://uploads.tapatalk-cdn.com/201...e0f025e238.jpg



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BMW K75gs RTW bike build
 

The bags over the cylinders were filled with sleeping bags so were quite soft and kept my knees warm! Helped get a bit more weight back into the center of the bike. Obviously 2 up with everything you need the bike could be a bit of a handful in deep sand or mud. But this configuration took us round the world on 3 different BMWs.

One pannier had cooking stuff, the other had spare parts, bags on the back had clothes/ tent. Cameras and papers in the tank bag, travellers cheques in the central frame tube.


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Been busy, put the big bits back on for a test look...….

Some more big bits added for a preview......

Side shot

What is the tube that runs from the tank to the windscreen?


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Forced air induction inlet?

Snorkel. The wade line will be tank height so long as the electrics are waterproof and you keep moving.

Andy

It looks like a Landrover dust snorkel, but all the ones I have seen have the openings pointing backwards.


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Well your about spot on fellas, it’s a high level air intake with a diversion butterfly valve that allows air to be taken from the screen or from behind the screen if its lashing down or sand storm ( not that you’d be continuing in a flippin sand storm like..!!). Nothing like a bit of Ram Air going on for the old induction system

Custom Radiator
 

The rad that came with the donar bike was peppered with holes found after a pressure test was performed so for the same cost of a standard one from BMW I had this custom alloy one made. The core is almost double thickness at 64mm and will come into it's own in the hotter climates along with the fan override....

A little view from the cockpit showing the auxiliary control pod which houses the heated clothes/grips controls, altitude switch, fan override, 2 x 12v sockets and a spare switched 12v feed which resides under the seat waiting for a purpose......

Electrical pod finally done so now have functional lights, indicators and heated grips/clothing sockets.....

Covid progress
 

Been riding it some but encountered first major snag, Magura hydraulic clutch slave cylinder failed quite badly so new Wilwood unit followed by a Brembo radial (19mm) master cylinder lever assembly, should be good to go then for it's inaugural MoT…..

Five year build ???

Sounds like one of mine :rofl:

Some excellent work there. What a great project. bier

Hydraulic clutch conversion
 

Been learning the principles of hydraulics of late the hard way and expensive I might add. The Magura unit was perhaps too under-engineered for the task (it failed) so have fitted this Wilwood unit from Trumpsville… With hydraulics SIZE does matter, the nearest we could get to the 7/8 piston size of the Wilwood slave cylinder as a match for the master cylinder was 19mm from a Brembo. It has an adjuster that can decrease or increase the bore effect by 1mm (please don't ask..!!). This we calculated would just give the travel range we needed but it hasn't FFS..!! We are now using geometry and Pythagoras to come to a resolve and get that range up..!!!! Aaarrgghhh..!!!!

A clutch cable and lever will be a back up solution should the hydraulic setup fail out in the field OR failing success BE the main solution....

If you count from the purchase of the donor bike it's 9 years, if from the idea concept it's 11 years.. Nearly there mind, MoT very soon-ish :D

BMW K75 engine...….. I love you...!!!! Been doing some miles on it and I have to swoon over this engine, weight and balance similar to my GSA as I expected but the pure silkiness of this engine is amazing and an utter pleasure to ride. Gone is the bar buzz and engine wobble that a boxer lump gives..!!!

Stoked to pieces :mchappy::mchappy::thumbup1:

Bump...!!!
 

Ok, i'm bored and away from home working so trying out my picture posting abilities and the long standing sideways issue here, let's see now..........

Yup, as always sideways..... Again please now I have some time, what's a good way of getting correctly oriented pic's uploaded...????

Preparation
 

Gerald Vince,
older brother to Austin:

"Spend your effort on the trip.
Not on preparing for the trip."

Not in this video.
But they share some experiences.

https://youtu.be/S_y6wV95WVk?t=377


Five years, work an money spent.
Could have been used for many wonderful trips.

My friend, it's called retirement or more to the point early retirement.... and I've done loads of travelling in the last ten years including a week with Austin..!!
I have my own agenda and time scale which is based on the fact I'm a working class father of 5 kids and need to see them settled into university first before setting off. How many travellers do you know with a hoard of kids...????
It's all good though, the plan is going accordingly. Feel free to comment further, no worries.....

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