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Author Topic: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build  (Read 18302 times)

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Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #80 on: August 24, 2014, 08:50:00 pm »
So... it's STILL not finished, but here are some pix of the final setup in the meantime. I need a couple days this week to work out how I'm cutting the wiring down at the front and simplifying things a bit. Everything's working at least. We're close... very close.










Offline tour

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #81 on: August 25, 2014, 06:24:19 am »
Looking very good there.  :thumleft:
 

Offline pietas

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #82 on: August 25, 2014, 07:49:54 am »
Nice work. Very neat

Question: do you have the contact details for the place you bought the wiring from in Montague Gardens?
Groot berge en lang grond paaie
 

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #83 on: August 25, 2014, 09:57:04 am »
Nice work. Very neat

Question: do you have the contact details for the place you bought the wiring from in Montague Gardens?

If you mean the actual wire itself, that came from Jedelect on Section St in Paarden Island 021-5110262. It's the silicone coated stuff - it's thinner, easier to work with, resists up to 180deg and carries a higher current. Perfect.

Offline pietas

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #84 on: August 26, 2014, 07:19:13 am »
 :thumleft:
Groot berge en lang grond paaie
 

Offline sidetrack

Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #85 on: August 26, 2014, 07:48:47 am »
Max it looks great, switched on the lights yet ?
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #86 on: August 26, 2014, 09:02:18 am »
Yeah - they're bright!! Main challenge is reducing the mini connections harness at the front. Getting there slowly...

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #87 on: August 26, 2014, 08:16:19 pm »
AT LAST! I have actually finished the wiring, and the bike will be off to roadworthy as soon as I collect the front brake pressure switch from KTM tomorrow. Test ride time this weekend...

Offline sidetrack

Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #88 on: August 27, 2014, 07:29:55 pm »
Some Q's if you don't mind :

A : what thichness is the HDPE (I'm guessing 8mm ?)
B : Distance between two centre points on the lights ?
C : Distance between bottom light and fender ?

Just curious  :peepwall:
« Last Edit: August 27, 2014, 07:30:21 pm by sidetrack »
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #89 on: August 28, 2014, 07:13:44 pm »
6mm HDPE, about 11cm between centres of lights and 7cm from bottom of lower light to centre crease in mudguard. These last two figures are a bit adjustable depending on rake of lights. There's a bit of adjustment capacity in the fairing system overall - hole options, some slots etc.

Offline sidetrack

Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #90 on: August 28, 2014, 08:05:43 pm »
6mm HDPE, about 11cm between centres of lights and 7cm from bottom of lower light to centre crease in mudguard. These last two figures are a bit adjustable depending on rake of lights. There's a bit of adjustment capacity in the fairing system overall - hole options, some slots etc.
:thumleft:
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #91 on: August 28, 2014, 10:34:50 pm »
Jeez, getting a bike through roadworthy can be a pain in the ass! After slaving away for days (nights) in ham-fisted fashion at the wiring, I finally got everything working and got a 3-day permit (not exactly generous) from the license dept yesterday. I then took a gap in the weather to whip down to the testing station on Sir Lowry to get it passed, and get the formalities out of the way.

Not so fast. Bastards went over the bike with a fine tooth comb and told me my fancy new flickers at the rear weren't visible enough, and my lights were spot lights (duh!) and didn't have the required cut off for the road.

We know what happened next, right? Yes. I dashed off to Midas for some 'road legal' cheapie spots that had been on my 690 and I thought might pass, and ferreted around in my spares box for some old flush mount flickers to tape on further back than my fancypants billet flickers. Luckily they were LEDs which means the flasher worked, and double lucky I had two spare relays and one spare 4-pin plug, so I could make up a little harness chop-chop for the new spots. They even fitted exactly in the HDB fairing. The gods were on my side, at last.

But I was still reaching a bit here to think this might all work. I took another break in the rain at lunchtime today, and went back... not without some trepidation. There's only so much time and money a man can waste. The testing guy with long enough legs to ride my bike (I kid you not) had gone to town and wouldn't be coming back for half an hour so I blew them off and went across to the other testing station at Culemborg.

Luckily the first lot had only looked over my bike (somewhat obsessively, if you ask me) and told me they would fail it, without actually taking my money, so I didn't have to pay twice. But... whatthefuck?? The same obsession with lights, and the junior testing guy was all for failing me outright. I mean, what is wrong with a little blinding of other road users?? Honestly, these Midas cheapies (which I shall hopefully be returning to tomorrow) aren't bright enough to blind a gnat, but I suppose that is beside the point.

The head honcho at the testing station is a biker, and after saying that actually the beam was sort of flattish, and he'd accept it, spent the rest of the test showing me photos of his 30-yr old racing Honda road bike while his assistant crawled around on the ground with a flashlight trying to find my engine no., (which was skulking deviously behind the brake lever)

And.... well... that was that! He wasn't interested in finding out if my flickers actually worked, or if there was a hooter, or if the brakes worked. And god forbid he'd actually ride the bike!

YYYEEEESSSSSS!!!!

Then back to my generous friend The Fox's garage to strip off all the offending crap: cheap lights, bad flickers, number plate holder, reflector, number plate light etc. And I celebrated by buying myself an utterly, thoroughly and comprehensively illegal numberplate the size of a postage stamp. If you're going to have an illegal numberplate, you may as well do the job properly.

I spent this evening fitting the fairing (I'd gone Mad Max to the testing station), grab straps, bash plate, one remaining rally peg (revelatory note: fitting KTM pegs takes about one zillionth the time and avoids shooting yourself in the eye with a spring if you have a mate to help!!) The lights are sensational, and yes, on brights they will absolutely blind other road users, but this is an off road bike isn't it? I guess I have a rally bike now. Job done. 

Did a rough set up of the sag and rear suspension, and that, as they say in the movies, is pretty much that. If my bloody flu lifts we'll give it a good test this weekend.

Peetchers tomorra...

Offline spokie

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #92 on: August 29, 2014, 01:53:15 am »
 :hello2: WELL DONE! It is (sometimes) hilarious how those guys operate! HAHAHA...!
If I may ask, why did you register roadworthy the bike after this rally conversion?
« Last Edit: August 29, 2014, 06:00:40 am by spokie »
 

Offline Aquatic

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #93 on: August 29, 2014, 02:48:23 am »
Hey Max

How do the HDB handguard mirrors work for you?
Considering a set for my Dakar. Roadworthy?
The conundrum that is life...
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Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #94 on: August 29, 2014, 06:48:10 am »
Hey Max

How do the HDB handguard mirrors work for you?
Considering a set for my Dakar. Roadworthy?

They're pretty good, actually. The right side is perfect - it's perhaps a little smaller than you're used to, but it seems to be a bit concave and gives a good view of the road behind. I haven't got the left one as well placed yet. Look, if you're looking for a good road mirror and doing a daily commute I'd suggest getting a Double Take http://www.doubletakemirror.com or something like that. But the HDB folds completely out of the way when you hit the dirt. I think it's a great design - I'm not putting standard mirrors on again. Seriously, all the HDB stuff is so well thought through - you want it on your bike.

Offline Vissie500

Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #95 on: August 29, 2014, 07:03:09 am »
Well done!!

I'm now seriously thinking of going this route with my 500.

 :ricky:
 

Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #96 on: August 29, 2014, 08:36:40 am »
Quote from: spokie
If I may ask, why did you [s
register[/s] roadworthy the bike after this rally conversion?

It's also my lightweight/rough touring bike. And my only road bike! :))

Offline T9ER

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #97 on: August 29, 2014, 08:50:25 am »
Your bike looks great, I think you have a winner there. Really nice build thanks for sharing.
I nearly lost an eye changing footpegs on mine until I decided to check out youtube and found a vid of a guy who shows you how to do it with a pair of long nose vice grips. I bought a pair and it takes about 2 min per peg on your own, super easy.
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Offline MaxThePanda

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Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #98 on: August 29, 2014, 09:40:06 am »
Yeah - that's Jeff Slaven I think. He makes it look easy but I couldn't find any long nose vice grips at the local hardware. A mate served equally well - difference between swearing and potential lost eyes, and a 60sec job!! :)

Offline SteveD

Re: PANDAMOBILE UNDER THE KNIFE: KTM 450 XCW Rally Lite build
« Reply #99 on: August 29, 2014, 09:59:03 am »
Quote from: spokie
If I may ask, why did you roadworthy the bike after this rally conversion?

From the Amageza SRs:

5.1. GENERAL CONDITIONS FOR ALL MOTORCYCLES AND QUADS
1. The Amageza Rallye is open to motorcycles and quads (hereinafter collectively referred to as ďmotorcyclesĒ) duly covered by a registration certificate and adapted to off-road use. The registration certificate must always reflect the modifications made to the motorcycle, in particular to the capacity, make, type and commercial description. These motorcycles and their equipment entered must, throughout the competition, comply with the International Vienna Convention of 1968, the national legal requirements for road traffic of the country in which the vehicle is registered, the road legislation of the country where the event is held and with other rules specified in the Supplementary Regulations. If a competition motorcycle does not require registration in the country where it comes from, the motorcycle must still respect the FIM Sporting and Technical rules.