450 exc being R$allye prepared

jonnywave

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I ave started to prepare a 2003 exc 450 for a rally and thought it may be of interest to some of you guys..

purchased the bike for £1600
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Got myself a big tight A BIG TANK 25 lt i think a bit tooooo big

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Roadbook and Imo
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Roadbook mount i was going to mount it strait to the frame but i was running out of time so i opted for this.

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IMO fitted.
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GPS Mount bolted on to side? not sure if it will stay there...

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Wireing needs some planning..

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I ran a single cable to the fuse box that is mounted under the roodbook frame.
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Armour cable thingy and a tidy up
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So i wanted to have some type of fairing to protect that expensive kit.
So in card board tying to get my head around what is needed.
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so this is the first shape, i think i can mount it.
Iv ordered some foam plastic stuff ( supposed to be easy to shape and mold) after speaking to a perspex suppliers and they recommended it, its not arrived yet.

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A bit too square. I will put more shape to it, as its mounted to the forks it has to move with the steering, the downside of using that type of roadbook mount...
 
Looks good johnny lights ok but my guess is that they will look much better when in the fairings :thumb
Is this a road legal bike or not:nenau
 
Lights

Yep the bike is currently road legal ish ,except it's missing a horn....to be refitted asap.

The lights are e marked ! I might flip horizontally! Just need to adjust lenses and get come brackets made up.. They are designed to be used with the fairing, which I haven't made yet! Got some plastic stuff and will have a go at shaping/ moulding this week.

I was going to enter this years taureg rallye, but it did not pan out. So next year for sure.

Finn thanks for the tank I will get it fitted next week.:thumb
 
Steering dampener

do you recone you will need a stearing damper ?

Iv never used one so don't really know if I need one! I know lots of people use them, they ain't cheep. Would get one second hand if the price is right :augie
 
lights and fairing

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Light wired in on a switch on the dash


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Plastic/ foam thingy, got two pieces this size for £30
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Using the template I made earlier

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Using a camping cooker i started to heat and shape the material, just like a i did in scholl in design tech:) It was pretty easy to shape and held its shape very well once cooled.

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I bolted it into place using the holes in the lighting mounts and some bracket clips
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Turned out ok for the first attempt, I might have a play and swap the light to horizontal .
Its still pretty light on the front but the light are draining too much juice, LED would be better. It actually gave pretty good protection, 50mph without with visor open= very sheltered.
 
Jonny, definitely go for a steering damper, it will make the bike handle a lot easier.

Iv never used one so don't really know if I need one! I know lots of people use them, they ain't cheep. Would get one second hand if the price is right :augie
 
Damper

Jonny, definitely go for a steering damper, it will make the bike handle a lot easier.

I will get one if one comes up second hand, I can't justify the money just yet. I purchased Ht Oil cooler from the states, will fit this weekend, it will nearly double the amount of oil in the engine, :D.
 
I will get one if one comes up second hand, I can't justify the money just yet. I purchased Ht Oil cooler from the states, will fit this weekend, it will nearly double the amount of oil in the engine, :D.

Sounds good J! (Get photies up on here!)

Jono has my 525EXC in for a full looking at. Can't wait to get it back after he's worked his magic on it!
 
Hres a pick of it and standard
004-1.jpg

005-3.jpg

Standard
003-2.jpg


It is a custom made with closed cell foam, new cover also. Made at Chaos Customs in Swansea Valley who does many seats for Mr Pavey
 


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