Superb job!
Project XChallenge
- Thread starter nicholsonj2252
- Start date
And some...
Nice job John 
Looks like it could have rolled off the production line - fantastic job indeed
Few more photos taken outside today....
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[img]https://farm5.staticflickr.com/4676/28387219059_af831f77a9_b.jpg
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[img]https://farm5.staticflickr.com/4676/28387219059_af831f77a9_b.jpg
The new single-cylinder models were developed under the leadership of BMW in cooperation with Aprilia S.p.A., Noale, Italy (Piaggio Group). Production is by Aprilia in their North Italian Scorzè Plant, naturally fulfilling all of BMW’s strict quality standards. And as on the F 650 models, the power unit comes from Austrian specialist Rotax, again following the specifications and requirements made by BMW Motorrad.
https://r.search.yahoo.com/_ylt=A9m...cations//RK=2/RS=.Zok7XaXridkdDdk2sijzHldITQ-
Yes - I knew the XChallenges were assembled by Aprillia in Italy (later XCountry's in China) , engines by Rotax in Austria (again apart from later XCountry's which were made in China) and undoubtably parts from a host of other European and Far Eastern locations so made in Germany was somewhat tongue in cheek
That is a really nice end product. If you are ever bored and at a loss at what to do . . . . . .
Aye, 9 hours last sunday to take engine out, remove abs whilst there, engine back in and frame/swingarm etc back on. Not a pleasant day; trying to fit the engine back in was like trying to line things up in a moving bowl of jelly; there is no structural integrity when the engine is out
Just about to go out now and finish it off. Fingers crossed this should be straight forward.
Aye, 9 hours last sunday to take engine out, remove abs whilst there, engine back in and frame/swingarm etc back on. Not a pleasant day; trying to fit the engine back in was like trying to line things up in a moving bowl of jelly; there is no structural integrity when the engine is out
Just about to go out now and finish it off. Fingers crossed this should be straight forward.
Good luck - strangely I had no issues getting engine back in , mind I did have a second pair of hands helping ;-)
I've been asked a few questions about the build so here is some information which may be helpful :
Special Tools needed :
Castle spanner to remove RHS frame to engine block fixing bolt - BMW Special Tool 83 30 0 401 621 ( I used an old F650 tool I already had and reduced the size of the pins using a cutting disc)
Stubby Allen key for the 3 fitted bolts in the joint between RHS Rear Frame section and the Main Frame section (I cut down a 6mm Allen key to suit)
28mm Thin spanner for locknut on RHS frame to Engine block fixing point
Front forks , a thin 19mm spanner to get the top adjuster cover locknut off the inner fork tube
Suppliers :
Williams BMW Manchester - All OEM genuine BMW parts - many thanks to Jim and team for an excellent service http://www.williamsbikes.co.uk/contact-us/
Saragon Custom Painting - thanks to Sarah for a superb job paining all of the Plastic Panels http://saragoncustompaint.co.uk
Bettablast - thanks to Bill for the usual excellent service an top quality powder coating to bot the frame and wheels http://www.bettablast.co.uk/contact.html
Saddlecraft - thanks to Les for a superb custom made seat http://www.saddlecraft.co.uk/contact/
Other information :
Front Headlamp conversion - second hand XCountry Headlamp , brackets and clock surround plus LED bulb upgrade
LED indicator upgrade - BMW R1200 LED indicators and 2 x 50 Ohm resistors wired into front circuit
Front & Rear brake discs by Brembo (68B407G5 & 68B40774)
Exhaust End Can - Leo Vince X3 (3606) http://leovince.co.uk/2007-2011_B226HBL.aspx
Engine Work Stand - https://www.ebay.co.uk/itm/Fully-Ad...012627?hash=item3affb2d2d3:g:iPEAAOSwWBJXA39w
Any other questions or information needed drop me a PM
Special Tools needed :
Castle spanner to remove RHS frame to engine block fixing bolt - BMW Special Tool 83 30 0 401 621 ( I used an old F650 tool I already had and reduced the size of the pins using a cutting disc)
Stubby Allen key for the 3 fitted bolts in the joint between RHS Rear Frame section and the Main Frame section (I cut down a 6mm Allen key to suit)
28mm Thin spanner for locknut on RHS frame to Engine block fixing point
Front forks , a thin 19mm spanner to get the top adjuster cover locknut off the inner fork tube
Suppliers :
Williams BMW Manchester - All OEM genuine BMW parts - many thanks to Jim and team for an excellent service http://www.williamsbikes.co.uk/contact-us/
Saragon Custom Painting - thanks to Sarah for a superb job paining all of the Plastic Panels http://saragoncustompaint.co.uk
Bettablast - thanks to Bill for the usual excellent service an top quality powder coating to bot the frame and wheels http://www.bettablast.co.uk/contact.html
Saddlecraft - thanks to Les for a superb custom made seat http://www.saddlecraft.co.uk/contact/
Other information :
Front Headlamp conversion - second hand XCountry Headlamp , brackets and clock surround plus LED bulb upgrade
LED indicator upgrade - BMW R1200 LED indicators and 2 x 50 Ohm resistors wired into front circuit
Front & Rear brake discs by Brembo (68B407G5 & 68B40774)
Exhaust End Can - Leo Vince X3 (3606) http://leovince.co.uk/2007-2011_B226HBL.aspx
Engine Work Stand - https://www.ebay.co.uk/itm/Fully-Ad...012627?hash=item3affb2d2d3:g:iPEAAOSwWBJXA39w
Any other questions or information needed drop me a PM
You should post this up on ADVrider - they'd love this... 
What LED headlight bulb did you get plz John.
Ta muchly....
You build splendid bike!!!!!!
A few people have asked about the clutch cover upgrade
The standard cover has no central bush and the aluminium bore wears , eventually causing the clutch disengagement to be "sticky" or even lock up
The clutch cover from a later model XCountry has a steel bush fitted and so does not suffer from this
Here are some pictures of the worn bore in an old cover :
and some pictures of the later type cover with the steel insert bush :
The standard cover has no central bush and the aluminium bore wears , eventually causing the clutch disengagement to be "sticky" or even lock up
The clutch cover from a later model XCountry has a steel bush fitted and so does not suffer from this
Here are some pictures of the worn bore in an old cover :
and some pictures of the later type cover with the steel insert bush :
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