Help & advice prepping an X Challenge for almost RTW trip

Clearandlock

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Hi All,

I am looking for help to prep an X Challenge for a RTW trip in April, I live in central london and do not have the space, tools or experience to prep the bike. (although I am not a total noobie with a spanner)

I am looking to bolt some TT bling , fairing/lamps/tank/subframe, shock and fork replacement, new pipe etc. Most of the RTW XC stuff that Colebatch seems to have tried and tested.

Ideally I would like to do as much of the hack work as possible under supervision, so I get to learn the bike (and how to fix it) and best practice.

I would need an expert to do a fork transplant and making the bike fit me as best it can.

In short I would like to do some of the monkey work and let the pros do the expert stuff, but I would like to look over their shoulder from time to time to learn what and why they are doing as it will be me doing it on the road. (i know there is a fine line between learning and getting in the way of a professional doing what they do)

If anyone could recommend someone (or a variety of specialists) that could help me with this part of the adventure it would be greatly appreciated, or advice on a better way to approach the bike prep would also be welcomed, it really is as much about learning as it is getting the work done.

I am not expecting anyone to do this for free, I know I could go to TT hand them a kidney and comeback to pick up my bike but I will learn nothing.

I think I have read a 1000 pages of forums on prepping the XC on advrider and here, but am sure there is a massive gulf between the theory and practice.

I think PM's would be the best way for any recommendations.

Many thanks in advance.

Clayton
 
I have to say I think you're barking up the wrong tree. Cole's bike was a machine basking in the luxury of an endless budget. You don't need any of that to do what you're planning. I mean new forks, why do you need them? Do you know what the benefits of that are? I think you need to go right down to basics and start there.

Choose the right bike, not just one you've seen used. What height are you, what is your skill level, what route are you taking? These answers might lead to a completely different need. The X-range has a great engine and management system and is one of the best RTW machines about but it's massively compromised. The small tank is a huge drawback in terms of range so you need to plan for that. Touratech make a good extended tank but it adds a huge amount of weight exactly where you don't want it. It's not ideal for enduro work with a full extra tank so are you planning around that?

The rear subframe is alloy and weak so you can't load a lot of luggage. You can get a touratech rear subframe with panniers and rails but it's expensive. The rear shock is rubbish so budget a new one. Progressive springs in the front if you're carrying weight or just because you want them is cheaper than rebuilding the front end. Ar you skilled enough to need a reworked front end? The lights are lousy. The seat is enduro biased and will not carry you far without pain, the windscreen gives no protection from the weather. The problems can be fixed but you have tripled the cost of the bike just to address the failings. That's without having a useful instrument panel, GPS, etc.

Have you even considered a different bike?

I'm assuming your route is over Russia? The bike has very weak electronics so heated grips are a luxury you might not want. Upgraded lights are a must because street lights won't be there to help you. How much gear do you need to carry? Are you solo? What tools and medical equipment do you need? Are you camping?

You need to go right back to the absolute basics first and then decide what bike you need (probably still this one, it's a great machine) and then what equipment you need to have.

Essentials... Decent seat, screen, luggage, fuel, upgraded chain, sprockets, headlights and then a complete service and check over the engine, brakes and running gear. Check clutch cable and think about replacing anything that might fail with something that is less likely to fail (for instance, remove indicator bulbs and replace with good quality LEDs).

I'm doing a big trip myself this year. I'm going from London to SE Asia through Europe, Turkey, Iran, Pakistan, India, Thailand, Cambodia, Vietnam, Laos and finish back in Thailand. I chose an X-county because it's a better bike on tarmac and still ok offroad, up to my skill level anyway. Also the seat is far more comfortable as standard. I've had the seat fitted with a gel-pad, order Wilbur shock, new exhaust (frees up more power and improves range while saving weight) upgraded chain/sprockets, led indicators, HID headlight, LED driving lights (5w drain only but as bright as normal bulbs) and offroad spotlights, high-level mudguard, acerbis auxiliary tank (tail mount, 5litre, gives about 200 mile range in total), Garmin GPS, front screen (modified R1 seat hump, cost less than £30). Luggage I'm still pondering but you get the idea.

You could actually confirm your bike is mechanically sound and just pack up and go. The bike is probably capable of making it but your arse will not thank you. I'm certainly not trying to put you off, far from it but trying to copy other people, even more experienced ones will suck your budget dry very fast. On top of that there is the inconvenience of the Carnet. That will make you estimate the value of your bike and then insure it against selling it abroad. A lot of countries require this so it's important to keep the costs low. Another point is that your insurance won't follow you everywhere so if your bike is stolen you could face a very substantial loss.

Go right back to basics and figure out what you need the bike to do and then start getting the parts to make it do that. Work out your budget and prioritise what's most important. Figure out your skill level too and decide what parts will help you and what parts you'll never get the benefit of.
Then... just do it.
 
Dont know what your access to Holland is, but Bas at Hyperpro in Alphen aan den Rijn is currently prepping a couple of X-Challenges for long distance travel for assorted clients. He is not only doing the suspension but fitting touratech stuff, and other aftermarket stuff the the XCs. He is very familiar with my bike and the mods done to it and the pros / cons of each mod.

While he is now a suspension specialist, he also worked for over 10 years as chief bike mechanic at a BMW dealer in Holland, so knows BMWs very well in general.

He is very reasonable price wise and doesnt mind you being in the workshop to help / watch.

Apart from him being in Holland, it sounds about what you are looking for - a guy to prep an X-Challenge for long distance travel without being a rip off. I cant PM you so will put the details here:

Hyperpro Service Center Alphen ad Rijn
Eikenlaan 261G
2404 BP Alphen aan de Rijn
Tel: +31-172-417171

As far as front suspension goes, I might be able to help you ... in a way much cheaper than a fork transplant. I have a pair of 45mm Marzocchi Factory Series forks (actually at Bas's workshop) that I was going to fit to the bike before deciding to stick with the WPs I have. The stanchion tubes and fully adjustable mechanism will fit into Marzocchi outer tubes from the XC ... meaning you wont have to change front wheels, axles and all that stuff. You would get the fully adjustable factory racing damping direct into your existing upper tubes by just replacing the damning mechanism and the lower tubes with those from the Factory Series forks. Again, Bas could do that easily and quickly.
 
Cole
I'd be interested in those Marzocchi's if they become available.
Regards
Felix
 
If you have the money and don't mind spending it, you couldn't do much better than following Colebatch's lead. The X-Ch with those mods would be at the top of my list for a RTW bike as well. Tested and proven platform, very reliable, good performance and weight. Can't say that about (m)any other bikes.
 
hey Arma,

thanks for your post. I have researched to the point of headache all the threads on ukgser/ADV rider and horizons unlimited. I have riden the XC and liked it!, way more manageable on the rough stuff than my GSA (which i love as a mile eater)

What I have learned in my research is...

There is no perfect RTW bike!

it seems every bike is a compromise whether it be in cost, weight, performance, maintenance or the intangible how it looks / makes you feel factor.

How we each weight the above variables against each other is the fun I have been having with this research. I like you, have decided that however compromised the XC is, it is a better base (for me) to start with.

I gulped when I added up the cost of building a colebath XC, but is sure is fit for purpose and supercool! (i would be lying if I didn't admit this is a big part).

I know all the real hardcore overlanders say i should take a 250 aircooled whatever, but I need to look at my bike everyday and think, that is the ducks nuts lets go!)

Back to the XC forks, I am 95kg/6ft. The felt spongy and without purpose. I am not a dakar god but i would like a planted front end that gives you confidence, whether that can be accomplished just with springs I dont know and if I am going to spend everyday for 6months with them I will get them as right as I can afford.

Have planned to rework all of what you have mentioned in your post.

Would like to hear more about your trip, when do you leave, I am planning for nepal via north africa in april.

Your bike setup sounds spot on, which way are you leaning on luggage? hard or soft? Have you done any reinforcement on the alloy subframe?

best clayton
 
Back to the XC forks, I am 95kg/6ft. The felt spongy and without purpose. I am not a dakar god but i would like a planted front end that gives you confidence, whether that can be accomplished just with springs I dont know and if I am going to spend everyday for 6months with them I will get them as right as I can afford.

Hi Clayton i'm 6'4" and about 95Kgs and the standard fork springs were dangerously soft for me so i had hagon progressive springs put in and its a lot better imho much more firm and stable, that cost me about £120 for the springs and a suspension specialist to put them in for me (he had to do a little bit of jiggery pockery to get a clean fit) however if you compare that to jesters/rossi £160 for a WP front end (as on advrider) then i might have gone that way to have the full flexibilty/adjustability ..... not that i know much about setting these things up or the skill to make full use of it

good luck
 
Hey Rossi,

Going to go with that cool fairing from the Lithuanian chap on adv rider, larger x tank, hyper-pro rear, remus, undecided on the forks, thinking either a WP swap or a Marzocchi shiver inards transplant, steel pony bags, a new seat, uni filter, barkbusters, heated grips and some upgrade xenon beams.

Things i am not 100% on are:

TT Rally Bash Plate - what can you put in there that does not mind getting wet or a std TT bash plate with tool tube.
Pivot Pegs - these seem clever
TT Radiator Hard Part - TT extra weight
TT Radiator Guard - TT extra weight
double take mirrors - seem clever

I have a spreadsheet on this and wince when I total it up, but hey you only live once!
 
Hey Rossi,

Going to go with that cool fairing from the Lithuanian chap on adv rider, larger x tank, hyper-pro rear, remus, undecided on the forks, thinking either a WP swap or a Marzocchi shiver inards transplant, steel pony bags, a new seat, uni filter, barkbusters, heated grips and some upgrade xenon beams.

very nice:drool

TT Rally Bash Plate - not sure you can still get that, i think stephan makes one. i would have one of his over the tt part, his full bash plate was lighter than the tt sports plate

Pivot Pegs - i like them, very comfortable i found

TT Radiator Hard Part - people have had problems fitting these

TT Radiator Guard - restricts cooling a bit but also less mud

I have a spreadsheet on this and wince when I total it up,

i'm not surprised:comfort
 
Hey Rossi,

Going to go with that cool fairing from the Lithuanian chap on adv rider, larger x tank, hyper-pro rear, remus, undecided on the forks, thinking either a WP swap or a Marzocchi shiver inards transplant, steel pony bags, a new seat, uni filter, barkbusters, heated grips and some upgrade xenon beams.

Things i am not 100% on are:

TT Rally Bash Plate - what can you put in there that does not mind getting wet or a std TT bash plate with tool tube.
Pivot Pegs - these seem clever
TT Radiator Hard Part - TT extra weight
TT Radiator Guard - TT extra weight
double take mirrors - seem clever

I have a spreadsheet on this and wince when I total it up, but hey you only live once!

I would fit the TT Chainguide & Rear disc guard as a priority

Plus KTM 27mm wheel nuts and stainless wheel spacers from Stephan, plus a steel gear lever from a F650GS
 
just saw this post now

ah i would have done the work fro free just to keep me occupied

well get a smuch spanner time in as possible as works out better for you as know te in and outs of the bike and wont be worried if have do road side work

as for forks, personally i think just get them pro rebuild with progressive springs for your weight

wilbers do great service and are same company so to speak as hyperpro.

i did a wr450f fork swop on dakar, they are excellent fork, much much cheaper than all the other forks as there so many of them on ebay.

i thnk this be cheaper option if you had to have fully adjestable forks

but trust me on this, money in the pocket is better than on the bike

if your not sure about working on forks then why need all the added adjustments? send forks to pro company like revs racing or Dr Shox and they will work their magic and you can save some cash for essential items like beer and bribes on the trip
 
Hi All,

Bas at hyperpro in Holland is going to be sorting the suspension for me and I will do the bike build in his workshop there. I am going to go with some WP forks off a CRF and a hyper pro on the rear.

Good advice on the chain guide and disc armour, do you need to drill break points in the F650 shift lever? (that was my plan for the stock item).

what are the thoughts on swapping bolts for stainless?
 
rad protection?

i tried to fit the TT radiator hard part - impossible - especially with the large TT bash plate on
i plan to go instead for the radiator guard. how difficult is it to fit? is there much 'taking other things off' involved to fit this?
i've bolted on a tool tube to the front of the bash plate and this seems to work well
cheers
 
Good advice on the chain guide and disc armour, do you need to drill break points in the F650 shift lever? (that was my plan for the stock item).

I wouldn't bother with drilling break points. the standard F650 gear lever is very soft- i've had one on my XC since new, and there has been more than one occassion that has seen this lever bent back right under the foot peg.

I'd also make sure you carry a spare. they will on bend and allow straightening so many times. don't ask me how i know :augie
 
i plan to go instead for the radiator guard. how difficult is it to fit? is there much 'taking other things off' involved to fit this?

just a single bolt at the top centre and then the bolts to the side panels, i've drilled into the top cover to attach the rubber cover up and over the air intake
 


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