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Strip a Superduke down to a frame!

104 posts · Started by BASH69 · 19 Sep 2011

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Post 1 by BASH69,

#1
Well i was gonna do a How-To on stripping an SD down to the chassis ready for powder coat! I thought it maybe a useful resource for anybody wanting to do the same thing, however, other than showing a few pics if various stages a cant really write a How-To other than, strip bike down to frame, get frame powder coated, rebuild bike with various new parts as you go along as needed

The only thing that may help you is various pics along the strip/rebuild process with how long each stage took me and any problems encountered and total time for the project

ps. dont ask what colour the frame is going to be cuz youl have to wait an see, needless to say most will hate it and it wont be orange (soz KTM, i dont want yet another SDR lookalikey )

So, 1st off, tidy your work space you scruffy git -

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Its amazing how quickly these SDs come to peices, so1.5 hours had the bike looking like this -

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Called it a night after this.

Next day and another 1.5 hours had the bike looking like this -

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Coolent out as im going to do the water pump rebuild whilst im at it.

So for 3 hours work youl end up with a garage resembling this -

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Engine to be dropped out next along with wiring loom and drop the rear subframe off and shes bascially ready to go to powder coat.

Gotta order various parts from KTM ready for the rebuild such as bearings, water pump parts, front brake pistons and seals as they are gonna get a rebuild also !

So, any problems so far? nothing, everythings easy and straight forward and ive taken a load of pics along the way for reference for such things as wiring loom routing etc

Il update this thread as and when i get time to work on the bike but im expecting 4-6 weeks in total (maybe )

Post 2 by MADDOG53,

#2
Hope your not going to fook with color on the "bell"

Post 3 by Colonel_Klinck,

#3
Bloody hell Stew that's a major job. Good luck m8 and look forward to seeing her in the new paint job.

Post 4 by SDNerd,

#4
LOL - show stopper (for me) at Step 1: "So, 1st off, tidy your work space you scruffy git - ".

It would never happen ...

Post 5 by BASH69,

#5
And another hours work done and your looking at this -

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Half hour later and your basically left with a whole load of parts scattered round the garage , an engine looking sorry for itself and several parts ready to go off to powder coat -

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So now the list is made of KTM parts that are needed and im just waiting on a date to drop the frame, swingarm, subframe, rear spring and maybe brake calipers!? to the coaters. (only the frame is being done in a special colour, all other parts are just being redone satin black )

Problems thus far, no real biggies, all wiring was labled and photographed as i went along. Biggest problem is balancing an engine whilst lifting a frame off single handedly

Next jobs, water pump rebuild, valve check, considering having the heads off to replace gaskets and head bolts

This thread will now be quiet for awhile till frame etc comes back, hopefully not too long

Post 6 by CEREC1,

#6
Well if you ain't changed you mind on the colour since our conversation at Silverstone,you will def get a reaction.

Post 7 by BASH69,

#7
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Post 8 by bic_bicknell,

#8
Pink?

Nice job mate. Always harder to put back together though!

Post 9 by Mr_Trecolareco,

#9
Nice effort, I know how hard it is to take photos step by step after getting the hands dirty.

I agree with bic though, good luck putting it all together nice and fresh.

Keep us in the loop.

Post 10 by Superdan,

#10
Nice work

Barbie pink frame coming up

Post 11 by MrZ32,

#11
while the engine is out... why dont you paint it a matt or crackle black? Keep all bolts same colour and all machined surfaces free of paint (and a colour of your choosing for the cam cover)... i think it would brilliant and a have not seen it done yet

Post 12 by BASH69,

#12
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Post 13 by MrZ32,

#13
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Post 14 by BASH69,

#14
Everything sorted, bolt holes filled and all bearings etc removed ready for powder coat tommorow -

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Post 15 by nampus,

#15
new frame colour looks awesome! When is it going back together?

Post 16 by bic_bicknell,

#16
You getting your chain powdercoated then? Pink will it be? Is the colour still a secret?

Post 17 by BASH69,

#17
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Post 18 by Superdan,

#18
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Post 19 by Exitman,

#19
Haha, that's fookin' awesome. I can't wait to see this done and I believe there's a little bit of me going in there
Nice work!

Post 20 by BASH69,

#20
As i said before im going to be without cylinder heads for a few weeks so started with the basics and cleaning and checking things like head/swing arm bearings as i go, re-greasing ect -

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Loom to be cleaned and drop back in place next then i really am stuck till the motors back in 1 piece

Post 21 by bic_bicknell,

#21
WOW! Wow! I'm lost for words!

I was joking too.

Post 22 by BASH69,

#22
updates please?

Post 23 by Jermo,

#23
No updates - im still waiting on Dave for his cylinder heads so they can be sent off with mine for head work. When they all come back the motor will be rebuilt and slotted back into the frame - i cant really do anything until the motor is back in im afraid

Post 24 by Colonel_Klinck,

#24
My girlfriend loves the black-pink combo so I'm afraid I'll have to do the same if I show these pics

I think it looks awesome by the way!

Post 25 by omky756,

#25
Well bro..???? Any updates..??? I don't have much of a designer's vision soooo...Can't wait to see it comin' together..

Post 26 by indy84,

#26
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Post 27 by BASH69,

#27
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Post 28 by Viking,

#28
Remember and post up dates if your doing a few trackdays dude. I'm planning a good year of it in 2011. Looking to do around 1 per month. It'd be good to meet up with a few more SD's on track.

Post 29 by loony888,

#29
oh i hope you're going to coat the cam covers the same pink!
these things are pretty easy to put together, you should be fine seeing as you actually pulled it apart and marked stuff like wiring etc!
pink! i still can't believe it, hope you're prepared to pass round the outside on your next track day, otherwise all the guys will be blowing you big wet kisses!

paul

Post 30 by loony888,

#30
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Post 31 by tripoddave,

#31
handlebar streamers. now that's a mint idea!

Post 32 by omky756,

#32
Replaced a bent frame on my 08SD last year. Took some pointers from Paul with his build. Bike bench which raises the bike from the floor for one. Other major ,would do it again item, is to use a motor stand to support the motor at trear down. This "A" frame stand supports the motor that stays put on the bike bench. Every thing can be removed / replace with the stand still connected to the motor. The frame can even be pivioted into place by using one rear frame bolt. The sub frame can also be piovoted into place. I even left the air box and TB inplace with wire harness and TB cabiling. I did all of this by my self. I will have to post some pictures of what I did to give back to this very helpfull site. Some times I might come across as a know it all...not the intent...I just want to share my knowlege or lack of it ..Got more than 300K miles on sport bikes and do most of my own wrenching. Will be 60 in May and started the bike bug before teen age. Will post later,,,going out now on my 300KTM 2 smoker for a 40 mile loop. FYI my gal had to bust the ice on the bird baths this am..Ride on

Post 33 by BASH69,

#33
So...any updates bro.???
Still want to see her all together...

Mike

Post 34 by indy84,

#34
Still nuthin yet Bro - still tryin to get the engine back in 1 peice (its only a 2 hour job then it can go straight back in the frame) but time has not been on my side over christmas what with family etc.

I had put aside the whole of new years day and then ended up with a 36hour stomach bug which is now doing the rounds in our household My lil boy has only been back at school 1 day and now hes off again for 2 days with illness (bloody schools wont let the kids back to school with in 24 hours of havin a illness - let them all have the shits i say!!!!) so now im lookin after him and our little girl for 2 days which puts me back with my own work so that means i can fookin write off anytime i had at the weekend to play catch up

Im determined to have the fookin bike 80% back together by mid jan then it will be just the small parts like replacing brake seals, fluids etc.

Somebody pray for me

ps. anybody got any pink Dainese leather s for sale

Post 35 by BASH69,

#35
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Post 36 by indy84,

#36
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Post 37 by BASH69,

#37
nice

Post 38 by Superdan,

#38
Engine is finally complete and just needs a clean down in places. Frame is already hovering over ready to drop on plus i have a few hours to myself tomorow

Updates to follow

Post 39 by BASH69,

#39
With pics, gotta see this bad boy frame

Post 40 by Superdan,

#40
3 more hours shes cumin along!!!

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Post 41 by Colonel_Klinck,

#41
Orsm!!

Post 42 by SDNerd,

#42
That is fooking awesome Stew.

Was a beautiful day here today. Really wish I'd been able to get out on the bike. That's not going to happen for at least another month.

Post 43 by Viking,

#43


Where's that "unsee" button when you need it!?

Post 44 by MADDOG53,

#44


I approve.

Post 45 by loony888,

#45
Black sub-frame

Post 46 by BASH69,

#46
nice mate.
fun isn't it!

Post 47 by nampus,

#47
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Post 48 by BASH69,

#48
That colour is awesome!

Post 49 by samba,

#49
not sure if I likes it.... should've gone kawi green!

Post 50 by Bert,

#50
lookin' good!
(the fork bottoms could use some black paint)

Post 51 by cdlabate,

#51
I see you have a bell.

I also have a bell.

Just wait till you get on that thing and give your bike a proper ringing!

Post 52 by Colonel_Klinck,

#52
Nearly there bud. Could be the test ride at the weekend of the weather holds

Post 53 by BASH69,

#53
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Post 54 by kowekiller,

#54
Howzbout some moly grease on that output shaft spline They like that lubed up

Post 55 by Colonel_Klinck,

#55
I feel real Gay right now. Please someone show show me a girl in a hot dress...quick quick! Out of all the powder coating colors out there may I ask why? They dont even make a leather racing dress.

Post 56 by cdlabate,

#56
Image

Post 57 by omky756,

#57
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Post 58 by ktmguy,

#58
Maybe put some tits on it..??????
lol
They say a real man can wear pink...

Isn't it a passive color though.????
doesn't it take the animal out of the man.????

No humming and singing going round-i-round I hope....

And no fookn one piece leather dresses...
Maybe a nice set of GarneGP1 pumps..????

Still can't wait to see 'er done bro...All kidding aside...

Post 59 by samba,

#59
A mate of mine did the frame of his kawa Z1000 cc custom (forgot what the model was exactly) 30 years ago in the same colour.
While he was rebuilding it everyone gave him stick about it. But when it was finished it looked damm good.
It was a black bike so this might work out nice too.

Post 60 by BASH69,

#60
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Post 61 by omky756,

#61
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Post 62 by BASH69,

#62
Isitdoneisitdoneisitdoenisitdoneisitdoneisitdoneisitdoneisitdoneisitdone.???????????????????????????


Ohhhh...thinkin a little ka ka brown next year.?????? lol...
anyone can wear ka ka though...I got a little in my pink panties right now...lol

Dude it's March now...Getn close..???

Post 63 by BASH69,

#63
little by little she keeps progressing

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Post 64 by Superdan,

#64
Another little update guys, this is the last photo i took but i now have the tank on and a few other bits and the big pink beast lives and breathes -

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Left to do -
Bleed brakes & clutch
Fit air filter (it left California yesterday so fingers crossed its a quick delivery) and finish breather off
Set quick shifter rod up
set chain
Panels on
Tyre pressures
Road TAX
Dyno set up
TRACKDAYS

Post 65 by cdlabate,

#65
Nice Stew! really like the frame.

Is it more of a dark pink? or just the camera/light?

Post 66 by nampus,

#66
Oh boy!

Post 67 by Viking,

#67
Looks like it's coming together nicely! I think this will look really nice with the bodywork on. Just showed this to my girlfriend al she could say was: WOW!

Post 68 by Superdan,

#68
That's cool as fook! Turned out really well with the black.

Is that ceramic coating on the exhaust? What's the story with that, does it wear ok and keep its colour?

Have you got a link for those bars? Are they the streetfighter ones?

Gutted now I didn't send the handlebar clamps to powdercoat with the rest of the stuff. Looks miles better.

Post 69 by BASH69,

#69
LSL drag bars I believe, quite a few guys running them.

Post 70 by BASH69,

#70
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Post 71 by BASH69,

#71
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Post 72 by Viking,

#72
Bit further -

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Post 73 by BASH69,

#73
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Post 74 by BASH69,

#74
Well she very nealry finished.

Just waiting on the Air filter, it managed to get from California to Heathrow in the UK in less than a day and now has just sat in Heathrow customs wating for clearance - fookin lazy bastardzzzzz So now im stuck till thats here

Threw a panel on it just to see what shes gonna lookie like when all buttoned up -

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Im more than happy with it!

So there you go, let the pi$$ taking begin

Post 75 by bic_bicknell,

#75
Let me be the first to say..... I actually quite like it. Good one.

Is that quickshifter set to change down when you go over speed humps?

Post 76 by BASH69,

#76
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Post 77 by samba,

#77
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Post 78 by Superdan,

#78
I think it needs more pink! Sweet.

Post 79 by Colonel_Klinck,

#79
Looking good dude Bet you're gagging to get out and play.

Post 80 by nampus,

#80
Nice! Looks like the pink works out!

Post 81 by omky756,

#81
wow...finally soemthing to look at..!!
Nice dude...
Maybe some pink rim tape would set it off..???
Seriously..that one wasn't teasing...
A bit more pink would be the ticket...
Good job..!!!!

Post 82 by Colonel_Klinck,

#82
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Post 83 by tripoddave,

#83
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Post 84 by BASH69,

#84
Thats looking pretty nice!
Just being nosey but what's the yellow ring on your fork leg?
Cheers

Post 85 by Colonel_Klinck,

#85
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Post 86 by KTM666,

#86
Should probably read "this side down"

We should actually hand out vinyls with that printed on to all Crashfest attendants

Post 87 by BASH69,

#87
......i was expecting ....more pink ...It look really good.......better than I imagined

I was waiting for a picture of the clocks......or did you give up on the inserts

Post 88 by BASH69,

#88
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Post 89 by KTM666,

#89
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Post 90 by Linga,

#90
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Post 91 by BASH69,

#91
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Post 92 by Linga,

#92
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Post 93 by BASH69,

#93
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Post 94 by Viking,

#94
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Post 95 by Anata,

#95
Finally had a chance to check this beast out on the laptop to get a good look at it.

I like it. Doesnt look too much, really suits it. I see you've opted for white panels, apparently thats the fastest colour for 2012.

Just going over the pics checking all the little bits you've changed to black. Doesnt look like much at 1st glance but there's loads. Makes a big difference.

Post 96 by jambox,

#96
Looking good. I think I speak for a few of us when I say the pink looks better than expected!

Post 97 by Colonel_Klinck,

#97
I knew what the yellow rings on the fork tubes are used for but the black ones on the exhaust cans? What's that about? Have you had the chance to put some miles on your handle bars yet? I like flat bars. I think my stockers have too much pull back.

Post 98 by BASH69,

#98
Black ones on the cans are there in case he decides to part company with the bike mid corner. These things can happen on the Crashfest.

Post 99 by bruders8146,

#99
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Post 100 by No. 47,

#100
sorry to bring an old thread up but i really like this..

Has anyone else done this?

this winter I'm going to do the same!! just a different colour.

Post 101 by bruders8146,

#101
"Has anyone else done this?"

Yo...still around if you need any pointers...

Sure like the way I did it.

Support the engine, hinge / lift the frame off.

One man deal, EZPZ.

Took a 510 Husky motor out of a frame and dropped it, fooked the compression release shaft, learned my lesson via the school of hard knocks.

Post 102 by Aphex,

#102
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Post 103 by Seeker 77,

#103
Any specific tools required.

Any useful techniques as mention above.

Post 104 by No. 47,

#104
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