SuperDuke winter transformation project

Looking good. Might need some heat on the stuck bolt mate....

can't wait to see the finished product.

Lovin' ALL you plans (except the ones with the word 'Orange' in front of them) should look real good when it's done. Beware of painting the swingarm, it will soon start to look tatty as the chain adjuster blocks scratch it off. Getting the bolt out of the shock can be a real pain. Are you having trouble getting to the bolt or trouble undoing it? Weeksy is right, maybe a little heat will shift it, but I would try soaking it in WD40 and leaving overnight before reaching for the blowlamp. If you can't find anything to reach the bolt, get a 12mm allen key, cut the short/bent end off and slip on a 12mm socket, you can then put some real leverage on it from a ratchet or strongbar.

dude, this is like a bigger version of my winter project that I've now finished. search for my tech thread called winter maintenance and waffle. I didn't remove the swing arm but I did get my rear spring powder coated and headers ceramic coated.

I totally know what u mean about the HP cans, I'll b watching yr progress closely cos I too hope to chat with jj about gettng me some soon. it would have to b the titanium corse style cans! I'd b super keen to hear them roar once fitted to your bike too, no doubt you'll post on you tube when yr up and running again. good luck with the project mate, I'll b enjoying your updates

Thanx for the support. Actually I went into the garage today and got scared to see the bike being such a pile of metal. I just hope I do remember how to get it all back together. I bet it will take me 5 times longer to put it together than dismentling (it took me only 4 hours).

The shock bolt I unscrewed easily, but I can not grip it to get it out.

If anyone knows where to get the orange chain and black sporcket let me know!


Here is even more terifieing picture:





Forgot to ad that I will also at least try to install the gear indicator knowing that it has to be calibrated on the road means I will have to have a police free highway

DR F:
You need to have at least some orrange to give credentials to KTM


The seasons starts here in mid April - so I have to get it running by then.

How should the color be applied to the hard parts - what is the process of powdercoating in English can you explain to me better. Is that that you bake the paint in an owen or just sand spraied, painted and paint cover applied?

Powder coating is different to paint, it's the application of a plastic/polyurathane coating to the metal. The parts are bead/sand blasted to clean them and give a good adhesion to the coating. It's then heated to around 300 degrees and hung up in a booth. The coating is sprayed on like paint but it comes out of the gun in a very fine dry powder which sticks to the hot metal. It is then returned to the oven and re heated to help the coating gel into a smooth surface finish and bake it on, it's then left to cool. It's Ok to powder coat the swingarm and don't forget to ask for satin black not gloss, but they will need to mask the areas for bearings etc, and you will have to be carefull with swingarm adjusters ect as sliding them up and down and tightening the wheel nuts could mark it by chewing up the plastic. It would be much better to have it anodised black, this does not involve any heating of the arm and as it is already anodised you will have the same coating as original except it will be black.

Looks much like my old speedtriple that i stripped to rebuild the lock stops,bolted the engine to an eazy rizer bike stand and lifted everything else off,just left the engine sitting there....... like you quite a few bits lying about

keep us posted how you get on,might as well get loads done while its apart,better now its in bits than when its all back together and you wished you had done it

Coolberg, You should be able to find the Orange X-ring by googling for it.

I found the following links which seems to sell them:

Doesn't state that it's for a SD but it's suitable for road bike >1000cc

Dr F:

Thanx - I finaly got what the powdercoating means! Thanx mate. Do you think the wheels also have to powdercoated or just painted?

For a small laugh guys I am taking the pile of the bike what is left there (the engine apparently) to the Dealer for the 15 000km service. I want to see the dealers face when he sees what has to be serviced

For another laugh about a very stupid thing that I did very stupid. I wanted to take off the front fork ends where the brakes screw on for painting them black. I looked how to unscrew them and found a nut at the end deeper inside. Started to screw it out and ended up full face with shock oil - fooking stupid, now I have to get the shock filled. That was so stupid I laughed alone in my garage about my stupidity. You can see the oil marks on the floor in the pictures

thanx BINK for the links - that is exacty what I looked for.

DO you guys have any suggestions what makes sence to do extra while the bike is totaly stripped down??? Give me suggestions - I do not want to end up puting it all together and only then remembering what I forgot

powder coat or anodise only, I would not paint anything metal on that bike, it wont last.

Ceramic coating the inside and outside of headers is well worth doing if you can.

Lube up and get ACF50 on all parts that need corrosion protection that you wont be able to access once rebuilt.

If you're feeling flush you could replace bolts with titanium versions from probolt or similar.

The art of dismantling stuff is a lot easier than putting it back together

I always end up with handfuls of stuff left over - nuts,bolts & other bits I don't remember. Still, as long as the bike runs - that's the important bit...

This is what I have always noticed that there is always a gap for any other aftermarket pipes - that does not look good.
I like these pipes - thay are veeeeerrryyy light actualy and sound quite good. For the transformation project with the R seat and tail I will need bigger piepes to complete the picture better.

So I am selling them 250 EUR for a set with Y piece and bafles

PM going to be sent shortly I am interested but have a few questions.

The project is moving on. The bike looks even more rediculous than on the pics. The engine is completely out - it was very easy to do the big servicing

I took the most aluminium parts to the anodising place (seems that here where I live it is damn difficult to find a place who does that). They did not take the rear subframe and the rear swingarm to anodize stating that the nuts in the swingarm as well as subframe are metal parts pressed in thus they would be damaged by the process of cleaning and anodizing, thus they did not take them and I had to take them to the powdercoating place.

Look what the stupid guy at the sandblasting did to my frame:

The sticker is now gone. DOES ANYBODY KNOW IF IT IS POSSIBLE TO ORDER THE STICKER AT KTM?

Look what has happened to my VIN number on the frame, it has rusted:

I think I will not paint and sandblast that area as it will be gone and will have problems at the registering office.

Look what kind of mirrors I found in Germany in Polo motorcycel accessories shop:


They were on sale for 25EUR each. The best part is that my friend bought exactly the same mirrors from UK site [url]www.streetfighterstore.co.uk
[/url] where they cost him 44 POUNDS each. So I got a good deal. I think they will look great.


I will get back all the powdercoating parts this week and the anodizing parts next week - they did the anodising, but it did not turn out good - some parts did not get colored and aluminium could be seen through, the expert said that it is due to the very hard laque done by the factory. We'll see

The projetc goes on and while it is bad weather outside it does not put any preassure on me

coolberg, those mirrors look great. Who is the manufacturer?

So the project is continuing:

I got the frame powdercoated orange ( I hope it maches the KTM orange)


Also got back the swingarm and the subframe powdercoated matted black


They were suposed to powdercoat the rear spring orange as well, but they mixed it up and did it black, so I made them redo it. Will have to pick it up tomorrow.

It all cost me 50EUR - looks good and is rather cheap.

I am still waiting to get aluminium parts from the anodizing place at the end of this week.

Does anyone know if it is possible to get from KTM the original sticker from the frame of the bike where the VIN number is located and other info??? (look at the picture in the previous post

Funny watchin the strip down
Can't wait for the end result though dude
REMEMBER!!! Orange is fastest
Keep the photo's comin, brilliant

Dont think it ever went back together.

Hi to everyone!
i`m the new one here..

i saw that some people of here was very interested in this project.
project was finished and for this moment looks like this:



Bike changed owners, so I joined this forum!

Wow. That's a lot of work... strange not to change the endcans tho.

... or add a Motobox!

Looks like he sold the bike to someone else and this is the new owner...

One more question....

Why do you have pillion footpegs and a single-seat?