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  #1  
Old 11th January 2018
Merch131ho Merch131ho is offline
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Join Date: Apr 2012
Posts: 206
Sportster/Buell Model: XL1000
Sportster/Buell Year: 1979
Other Motorcycle Model: Merch 131
Other Motorcycle Year: 2004
Reputation: 49535
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Default XL883 / 1250 Scrambler Project

I was helping my mate with the final assembly of his XL883 Scrambler project. The engine has a 1250 big bore kit from Hammer Performance, the heads have bigger valves and have been gas flowed by a specialist here in the UK.

I found the bike for my mate Tim about 5 years ago, so its been a very long term project, and its evolved over the years. Tim owns a bike shop and Dyno, but its seems he's always too busy to work on his own bikes.

But finally he's at the point of putting the bike back together for the last time

The alloy swing arm is by Metchemex, while the rear shocks are recently released by K Tech, called Razerback. The front end is a mixture of one off billet yokes with GSXR K7 forks, which have been modified with KTech internals.

The fork uppers and many other parts have been ceramically coated.. not sure the exact product, but its impressively hard wearing. For example, the coated cylinder head bolts were unmarked having been torqued down.

Also the oil tank has been replaced with a one off tank in alloy, which sits between the down tubes low down in front of the engine.

It also has a hydraulic clutch conversion, and switchgear from a Honda VFR800.

I'll go back next week when it should be back on its wheels, and fingers crossed be running and put on the Dyno soon after.. Hopefully I'll be free that day so I can film the action..

Here are some pics from today..





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  #2  
Old 5th February 2018
Merch131ho Merch131ho is offline
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Default

On its wheels, the bodywork is off being painted at the moment..

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  #3  
Old 5th February 2018
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lugster lugster is offline
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Quote:
Originally Posted by Merch131ho View Post
On its wheels, the bodywork is off being painted at the moment..

Man that pic is way to big....
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  #4  
Old 5th February 2018
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norseXL norseXL is offline
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Join Date: May 2011
Location: Ultima Thule
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Sportster/Buell Model: xlh883/1250
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Sportster/Buell Model #2: XLH 1200 (Pia's)
Sportster/Buell Year #2: 1994
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So, where does the oil go?

.
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  #5  
Old 5th February 2018
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Jheitt Jheitt is offline
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That is sweet!

Sent from my SM-G950W using Tapatalk
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  #6  
Old 6th February 2018
Merch131ho Merch131ho is offline
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Quote:
Originally Posted by norseXL View Post
So, where does the oil go?

.
The new alloy oil tank sits low down in front of the engine, between the frame rails.

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  #7  
Old 6th February 2018
Merch131ho Merch131ho is offline
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Quote:
Originally Posted by lugster View Post
Man that pic is way to big....
Your right, didn't expect it to be so big, this better..

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  #8  
Old 9th February 2018
Merch131ho Merch131ho is offline
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Default

The bike originally had a number board with a small LED headlight set into it. But it didn't look quite right, so it was replaced with a conventional chrome headlight, along with a odd looking mount. This mount had to use the three mounting holes drilled and threaded into the top and bottom billet yokes.

It looks a lot better now its been blacked out using ceramic anodising, to match the rest of the bike.

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  #9  
Old 24th February 2018
Merch131ho Merch131ho is offline
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Here's a quick video of the bike I made a couple of weeks ago..

https://youtu.be/JZh7TL4uQ84
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  #10  
Old 24th February 2018
Wolff Wolff is offline
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Looks great! How did you solve the coil bracket? Was that a separate assembly or drilled holes in the existing bracket that holds the choke?

Thanks!
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