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  #1  
Old 26th February 2019
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Default Transformer XR1200

I thought someone might be interested in how I transform my XR for longer trips.

With the cooler months approaching I plan to ride out to my job, which is about 350k's away. Plus riding between the camp site and the work site, which adds about another 150k's per week. So 850k's all up. Doesn't sound alot but its all rough outback country roads on an XR!!

I work a 5 day on 5 day off roster, and stay on site for the time I'm working, so I will need to carry abit of gear. I want a bit more comfort, because I'm getting a bit sooky in my old age, and codeine is not an option, the company drug test us . And lastly I want better fuel economy, which will also make it less buzzy, adding to the comfort department.

Here's the collection of parts I will be adding:

Higher Handlebars
Longer clutch cable (to fit the higher handlebars)
Windscreen
Rear Luggage Rack
Gear bag (attached to the rear rack)
Tank bag
Gel seat cushion
30T front pulley and 66T rear pulley



I will be driving my car back out to work tonight but on my next days off I plan on starting the transformation. Here are the customary before photos.



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  #2  
Old 26th February 2019
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Very well done!!, I like those mods you have planned, the addition of that gearing change should really help out at highway speeds and get you better gas mileage.
I really like the fact you have the X model with the orange bodywork, I think it looks the best. Tell us how things went, when you get back
Regards
Roy
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  #3  
Old 26th February 2019
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Sounds good. Can't wait to see and hear more about it.
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Old 4th March 2019
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First day back from work today

I changed the handlebars this morning and put the windscreen on. I wanted to use the barend mirrors on the higher bars but I can remember knocking the plugs home with a hammer in the thick walled biltwell trackers, so they are firmly wedged in there and I don’t want to damage the plugs trying to removing them, so they can stay with the lower bars along with the mirrors. I will just use the original mirrors for now and order a new set of barend mirrors for the high bars, the mirrors are just cheap things from China, they work well.

The before and after pictures.



Last edited by Davo_137; 4th March 2019 at 12:52.. Reason: resize pictures
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Old 4th March 2019
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Back in the shed this afternoon for a short stint. Started 2 jobs but couldn’t complete either, a trip to the fastener shop will be needed to get both jobs finished.

First job was move the rear shocks back to their original location. I don’t think I will need the 2” rise for touring so the riser blocks have come off. Also I will be using a gel seat cushion which lifts the seat height up. I’m just over 6ft but with the 2” riser blocks and gel cushion together has me reaching for the floor.

With the riser blocks


The original position


The riser blocks bolt to the passenger footpeg bracket holes. Legally I have to leave the passenger footpegs off the bike because I have the bike registered for solo use only, it costs a lot less but if you get caught carrying a passenger or even having passenger pegs on the bike the fines are huge. So I need shorter bolts or plastic caps to fill the bolt holes on the left side, and shorter bolts to anchor the exhaust bracket on the right side.


Last edited by Davo_137; 4th March 2019 at 12:55..
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Old 4th March 2019
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The second job this afternoon was fit the lower part of the rear luggage rack. I got the rack secondhand and a couple of the Allen head bolts that came with it had stripped heads. I used them when I fitted it the first time by holding the heads with vice grips, and when I removed it, but had forgotten about them until today. I want to make that right this time.

It’s a bit of a jigsaw puzzle getting this on but once you work it out it’s quite easy.

Last edited by Davo_137; 4th March 2019 at 12:56..
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Old 4th March 2019
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Just figured out how to resize the pictures. I posted with my phone this afternoon and didn't realise how big they were untill viewing the thread with my laptop. Sorry about that
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Old 4th March 2019
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Ordered these mirrors. $23 delivered. Cheap bastard you might say.. you would be right, actually I crashed once with these mirrors, a lowside, and these mirrors survived that, so thats good enough for me
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Old 5th March 2019
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More tinkering this afternoon.

Took wifey into town today, made a detour to the fastener shop on the way home. I got some nice stainless steel bolts and washers to finish off the installation of the bottom half of the rear rack brackets and the exhaust mount. Then I fitted the seat unit and the top half of the rear rack brackets. I have an old rear seat cowl I use with the rack, its had a piece cut out to make it work with rack brackets. The rack is designed to fit with the rear seat but due to the solo road registration I can't use the seat, its the same deal as the rear footpegs I spoke about in yesterdays post, big fine by the man if caught.

A picture of the rear rack brackets and modified seat cowl (yes it needs a paint job). You can also see the gel cushion I will be using.


I won't be using the OEM rack. It doesn't work with the gear bag I have. I have some aluminium plate and stainless steel pipe. I will attempt to make something out of that to attach to the rear rack bracket that should accommodate the bag... not sure how that will turn out haha.

The OEM rack.


The plate and pipe.



The only other job I done today was fit the longer clutch cable. Lucky I did because I have to take off the shifter shaft linkage to get the derby cover off and found the allen head set screw that holds the linkage to the shifter shaft was loose and would probably have fallen out next ride, which could of been expensive.






Just sitting on the bike in the shed today felt kinda weird. Feels like I'm sitting way way back on the bike due to the higher handlebars. I've gotten used to those low tracker bars. Going back to the standard geometry is probably adding to this weird feeling aswell I guess. Should be like riding a new bike, can't wait
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Old 5th March 2019
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I had a bit of a scare last night, my laptop decided it was going to give up the ghost. I thought I had lost all pictures, videos, documents etc but most importantly my powervision stuff (going to need that when I change the gearing) and my sportster workshop manuals. Restore to a previous setting wasn’t working, but looks like a complete reset has worked this morning and I haven’t lost any files but will need to install all the software again. So today will be search and rescue of the powervision stuff, when I find the disc, and then hopefully get the pulleys changed out, reflash the ecm and make a start on my idea with the luggage rack. Also need to tune the suspension for the extra weight, I’m not sure how much extra weight I have added plus when fully loaded so I’m just going with 15kg’s for now and see how that feels. That can be adjusted on the road.
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