How can I set up my bike for timed D14 Enduros?

ws6transam · Oct 28, 2008

I'd like to try some enduros next spring, and I bought myself a 1992 WR500. It's equipped with a lighting coil, but no lights. It has a rather loud muffler. It's got seventeen year old motocross tires on it. However it's a fresh engine that starts as easy as you can ask of a Yamaha 490.

My goal is to put on a Baja Designs street legal lighting kit, some Kenda DOT-legal Waushagoul tires in stock size (120-100-18?/110-100-21??), and retrofit some sort of spark arrestor muffler that'll blow less than 94 db.

What else should I consider for making this into a decent & fun enduro bike? I hold no illusions of going in as a rookie and being competitive but I'd like to make a decent go of it.

I've recently bought a NOS Yamaha mechanical odometer retrofit kit for this bike. However, would it be more economical to install a Trailtech Vapor instead?

Any other suggestions on what I might need in order to make it enduro-worthy? --Tell you what, I took it out to Ionia's Honda/Yamaha shop last Thursday and rode it around their practice MX track out back, and this thing is way more bike than I've ever experienced. I might need more than a 90-degree throttle twist, plus a flywheel weight and a different pipe.

ws6transam · Oct 31, 2008

For Enduro use, I need some kind of time-keeping device and a scrolling map holder. Is that right, or is there some new method that people are using, such as GPS?

What else is handy? Chair for sitting in the pits? What about backup equipment like extra fuel, tools, tire changing irons, etcetera? What should I bring to a first enduro, besides myself and the bike?

_JOE_ · Oct 31, 2008

Wow, that thing looks surprisingly clean for a 92!

I would start with swapping the 17 y/o rubber out. Bark busters would probly be a good idea as I'm sure the front wheel likes to come up and that can be bad exiting a tight turn in thick woods. The suspension is likely 15 years overdue for service.

Those old big bores were pretty wild. A guy I ride with has a CR480, with left hand kick! :yikes: At least you don't have to worrk about crushing a radiator. :cool:

How are the brakes? Clutch cable? Anything that might break and leave you stranded should be examined/replaced.

ws6transam · Oct 31, 2008

Good idea on the barkbusters & suspension service: Yes I think a service is due. This is WR500 serial number 000253, making it the 153rd off the assembly line, in early 1991. From the looks of the dirt on the monoshock, it's never been out of the frame. Same thing for the forks. I think this is a low mileage '92, for even the chain guides look only slightly worn. Suspension bearings all squeak though. It's getting disassembled over the winter. Budget dictates that I may only have enough to change shock oil and fix any sticky bearings for this season. Next season (2010) I will probably have a chance to re-powdercoat the frame and give it the Tech-Care suspension treatment.

Brakes are great, and clutch cable & throttle cable are excelle nt. I do have a slight warp in the front brake, so I miht need to buy a new rotor. However it's minor and I might be able to live with it for now.

_JOE_ · Nov 1, 2008

I would at least change the oil in the forks. It will cost you less than 20 bucks and take about an hour or two. It's useless to try and tune suspension with low or burnt oil.

And where's the hot pink seat cover?

ws6transam · Nov 1, 2008

I'm working on the hot pink seat cover! One just came up for sale on EBAY. I'll install it once I find the matching pink Alpinestars and vintage pink & blue Fox jersey. ;p

_JOE_ · Nov 2, 2008

LOL, weren't the early 90s awesome!

duckboy · Nov 7, 2008

Baja design kits are pricey and take forever to get, a $10 50watt driving light works great mounted behind the number plate. The trail tech vapor is better than mechanical odo's and it'll do everything you really need. A plastic roll chart holder http://www.enduroeng.com/ProductDetail.jsp?LISTID=8000013C-1177528226 will do the rest. The tail light just needs to be red and placed carefully so it doesn't get torn off. You're better off using hand signals to stop and turn. Turn signals WILL get torn off or crushed. The barkbusters must be metal wrap around with a large shield to keep your fingers from getting whipped. A small gas can and cooler are great for putting on the gas trailer for the lunch break. Also a roll of clear packaging and storage tape to tape your scorecard to a flat spot on your front fender.
Then all you'll need is a police officer to sign your green sheet from the Secretary of State. If the officer requires a horn and mirror get the cheap plastic ones from the bicycle department. :cool:

ws6transam · Nov 7, 2008

Hi Duckboy,
Well, I just had a big go-around at the E.Lansing Sec State, because the old WR didn't have a title. It took a few trips, but the Lansing central office agreed and offered me the exact paragraph, section, and page that stated I could make a self-certification of ownership and apply for a replacement title. A national VIN search turned up no previous record anywhere in the USA, so it appears this is a "virgin" bike, never before registered or reported stolen. So, they have issued a title, which should come in the mail in a few weeks. I'm not sure yet but it looks like the title *might* be a regular motorcycle title, not an offroad title. If so, then the process of plating ought to be much, much easier. I like the ideas you've listed, but still think I'll be doing the Baja designs kit, mostly because I like the elegance of the kit. You are on the mark with the blinkers--- I'll most likely remove them when doing the tight stuff. I want them anyway.

Gas can... I am thinking of getting a metal 5-gallon can. I have a poly can and it's filled with 4 gallons of race fuel, and I swear, I can smell the race gas just leeching through the plastic. If its sealed in steel, it ought to stay fresher, I think.

I really like the other ideas and will put them on the list! I still need to find one other, critical thing though: .. a riding buddy. Someone who is patient enough to wait while I re-learn skills I haven't used in nearly 20 years.

duckboy · Nov 8, 2008

There's no shortage of riding buddies in Mi. Try this link for guys riding all year in Mi.
http://www.dirtrider.net/forums3/forumdisplay.php?f=69
Now if you want an enduro practise before a D14 race, just show up on Saturday and do the family enduro. http://www.d14enduro.org/ It's 12mph for the first loop them 18 for the second, so it's great time keeping practise.

dirtmark · Nov 9, 2008

the guys @ sicassracing.com in michigan make real nice kits also & you will get local support :nod: .

ws6transam · Nov 10, 2008

Thanks for the tip. I'll check them out and see how they look.
The bike is coming along nicely now. I still need to order new suspension bearings and get the forks redone, but that's an over-the-winter project. Hopefully the new title is on the way so that I can get the appropriate ORV sticker.

motorhead434 · Dec 19, 2008

dirtmark said:
the guys @ sicassracing.com in michigan make real nice kits also & you will get local support :nod: .

And they make/sell killer copies of the old school mudmuckers (elephant ears) to go over yer barkbusters when really muddy and or cold.Imo that overpriced baja kit is a waste for what we need to "be legal" to ride enduro's,unless yer gonna ride it to work or tour the hiways&byways.

ws6transam · Dec 19, 2008

Funny I just got off the phone with Sicassracing this morning and it looks as if I might be bringing them the WR500 in January to get it outfitted for a lighting kit, complete with LED turnsignals built into the barkbusters. Yea I know I can make it on less stuff, but I do plan on riding this bike to work & back, plus I want no question as to legaility when I take it with me to the various parks that we go to each summer. I want to weld up a motorcycle carrier to fit onto the back of my camper so that we can take the bike with us wherever we go.

I remember in the summer and fall of 1990, I used to ride my street legal IT250K all around Cocoa Beach in Florida, and once every couple weeks, I would get pulled over and the police would check my license plate & rego against the head stem VIN to verify that it was really and truly road registered and insured. I think that by having the little extra bits there will be less question as to it's street legality.

KTM Mike · Dec 30, 2008

Ws6 - I have seen your various posts over in the Mich. Trail Riders section, had not noticed this one here before.

A couple of suggestions - dont invest tons of $ into any sort of "specialized" equipment for enduros to start with. (beyond the basic woods worthy bike set up stuff) Do some of the FES events first - all they allow is an ODO and watch and route sheet. For the odo, a good old mechanical one is fine, or do the Trail Tech knowing your intent to ride on road (a speedo is handy!). For the FES events, you do not need any lights or to be street legal. I dont know what your prior woods riding experience is, but you might be suprised how tight the woods are the FES events run in when they have event trail. The LED turnsignal integrated bark busters make lots of sense for your street legal use and needs, but will not likely last long in event trail - so you may want a second set of conventional barkbusters to do the events with.

You are on track with the idea of flywheel weight. Consider a G2 throttle cam system as well. New tires a must. Barkbusters a must. Maybe gear that bike way up as well so it wont grab ya so easy!

If you plan on some of the D14 series events, Be sure to post in the MTR section when you are planning on participating in your first event. I can guarantee someone will take you under their wing and show you the ropes. I hope to do some of the FES events on my Penton this year, and will do a few of the D14 events if my back allows me to. You can get some commentary on how "newbie friendly" a given event might be prior to entering it - some are more so than others.

If you are planning any spring rides "up north", shoot me an email at ktm.mike.585<<<...AT...>>>gmail.com - I have some "event trail" on my property you can ride to see how you like it (duckboy knows it well!) It would be a great way to get a taste of event trail in a nice low key manner.

ws6transam · Dec 30, 2008

Thanks a lot for the reply!
I was working on the bike tonight, actually. I just ordered a set of the sticky Kenda Washougal K775's in 110/100/18 for the rear, and 90/100/21 for the front. They have recently gotten DOT certification.

In looking at the sprockets, I found that the prior owner geared it down to 14/52. I'm seriously thinking of moving up to 15/48T which is a pretty radical change. All I know is that 1st is unusable, second is way too jumpy and third currently does rollon wheelies. A gear change might let me tame second gear.

I appreciate the invite, I'd love to take you up on it- Tight stuff is going to be a new experience as most of my riding was in the desert scrubland of central Australia. Back there it was very dusty, semi-open terrain, with lots and lots of rocks. We used to climb Mt. Gillen with the bikes: It's in the background of this old photo.

KTM Mike · Dec 31, 2008

Yep - based on that picture I would say the tight woods stuff may be quite an adjustment! For woods use, I would definetly go to the 48 rear. If that isnt enough, then doing the 15 front later on would be easy and cheap enough. I am not familiar with that tire combo you mentioned. I have seen good reports on the Kenda Millville sticky for Michigan use (look for some posts in the MTR section on that from DW). I tried the Kenda Southwick, and did not really care for it. 90% of the guys I know with "plated" offroad bikes in Michigan dont bother with using a DOT tire, and take their chances. I have 4 plated dirt bikes in the garage right now - not a one with DOT rubber.

LMK when you are ready to do some riding this spring. I am recovering from a ruptured disc - so wont be ready to ride (according to my Doc) until end of March.

ws6transam · Jan 6, 2009

new bike pictures:

I'll be heading to Sicassracing in a week or two, I think, to get it kitted with lights.

How can I set up my bike for timed D14 Enduros?

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