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Thread: VOR En to Motard Conversion & complete rebuild

  1. #1
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    Default VOR En to Motard Conversion & complete rebuild

    Hey Guys

    I am new to this forum, So i hope all my pictures get loaded correctly, If not, Please bear with while I get used to the site.

    I though I want to share my project with you all. I have decided to rebuild my current VOR 450 EN to a road legal Motard. The reason for this is that I feel so sorry for my bike in the bush and the fact that I struggle to source parts when something does go wrong. Hopefully if I stay out of the bush with the bike, It will not require parts as often......
    (I will be getting another bike for the bush)

    Here is my Before picture. and a picture of the Motard rims I have already aquired.
    I will be report back frequently and post pictures regarding my progress.

    is there any tips you guys wanna give me before I start?





    Cheers for now. Will be back soon...

  2. #2
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    Hi Guys

    A quick update on the start of my project….

    The VOR was running on Excell offroad rims. So I got a good deal on some BEHR Motard Rims. The rear rim fitted 100%, the front wheel however did not fit so good. I needed new spacers, Shaft and bearings. Now, I am an engineer by trade, so if I can make a part instead of buying one, that is what I will do…. I drew up my parts list on CAD, and sent it of to be machined. Should be receiving it back within the next couple of days. Just for info, I had it made for 1/3 of the price what a new parts would have costed me… (Will post pics soon)



    When I get the shaft and spacers back, I will have to check for correct for of the caliper, as I would have to make a spacer for that as well to accommodate the larger brake disk.

    When I am 100% confident about the fitment of these rims, I will start the major stripdown. Below is a summary of what I am planning to do to the Bike.

    Frame
    Silver annodizing (maybe powder coat if I can get a nice shine from it)
    Swingarm
    As it is aluminuim, Just requires a thorough flat and polish.
    Rims
    Currently chrome, Just need a good poilish as the chrome is still in good condition, no n scratches whatsoever. I am also thinking of powder coating the outer rims black and keeping the spokes chrome. Will need to powder coat the hub black too.
    Plastics
    I am busy designing a custom decal set for my bike, Will post pictures. However, I still need to get a motard from fender and a decent looking headlight.


    Till later.
    Last edited by VORMOTO; 06-19-2012 at 05:36 AM.

  3. #3
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    Are they going to make that axle shaft hollow? If not you'll have a bit of extra unnecessary weight and no place to bolt on fork sliders in the future.

    Looks like you're off to a good start so far.

  4. #4
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    Hi, yes. It will be hollow. Just not indicated on drawing. Will be a 13mm diameter hole. Will be Using SAE 5160 steel for the axel shaft. Getting it back tommorow, then I will be taking the bike to the track this weekend for a couple of test laps before the big stripdown. Really want to get this project done ASAP without compromising quality.

    Cheers for now.
    Shaun

  5. #5
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    This is my axel after being machined. Did a quick Fitment check and all is 100% just gonna get it nickel plated to prevent future rusting and buy the bearings and the seals, Then its done.

    really getting into this project now with stuff getting done


  6. #6
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    Sweet..those VOR's are pretty rare. Keep up the posts
    2008 Husqvarna SM450R
    Check out the Supermoto Central Shop for the new Supermoto Central gear!

  7. #7
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    Getting my plated shaft back tomorrow, can't wait! For me, the quality of the rebuild will depend on the small things...

  8. #8
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    Hey. Got my plated shaft back, Fitted it with new bearings and seals and went for a spin. Bike runs great, so now the big strip is starting. Will post pics soon. I am first sorting out my garage so that I don't have clutter and sh1t around me for when I start.
    Attached Images Attached Images

  9. #9
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    Some updates on my rebuild.

    Started the stripdown, took about 5hours to completly strip it down.

    I think i have to rename the Forum to "RESTORATION" as alot of the parts I removed will have to restored because i doubt if I will find suitable parts "off the shelf"








  10. #10
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    Guys, this is were I will need your help and input.

    I cannot for the life of me decide on what I want to do with the frame and swingarm. I had some ideas floating in my mind, but now that my frame and swingarm has been prepped for blasting and coating, I am thinking about a 1000 things at once. these are my options

    - Silver frame, polished alu swingarm and polished chrome rims
    - Silver frame, Black swingarm and silver rims.
    - Black frame, Black swingarm and black rims with with polished chrome spokes. (maybe silver or red hubs)

    Any ideas from your side? I will take a couple of days to think this thru..... Just to give you and idea of my plastics, see picture below, Not done with it, still waqnt to add some logo`s, writing etc.....
    But this will be my colour scheme (red, White & black). I want to stay with the original VOR colours.

    Saw a picture of a VOR once with decals like this, So I decided to draw my own instead of searching worldwide for it. if anybody wants the outlines to do their own designwork, Please feel free to ask for it, I will gladly provide it to you for fokol.

    (fokol = Fuckall in Afrikaans)


  11. #11
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    How did you draw your own like that? Looking good though. That is a crazy looking frame.
    2013 KTM EXC 500 SM | 2009 Yamaha Zuma 50 | 2003 Kawasaki z1000

  12. #12
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    Quote Originally Posted by 225 View Post
    How did you draw your own like that? Looking good though. That is a crazy looking frame.
    I did it old school way, took some sheets of paper, placed them over the plastics, traced the outlines, digitized the tracings, converted the file to .dwg, pulled it into AutoCad, plotted scale 1:1 on normal paper. Check fitment, made some manual changes on cad, check it again, and then I started rendering. Quite simple actually but very time consuming.... ;-)

    Ja, the frame is very robust.

  13. #13
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    Hey Guys, While i am deciding on what to do tho my frame and swingarm, I was thinking of getting my exhasut chromed, What are your thoughts about this? Will it affect my motor in any way?

  14. #14
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    Looks good, nice job!

  15. #15
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    Default Chroming your exhaust...

    Quote Originally Posted by VORMOTO View Post
    Hey Guys, While i am deciding on what to do tho my frame and swingarm, I was thinking of getting my exhasut chromed, What are your thoughts about this? Will it affect my motor in any way?
    Man... chrome?
    If your headers are stainless then sand and polish if there Titanuim then clean and buff and let 'em blue!

    Of-course that's just my own tastes... so who cares right, build the bike you wanna ride!
    BTW, I like the build, you're lookin sweet so far!

    Cheers'
    Mike

  16. #16
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    Thanks man.
    I have decided on the powder coating. Will be going Jet-black for the swingarm, silver on the frame. Will be taking it in only in 2 weeks time due to work. Will keep the updates coming.....

  17. #17
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    Dropped of my frame and swingarm off for coating!
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  18. #18
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    Quote Originally Posted by VORMOTO View Post
    Dropped of my frame and swingarm off for coating!
    Excellent, getting close to the final product.
    You have tompost some photos when you get it together bro.

    Mike

  19. #19
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    Will post pics of the powder coating when I get It back, its gonna look sick! The way I see it, the real work is only starting now, still have a shitload to do!! The bike is going to be a show stopper! I'll probably only take it out the gargage to admire and then put back. Haha! Need to get my a YZ or somthing else for daily use......
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  20. #20
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    Got my frame and swingarms a couple of days ago. Swingarm came out great! Frame, not so great. The place I took it to had a new employee, and he fucked my frame up by not cleaning it properly after being sandblasted. Frame looked like 600grit sandpaper......! Now it has to be stripped and re-coated. The owner of the place was very sorry and offered to to do my rims at no charge whenever I am ready to bring them in. Spend the last couple of days just cleaning up my motor and refurbishing various parts. Pics to follow soon.....
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  21. #21
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    as promised, here are the pics of my frame and swingarm. The frame needed to be stripped and recoated as explained earlier on.

    The pics does not do any justice to the actual colour of the frame. it is a mettalic silver. on the pictures it actually looks greyish.

    damage to powder coating


    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  22. #22
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    Arrow

    Subscribed!

    I found a local guy selling a VOR supermoto and and I think I've got him interested in keeping it so he can race supermoto

  23. #23
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    Got my motor all cleaned up and fitted. I am hesitating on stripping the entire motor end rebuilding due to the availibility of parts. My engine was running 100% before the time....








    Next up is the tripple clamps & wheels. My shocks are currently in the shop for new seals etc....

    Got a issue with my rear shock though, Waiting on a reply from our local Ohlins dealer if he can sort this out for me


    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  24. #24
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    Great build mate! Love the black swingarm! The motor you can still get piston kits from wossner I just got one for my 503. I ended up getting it from eBay!! Other than a piston the parts in side are pretty strong and won't need much doing to them other than replacing things like bearings and seals. Im building a MX503 2000 (the first vor in aus ever sold) right now which is my dads but has been in bits for about 10 years so I thought I would build up and give it to him for his 50th in January. Also if you need parts the old importers in Australia cross country action in cessnock are doing a big sell off of all there parts.

  25. #25
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    As I said, the bike runs 100%, no oil smoke,leaks or lack of power,but I think I might just start buying some parts to have incase something goes wrong. I have a got buddy in Australia that can get the parts for me, when he comes back to SA he can bring it with, he can trow it in his furniture container. We get screwed with import taxes here in SA. Almost always the same price we pay for the item.

    On another note. I have been busy with some small stuff around my bike, doing the cooling system, polishing my exhaust etc... Wil uplaod photos later on, need to take pics still.

    Below is a update of my decals.
    I think this should do?????
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  26. #26
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    What happened to this build? Did you get it finished? Good to see you from SA!!! I am busy with my build at the moment, waiting to get it done and will post every thing! please post the rest of the pics so we can see the end result!
    06 610 Sm

  27. #27
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    Hi guys, sorry for the delay in getting pics up. Ive been out of the running for while due to some setbacks. But i am back, i have pulled of the sheets from the bikke, and i'm ready to carry on from where I left off. The only progress i have made thus far from the last pics was that i managed to get my rims done. Powdercoated and respoked. Looks flippen awesome. Will upload pic tommorow. (Working on ipad now). Cheerio
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  28. #28
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    Quote Originally Posted by VORMOTO View Post
    Hi guys, sorry for the delay in getting pics up. Ive been out of the running for while due to some setbacks. But i am back, i have pulled of the sheets from the bikke, and i'm ready to carry on from where I left off. The only progress i have made thus far from the last pics was that i managed to get my rims done. Powdercoated and respoked. Looks flippen awesome. Will upload pic tommorow. (Working on ipad now). Cheerio
    looking forward to seeing this back on track!
    06 610 Sm

  29. #29
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    Pics as promised...... More to come.

    [IMG][/IMG]
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  30. #30
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    More pics to follow
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  31. #31
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    More
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  32. #32
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    Thumbs up

    Im back!!

    Managed to get some work done on my triple clamp and handles. Polished my aluminuim clamps and riser, powder coated the resevior and handlebar. And put some new grips on. These grips will be replaced by some awesome ones later, waiting on them to be delivered.

    Full steam ahead from now on!!!
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  33. #33
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    holy Feck ! nice job so far ! any bike that has Ohlins definitely deserves all the love your giving it ! keep up with the pictures...
    Brian # 30


    KTM 450 SMR

    "Everyday is a good day" Just some days are better than others

  34. #34
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    Nice work dude it's so good to see people working and rebuilding these awsome bikes!
    Check the valve clearance regularly and if possible replace the water pump seals every year and you will be fine with that engine
    You can get almost anything directly from Italy. Let me know if you need any help with that.

  35. #35
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    Quote Originally Posted by Space Cowboy View Post
    Nice work dude it's so good to see people working and rebuilding these awsome bikes!
    Check the valve clearance regularly and if possible replace the water pump seals every year and you will be fine with that engine
    You can get almost anything directly from Italy. Let me know if you need any help with that.

    Thanks, I saw the link fmfrigerio@libero.it on your build. I do actually do need a waterpump seal, mailed the okes this morning. I really hope thier english is good on return email, as I cannot make out the descriptions on their site.
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  36. #36
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    I don't know about their english i allways translate to italian to make sure we understand each other Fabio is allways very helpful just give him the parts numbers from the workshop manual (let me know if you need it)

  37. #37
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    Hey guys. Was planning on starting with my plastics this weekend,then i got faced with a bit of a dilema. As you can see by the pic below, all my bolts are stuck inside the plastic mould of the tank. I cannot get this out, it is stripped. Arghhhhhh!!!!

    Has anyone one of younhave this problem before?

    I tried drilling it out,but the "housing" is so stripped, it just turns with the drillbit.

    Before i cut it out, and try to remould the tank in that area, doesnt anyone have any ideas?

    I dont want to buy a brand new tank, that is going to cost me in the regions of ZAR 2300 to get it all the way to sunny South Africa. That is equivelant to 57.5 big mac meals......

    The rest of the tank is in great condition.

    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  38. #38
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    On my Husky, you could pull the inserts out with the stripped bolt. Then remove the bolt (maybe use a vise) and reuse the threaded part if possible. I just glued it back in, not a problem since then. Always put a bt of grease on the screw´s thread before you put them in. Otherwise they´ll corrode as you see. Good luck.

  39. #39
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    In my case, the entire insert is stripped within the housing, but yes, i will try and pull it out with a vicegrip, just dont hope I pull hole into the tank.
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  40. #40
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    To remove that just heat up the plastic a little bit with a heat gun and pull it with a bolt. Pay atention to the bolt's lenght when it's time to get the plastics back in (i used longer bolts in mine and they went through into the fuel tank )

  41. #41
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    Quote Originally Posted by VORMOTO View Post
    In my case, the entire insert is stripped within the housing, but yes, i will try and pull it out with a vicegrip, just dont hope I pull hole into the tank.
    It´s broken now anyway, so give it a shot.

    If the insert is stripped, maybe glue in a screw nut if new inserts at VOR are discontinued.

  42. #42
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    1st try with a little bit if brutal force and heat it came out. 1 down, 2 more to go. As you can see on my second photo, i dont have any leverage to attach my vicegrip to. I will sort something out tommorow night.

    Also, what worries me about the second one is that you can see the diffrence in lenghts of the bolt to the insert depth.(1st bolt) The bolt is 20mm and the insert depth is only 11mm. If the same bolt is used on the 2nd insert, i forsee some problems. I dont feel the bolts coming out on the inside of the tank.....and the tank never leaked.





    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  43. #43
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    I had the same problem and solved it with some plastic threaded pieces like this from an IKEA furniture

    Just glued them on the hole

  44. #44
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    Ok, finally got the last one out. Had to destroy the plastic to be able to get leverage on the bolt. Only occured to me afterwards that i could just have welded something on the bolt...... Atleast I have an extra shroud,

    Also got some damage to the tank, but that is fixable.

    The wife is going away on saterday, so i get to use the dishwasher to degrease all my plastics, tank etc... She will kill me if she knew ishat I have cleaned in there before. Just make sure i clean the filters afterwards.



    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  45. #45
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    By the way. I have found the supermotojunkie app for ipad, so much quicker and easy to reply and add pics. Quite cool.... App is called "tapatalk"
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  46. #46
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    Tapatalk is universal for many forums.

    Good to see you got it out!

  47. #47
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    Quote Originally Posted by Space Cowboy View Post
    Nice work dude it's so good to see people working and rebuilding these awsome bikes!
    Check the valve clearance regularly and if possible replace the water pump seals every year and you will be fine with that engine
    You can get almost anything directly from Italy. Let me know if you need any help with that.
    I contacted Fabio, and he has got some seals for me, the only problem is that they are summer holiday and are only returning back to normal routine towards the end of the month..... And that is the only thing keeping me from starting my bike up for a test fire to check my wiring....Any change you might have an extra water pump seal laying around? I can sort you out via PayPal? :-)
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  48. #48
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    Quote Originally Posted by VORMOTO View Post
    I contacted Fabio, and he has got some seals for me, the only problem is that they are summer holiday and are only returning back to normal routine towards the end of the month..... And that is the only thing keeping me from starting my bike up for a test fire to check my wiring....Any change you might have an extra water pump seal laying around? I can sort you out via PayPal? :-)
    Yes i think i have an extra set laying around in my garage i will check tomorrow ok? If i find it i can send it i'm glap i can help out
    Add me on facebook or send me an email with your address please

  49. #49
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    Quote Originally Posted by Space Cowboy View Post
    Yes i think i have an extra set laying around in my garage i will check tomorrow ok? If i find it i can send it i'm glap i can help out
    Add me on facebook or send me an email with your address please
    Thanks dude!!!!!

    I sent you a mail, please let me know what I owe you!!
    2005 VOR EN 450 - rebuilding to motard.
    2005 VOR 450 MX - burned out
    http://www.supermotojunkie.com/showt...mplete-rebuild

  50. #50
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    nice refurb
    jc
    O6 TE450
    2008 KTM 690 SMC gone
    2005 KTM 625 SMC (sold )

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