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post #1 of 55 (permalink) Old 10-16-2019, 11:12 AM Thread Starter
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Main Motorcycle: '06 Triumph Sprint 1050
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Naked Sprint build

This is my second '06 Sprint ST. Lost the first one in the flooding from Harvey in '17 and picked this one up as a replacement back in '18. Since I've been documenting this one since day one, I figured I would make a build thread to share what I've been up to.

First off, the permanent (I hope) album link where all the pics will end up. Go here to see things full-size, as I'm not doing all the url tagging to just click the pic. https://imgur.com/a/SZcaAPr

The bike when I got it:


Wasn't planning on repairing the damaged fairings, I liked my other one naked, and it's not too difficult to make the mods necessary.


Got the Two Brothers exhaust on that I'd pulled off the old Sprint... had to do something to replace that stupid GP-style tip they put on the end of the mid pipe under the tail.


There was a lot of wiring, normally tucked into the front fairing, that I had to deal with once I got the headlight and mini-fairing placement sorted...


...quite a bit. It all tucks inside the frame around the air box nice enough though.


While scared up, the stator cover at least did not need to be replaced. I sanded it out and added some R&G sliders on both sides.


With everything back together it was ready for road-worthy inspection and registration.
[/QUOTE]

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #2 of 55 (permalink) Old 10-16-2019, 11:20 AM Thread Starter
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Next thing to address was the coolant overflow reservoir. I really liked having the Lone Star beer can as the overflow on my Venture, but wanted something a little more professional. Enter the aluminum water bottle. Shaved the lid and drilled it to run a hose through to the bottom of the can, then put another toward the top on the side as an overflow vent. The few of you who saw my thread on my old Sprint from 2015 may remember this mod from that bike. Eventually (hopefully soon) I'll do these a little more correctly using some threaded brass fittings. Anyway, mounted the bicycle bottle cage, cut up a Lone Star can, and this was the result.


Bike badly needed a front tire and the forks felt awful. I decided to tackle both while the front wheel was off anyway. Progressive fork springs were added along with new fork oil (once everything was cleaned out), and tapered steering stem bearings were installed to replace the original ball bearings.







If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.

Last edited by jaewastooshort; 10-16-2019 at 11:23 AM.
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post #3 of 55 (permalink) Old 10-16-2019, 11:29 AM Thread Starter
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Main Motorcycle: '06 Triumph Sprint 1050
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While rebuilding the forks I found out one of the tubes was slightly bent. Very annoying, and helps explain why the forks felt like they were binding a bit occasionally, so I did the prudent thing and just put them back together with the new sliders and seals, then back on the bike to continue riding on them for another year. You can see the bend here, on the far right. Not too drastic, but definitely there.


Needless to say, it wasn't confidence-inspiring, so I recently set about locating a set of Hayabusa forks to swap in. Whoops, spoiled it in the previous pic. Triple tree clamps were from a TL-S. Another new set of tapered head bearings (no way I was getting the lower bearing off the Triumph stem without destroying it).

When I started receiving parts


Comparing length, as guys do


Bike seems supported well enough...


Hmm... that tab on the neck might be useful.


Stock front end coming apart for the last time


Snap of the fingers, and ALL DONE! (I wish)

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #4 of 55 (permalink) Old 10-16-2019, 11:41 AM Thread Starter
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Had to drill the TL-S top clamp in order to run a standard bar setup.


I pulled these risers and bars off another bike that's partially disassembled, but they won't be used in the long run...


I had to do a little work to get the front wheel spaced properly. The Sprint used offset spacers on the front axle (to accommodate the ABS ring on models so-equipped), but the Busa front end was set up to have the front wheel centered. Cutting down the Sprint spacers to the right width worked out just right.


Testing fit and measuring before cutting the second spacer


How did I trim them without a lathe? Made my own out of a cordless drill, a bench vise, and the wheel balancing setup for the triumph's rear wheel. Just press the two tapered spacers into the wheel spacer as tight as I can, tighten the set screw, and cut along the Triumph-supplied groove with a hacksaw held stationary while the drill turns the shaft. The fitting held in the vise has bearings to support the shaft.


Onto the finer details...

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #5 of 55 (permalink) Old 10-16-2019, 11:42 AM Thread Starter
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I wanted to be able to use the steering damper in its stock location, so I decided to make a bracket to attach it to that tab on the steering neck. Yes, it looks really bad, but don't worry, we're far from done. Consider this just "proof of concept".


Looks like it'll work to me.


What other details do we need to address? Ignition switch doesn't really get close to fitting the TL-S upper. Had to trim the mounting posts on the top clamp by about 15mm and take another 15mm or so off the steering lock and ignition switch housing because it sits so much closer to the neck now. Those numbers may be off a bit, I honestly can't remember the original length of the parts I cut down. I started with the measurements listed in the fork swap thread, or as near as I could approximate by marking with a Sharpie and using a dremel and file, but ended up doing the measure/cut/test fit cycle 3 or 4 times over two evenings before everything fit as it should.


Got it pretty damn close.

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.

Last edited by jaewastooshort; 10-16-2019 at 12:02 PM.
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post #6 of 55 (permalink) Old 10-16-2019, 12:03 PM Thread Starter
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The ears I had for the 7" round headlight were designed for 35-39mm fork tubes and are not going to fit the 50mm Busa uppers. I decided to try out a fixed headlight setup that would tie in with the steering damper. Figured the more I can kind of tie in together, the stronger it would all be.

Making the base flanges for the headlight ears. You can also see here how the steering lock was rubbing while I was test fitting to see if I'd cut it down enough.


Oh yeah, also decided that I wanted to do some ProTaper style bars, so I got myself some 1-1/8" bar risers and a set of bars that looked like they might land about where I want them. We'll see how they fit me once I get the bike back on the road.


A little cardboard-aided-design to help me out with placing the headlight bucket in relation to the forks and mounts




Coat hangers are easier to bend than 3/8" solid rod

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.

Last edited by jaewastooshort; 10-16-2019 at 12:06 PM.
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post #7 of 55 (permalink) Old 10-16-2019, 12:08 PM Thread Starter
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I took a short break from the headlight to do the mount for the auxiliary LED light bar when it came in. I was never particularly happy with the light output from the stock halogen bulb in that 7" housing, but until I decide on what to replace it with, I figured I'd add an auxiliary light.




Pretty happy with this fitment.

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #8 of 55 (permalink) Old 10-16-2019, 12:08 PM Thread Starter
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Back to mounting the headlight... ended up reusing part of the bracket I'd made to mount the stock gauges on the old setup. I'm not going to provide too much other commentary here, pictures should speak for themselves.















Ok, I lied, I can't stop commenting. Was really happy with the headlight bucket placement, but it needed a third point of contact to set the vertical light cut off, which means it'd also better be adjustable.


I don't have a clue where that spring came from, but it ended up being the perfect size to provide a firm, yet compliant force on the headlight without having to use double nuts at each contact point on the adjustment bolt.

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #9 of 55 (permalink) Old 10-16-2019, 12:09 PM Thread Starter
Supersport 400
Main Motorcycle: '06 Triumph Sprint 1050
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Location: Houston, TX
Posts: 94
Other Motorcycle: '08 GSXR 600
Extra Motorcycle: '92 Honda Z50 (125cc now)
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I got the headlight mounts wrapped up and installed back on the bike this weekend. Got the mounting nuts tacked on, sharp corners rounded off on a grinder wheel, and cleaned up the remaining welding slag/spatter and edges with a flapper wheel and then primed/painted all the pieces.







About time to start body work so I can get the tank, belly pan and tail plastics painted.

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.
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post #10 of 55 (permalink) Old 10-16-2019, 12:25 PM Thread Starter
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One more minor bracket down. Needed something to support the brake fluid reservoir on the handlebars, as the original mount was secured on the stock clip on.












Anyway, here's the bike as she sits this morning.


Got that bracket painted last night, but forgot to get a pic. I also ordered a set of Speed Triple gauges this morning that I'll be mounting as soon as they come in (and I verify they work with this setup). I've been watching ebay and waiting for a set to pop up for sale for several weeks and this is the first one that's been relatively clean and under $500.



Oh yeah, finally skinned my coolant reservoir as well.

If I had all the money back I'd ever spent on motorcycles, I'd go spend it all on motorcycles.

Last edited by jaewastooshort; 10-16-2019 at 12:34 PM.
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