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With a highly modified bike you have to spend ages designing and building sub-systems. This is the fuse array

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These freshly-crimped chaps – complete with little grey seals – are about to go into a water-resistant Delphi connector plug

Sean’s XR650 overland bike

This bike isn’t finished yet but it’s so complicated and ambitious it’s already worth writing about. Owner Sean is planning a big trip to the Americas and beyond, and the bike is Honda’s water cooled XR650 enduro bike. It’s got huge suspension, no battery and moped-basic lighting. His plan is more suited to multi-country travel: high power lighting, USB charging, an ignition switch, a Vapor dash and – to power it all – a new alternator stator plus reg rec to charge a battery.

Fitting all this stuff to a racebike with absolutely no space asks for some very creative thinking. The lights were already mounted but the Denali spots were shaded by the front mudguard. Scott the fabricator made some amazing brackets to put the spots up high where their beams could light the road ahead without obstruction. The right hand bracket also acts as a mount for the fuses. The USB charger snuck in next to the dash, and the Yamaha ignition switch sits on its own chunky bracket. The regulator rectifier squeezed in under the seat, but the battery was a real headache.

The only place it could go (without getting overheated or hammered by gravel) was under the rear luggage rack. The meant chopping the rack up, extending it upwards, making a box, making a water resistant lid, welding the box to the rack and fitting a closing strap. Not the sort of thing you can accomplish in half a day.

Plenty more to do yet.

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Work in progress. The original rack rails sit under the new top loop, which is now high enough to let a battery box fit underneath

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Ignition box is in its original position. Flasher unit, tail and charging connectors, and regulator rectifier squeeze next to it