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February 18, 2009

Building The TransAlp Racer - A Middleweight Adventure Sportsbike

Building the Transalp

Overview: Start with an old Honda Transalp: give it a heart transplant, hop-up the new donor engine, custom build an exhaust pipe, grab a refurbished swing arm, install new forks and fabricate rear disc brakes, pressure wash and the final touch is aerosol paint… go racing.

We caught up with Dave Jansen of Combustion Cycle at his shop in Durham, NC to see how his project was coming along.

Out with the Old

Old Transalp Engine Old Engine is Benched

The original Transalp engine is a liquid-cooled, six-valve, four-stroke, 52 degree V-twin. It made approximately 50HP.

The D&D Performance Enterprises Exhaust Connection
Dave sells D&D performance pipes at his independent dealership and got together with the lead engineer, Aaron Whitney of D&D, to assist him in developing a pipe for the motorbike.

Since Jansen transplanted the engine with the Honda Hawk, Aaron didn't have a standard pipe to fit the bike.

He put together a selection of pipe pieces including multiple pipe bends, straight pieces and a collector, which allows Jansen to fabricate his own custom pipe.

Pipe is Measured Twice then Cut Pipe is Measured Twice then Cut

D&D sent some off-the-shelf parts as well as some specific bends for Jansen's racer.

D&D Bends Pipe to Specific Lengths D&D Bends Pipe to Specific Lengths

After the pipe is cut, it is then bent to size.

After Cuts & Welds the Pipe is Ground Smooth After Cuts & Welds the Pipe is Ground Smooth

It's important to make sure that the interior of the pipe is smooth as it improves exhaust gas flow.

D&D Pipes for Transalp Dave Makes Cuts to Create his Exhaust System
As we walked into Combustion Cycles the race bike was on the lift with the new engine bolted in.

D&D Pipes for Transalp
Tacking the Pipe

Dave is shown here tacking his new exhaust system together while it is on the motorcycle.

Old Transalp Engine The Transalp is Getting Ready to Rumble

Dealership Details

Name: David Jansen

Company: Combustion Cycle

Address: 911-C East Trinity Avenue
Durham, NC 27704

Phone: (877) 652-4073

February 18, 2009 8:13 AM | send page