The sumpguard is quite a structure on the Honda Europe kit and provides three litres of emergency water capacity in two tanks in the bulbous front section. We decided to add a bit more protection underneath in the form of a couple of 4mm think ally panels and an extra thick section running close to the beautiful, titanium, Akrapovich underslung exhaust mounted under the right hand footpeg.
Click image to learn more about shock and exhaust set-up

The kit bolted on in a largely trouble free fashion, though the milling machine and lathe took a caning from all the custom made brackets and modifications to make things fit us more comfortably and to strengthen things we didn't think were up to the job... Cable routings and loom routings (a whole new loom for the rally bike!) took ages but were strangely satisfying to do...
We did decide that the lack of good airflow through the bike with all the extra fuel meant we should run larger rads which helped enormously and meant that in all but the dunes we didn't use the CRF250X fan which we put on a manual switch rather than a heat sender.

We also decide we need heat protection for the underneath of the main tanks which came in the form of a reflective blanket as used on some superbike builds. The exhaust doesn't get much airflow to it despite drillings in the sumpguard, so we decided to wrap the front section to prevent the carbon fibre resin getting too hot. We also used exhaust wrap on the rear section to stop us burning our boots! The only other major deviation from the Honda Europe kit was to build a small tubular steel subframe for the toolpack on the rear mudguard, mostly to strengthen the mudguard for the toolpack, but also to give us somewhere stable to grab the bike to pick it back up out of the sand! Hey, we don't plan on dropping it, but we were boy scouts, prepared for every eventuality!

 

 
 
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