Turn your KTM950 into AWD in 3,4,5,??? easy steps

[JRod152]

I have the day off today. Just spent most of the morning reading through this entire thread, with a little too much caffeine. I guess I better pay some attention to my kids now! What a build. Thanks for taking the time for pics, documentation, and sharing. I am realizing, as a n00b, just how much info is available on this forum!

Impressive, Craig! You've been a busy man. Props for pursuing your passion.

Jared

[Rich2wd]

Originally Posted by cjracer

Great lookingg bike Rich, that 300 must be a blast.

The chain I use is the ONLY 420 o-ring chain I have found in the market.

EK 420SRO 132 link. If you need help getting on down under, let me know. I can send you one to try. These are all Clip link chains, but I've never had an issue. This should be good for you to get 2 chains, plus you'll need an extra Master Link.

Not 100% sure it will work on your bike, as I designed my chain housing to have a little more room from the start, knowing I wanted to go this direction. The guys at Christini said they still run and send the bikes out with Non-o-ring chains as the smaller engine would or could notice a HP drain using an O-ring chain. Every little bit helps.

I've run my 950 on the dyno with the front chain on, AWD disengaged. No HP loss was noticed to the rear wheel. Not that I'm concerned, there is plenty there to spin up BOTH wheels at will in the dirt.

Not sure how to embed this???

http://www.youtube.com/watch?v=gj9I2Ma_duM

Thanks CJ, I'll shoot you an email when I'm looking at getting a new chain.

Cheers Rich

[BaronVonDarrin]

Originally Posted by cjracer

Maybe, but it most likely won't be through Christini. And this isn't a bolt on system.

If it does, I'll be sure to add info. Lots of work to make this production ready.

If not a kit, then something we could contract you to do? (hell I would probably kick a litter of puppies and steal candy from every kid in the preschool across the street just to get those aluminum tanks made)

[cjracer]

A few pics from the tear down.

This looks like some space Alien....
1

Parts hanging are the Drive Shaft out put tubes and the bellow that protects them. Everything is very well sealed up and protected.

The Drive shafts look perfect and no notches in them anywhere. The linear bearing still slide smooth.
2

Bellows are a little dirty, but not torn. (These cover the drive shafts through out the suspension stroke.)
3

Fork tubes out, ready to go through the bearings.
4

The tubes drop out easy.
-Remove the bottom drive shaft bellow clamp and lift up bellow.
-Remove set screw in drive shaft to unlock it from drop out pinion gear.
-Lift up on drive shaft to release from pinion.
-Remove pinch bolts from Triple clamps like a normal bike.
-Drop forks out.

This might take 15-20 min extra your first time.

I removed the left side tank to inspect the rest of my drive train. Everything is looking good.
5

Most bikes would have a steering stem here..... I have two drive shafts and some spur gears.
6

The head bearings on this setup are huge and handle the 950 weight and abuse no problem. (Think Car Wheel bearing size) They still pivot free and perfect, ready for many more miles. These are the same that are used on the NEW Christini bikes. Should be no problem, ever, on a 450 or 300.

7

8

[cjracer]

Drive chain "INSIDE" the lower triple clamp.

9

Drive sprocket "INSIDE" the lower triple clamp. Both look perfect.

10

These will go back in for more use.

The is the lower access plate the holds and supports the output drive shaft from the triple clamp.

11

There are plastic sliders (WHITE SQUARES) installed to keep the chain from rubbing on Aluminum. These are still in great shape. No replacement needed.

One of the spur gears in the head tube. This is the bottom one.

12

Wear pattern looks nice and even on all teeth. I must have gotten the head spacer lengths correct when I modified them for 950 ADV frame use.

Drive spline bearing packs, apart and cleaned. Perfect again. Relube and put back in use.

13

my mess..... About 50 projects going on at once....
14

15

I will be replacing as many bearings that I can at this time as a preventive measure while I'm in here. All this could have been done with the lower triple clamp on the bike, but I wanted to see how the Head Tube Spur gears were holding up.

I've put numbers next to the pictures. If you have a question, please reference the pic # and I'll do my best to answer.

Once parts show up I'll post more info.

[Katoom119]

Man that's awesome...

[Pistolero]

[Dan950ser]

So sweet. So when are you doing the super enduro?

[cjracer]

Originally Posted by Dan950ser

So sweet. So when are you doing the super enduro?

Not soon enough.....

Come out and try the ADV and 450 in July.

[kamanya]

Seeing as you didn't finish your build story, do you have some side on shots of the installation?

Also with the packaging of the drive, would a kit (if you ever built one) need a modified left tank?

[Pete640]

When u do mine can u add a mount for my steering damper?

[cjracer]

Originally Posted by kamanya

Seeing as you didn't finish your build story, do you have some side on shots of the installation?

I plan to get back to that at a later date, just wanted to add this in while it was fresh in my head. Sorry for skipping around.

Also with the packaging of the drive, would a kit (if you ever built one) need a modified left tank?

With this current version, Yes. A modified tank would be needed. KTM is just so crafty at making tanks that mold into every nook and cranny.

They give us no room to work.

Maybe future version could be figured out to not need it, but nothing that I have tested yet.

Later,
cj

[cjracer]

Originally Posted by Pete640

When u do mine can u add a mount for my steering damper?

We've found that the AWD system feels like a steering damper. It naturally wants to pull you forward and straighten out the bars to a small degree keeping me straight through rough stuff, but it would interesting to try and see how it would work combined. I've never ridden a bike with a damper, so I'm not the best experienced with that. I'm going by what other riders of this bike have commented on it to me.

Currently on the ON/OFF switch is mounted where a damper Pin would bolt onto the frame. The Cables were not long enough and I had no more bar room to move it up there anyways.

Definitely in my notes for upgrade on future versions. I've been thinking about an electronic solenoid that could be triggered with a handle bar button and a Cable back up, just in case. But that might be too fancy. We're almost getting into that GS category.

[BaronVonDarrin]

Are you just building these for friends at the moment?

[cjracer]

Originally Posted by BaronVonDarrin

Are you just building these for friends at the moment?

At the moment I'm not building any. There is only 1 of these built and future bike test is on going.