2004 950 Refresh

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by kamanya, Jan 9, 2012.

  1. kamanya

    kamanya Andrew to most

    Joined:
    Jun 3, 2004
    Oddometer:
    1,331
    Location:
    Southern Tip of Africa
    I have a venerable 2004 950 that I have really loved riding. It has 65 000k’s of mostly very hard riding on it. I don’t commute on it. I don’t have a smaller plastic play bike so this is the one that gets beaten on regularly.


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    It has never left me stranded, though I have, more in the beginning years, had some big issues. Some were caused exclusively by me, others KTM’s fault. All has been documented in this forum at some time. Sorting these issues out was often quite satisfying. I learnt almost everything through this site and the H.O.W. Although it looks quite different with the big Safari tanks on, it is almost standard. The only things that are different apart from the tanks are the fuel pump, bash plate, bar risers, fork springs, valving, ceramic coated exhausts and aftermarket pipes.

    It is still running pretty strong but I have come to a fork in the road where it is either flog it and get a new one or restore it. The biggest issues are;

    It’s looking a bit tatty.
    The engine has had a very slow small oil leak somewhere in between the pots for the last few years that is irritating me. I suspect the base gasket on the front pot. It hasn’t gotten any worse.
    The water pump cover has a very small leak at the gasket that only started recently. It loses very little, but enough to piss me off.
    Though the engine is still very strong up to 7000 rpm, it gets a bit slow above that. I suspect the carburettor parts are worn.
    My engine and many others of its generation is very mechanically loud. It’s getting boring.
    The suspension needs some love.
    Lots of minor wear a tear items are nearing the end of their life terms. Lots of the plastic bits are thoroughly worn.

    Call me stubborn or nostalgic, but I have chosen to refresh it. I could try to justify this exercise through cost as it will be, even with the inevitable budget creep, maybe a third of the price of a new one. But I know that saving some pennies would not be the whole story. I still don’t quite know why. I suppose it is a mix of;

    Really liking this particular one, we’ve done a lot together.
    Not being that much more impressed with a new one I rode recently even though it was an R.
    Wanting another mechanical project.
    It’s a good excuse to get some new tools.
    Curiosity.

    So I am going to be doing this in between work and also waiting on parts to arrive, I don’t think that it will be a quick thing, though I hope to have it finished by end March. I am also undecided yet on some large ticket items such as Woodys wheels and hubs and getting right down to a full respray etc. I’ll see as I go along and hopefully in the places I get stuck you guys can chime in.

    So, first off, the engine.

    To refresh my engine I think would just require a new gasket set, fork rollers and a few seals. Maybe a bit of love to the valves but there really is not much wrong with it. I am certain the rings are all good for another 50k. It starts easily, idles well and pulls hard.

    So, as I was pondering this I got quite a fright when a low mileage 990SD engine from Texas sprung out of eBay and attacked my credit card. What can a guy do? It is a 2007 with 4300 miles on it. An unusual way to fix an oil leak, but there you go. Almost at the same time another inmate very unselfishly threw his set of 39mm Keihins at my Paypal account. I’ve always wondered about these so hopefully I’ll be able to tell you in the near future.

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    If any of you are wondering, it is not that much fun getting an engine to Cape Town South Africa. I got lucky with a friend who had a container coming over but otherwise it inflates the price considerably. Considering the parts for the 950 and labour if I’d sent it to the dealer to get fixed, I think this way is just a bit more pricier but I get a low km engine.

    The valves were all on the loose side and over spec so that’s been sorted. It is interesting to see the difference in care of finishing between the Adventure inlets and the SD ones, hmmmm I like!

    The white residue is the fuel additives that they choke their engines with over there. I am not sure how to get it out and probably will just let our fuel wash it out.

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    First issue I have is that the boots for the 990 do not fit the 39mm carbs. I have yet to see if the 950 boots will do any better. Any ideas anyone?

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    Yesterday, I got cracking at getting the bike apart and in 2 hours this time lapse video of the tear down.

    <object width="420" height="315"><param name="movie" value="http://www.youtube.com/v/3mNX1BTFo3w?version=3&amp;hl=en_US"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/3mNX1BTFo3w?version=3&amp;hl=en_US" type="application/x-shockwave-flash" width="420" height="315" allowscriptaccess="always" allowfullscreen="true"></embed></object>

    Got me to here.

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    The old 950 engines sump plug doesn’t show anything unusual

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    Forks and shock are off to the experts.

    Next up is the swing arm and engine out.
    #1
  2. DeeGee

    DeeGee I'm a Yorkshireman thanoz

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    Love the "bare footin'" vid :D
    #2
  3. gefr

    gefr Life is a trip

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    I do not know about the FCRs. I installed a 990 on my carbed 950 and the one pair of boots fitted. I do not recall which one but I managed without anything more. Cheers.
    #3
  4. LocuL

    LocuL Gnarly Infantry

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    This is awsome...

    I like bringing back life to used bikes. The idea is super.

    Keep it up and enjoy.

    regards
    #4
  5. Oldfatbeerman

    Oldfatbeerman Enroute to a PUB

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    Cool , I get to learn all about a 9X0 refresh without spending a cent :D .
    #5
  6. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

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    Awesome decision! :freaky

    I don't have ideas about the carb boot issue, sorry.
    #6
  7. Seth S

    Seth S Will _____ for _____

    Joined:
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    While you have it torn down you should have the frame powder coated a new color. I did my 690 in a light gray which makes it so much easier to work on. The black frame absorbs light making it difficult to see leaks, wires, hoses etc. It cost me $150 to have the frame bead blasted and powder coated. Be sure to tell your vendor to mask off your frame stickers...or make sure you can get a new set from your dealer and spray the old ones off.

    Stock black:
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    VS

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    #7
  8. Qwik

    Qwik Adrenaline Addict

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    Location:
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    Ooooo.:huh This is an eventual project for Mine as well. But not for a bit. The gray frame looks good.
    #8
  9. nomad guy

    nomad guy A legal alien

    Joined:
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    Stranded in Berkeley, CA
    Let the fun begin :lurk
    #9
  10. xdbx

    xdbx Motorcycle Connoisseur

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    NorCal
    Hey Buddy :wave

    Glad you've still got the bike and its treating you well! I'll be checking in often and offer what advice I can. Feel free to PM or email if you have a pic/info request from my engine work.
    #10
  11. kamanya

    kamanya Andrew to most

    Joined:
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    Southern Tip of Africa
    Wow, that looks great. You have me thinking...




    Do you like my bike lift? It’s by Plascon, the Micatex 25 litre model specifically. They could have done a better job as I really wanted one with a jack and wheels under it. Oh, well.

    It looks a little sad sitting there like that. I was amazed at how easy and quick it was to get to here. I have no doubt the reverse is going to take way more time.

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    I know the dealer had to do it twice but since then I have never removed the swing arm from the bike and was relieved when it came out without too much hassle. I did need a bigger hammer at one stage but nothing like what some have dealt with. The races, seals and bearings looked surprisingly great. I suppose never having washed the bike with a pressure hose and living in a drier part of the world helps.

    Sadly the chain slide guards lower bolt was corroded into the aluminium. The top side one was pretty stiff too. The guy doing my suspension has taken it away to do the dirty work. I normally end up duffing it up when I try to drill them out.

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    My house is currently being painted and we have a painter who is in and out of the garage. As my garage opens onto the street, some shit made use of the opportunity to liberate me of my Bosch cordless. I wanted to do this project knowing that new tools were going to be part of it, I didn’t expect that I was going to get some because I have to replace the ones I already had! :dog

    Some preliminary work with the gearing for those that are interested.

    Only after I had bought the engine did I go and check the gearing in it. The Adventures of all years 990’s and 950’s have the same gearing. The 990/950 SD motors though, have a taller first gear and shorter 6th gear with closer ratios in-between. This might make the bike too highly geared for technical or too low for tar depending on the sprockets. Looking through the http://www.gearingcommander.com/ website if I keep the 16/42 it looks like the slow stuff won’t be much changed, but up higher into the gears, it might seem a bit short legged. I found on the 950 engine that for long distance touring, between 5500 & 5900 rpm was a sweet spot that gave in the mid to high 140’s. With this motor it seems for the same revs it will give about the mid 130’s. Not good for fuel consumption? If I put the 17/42 on then it moves into the old 16/42 rev/speed range for the 5th and 6th gears but the slow speed stuff might become a high clutch lever workout.

    One chap in Greece has an SD engine in his, so once mine is in I’ll let you know how it works… or not.


    Good news, the 950 boots fit the FCR 39’s and more importantely fit the intakes too.

    There is quite a difference between the boots. Here you can see a 990 vs a 950 boot. What you see is the FI vs the carb side of the boots.

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    And here stacked on each other the intake sides mated together.

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    With the carb mounted.

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    #11
  12. Seth S

    Seth S Will _____ for _____

    Joined:
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    4,842
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    Another suggestion I have is to replace your wiring harness. Now is a good time to rewire the machine with a simpler setup and better wires. You can undo that rats nest that runs through the frame at the steering head. Charging circuit, ignition, and then lights and accessories. his way you can have 3 independant harnesses that can be trouble shot more easily. You can run better wire for your lights and accessories t help improve output with less line loss. You can install more weather resistant connectors to reduce problems associated with water logging.

    When you get it done you can market them so i don't have to make one :rofl
    #12
  13. kamanya

    kamanya Andrew to most

    Joined:
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    1,331
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    Funny Guy!

    As I was reading I was thinking, "Hell yeah, put me down for one of those". Only to find out that it wasn't you offering.

    Electrics are not my stronger thing. I'll just stick with a new OEM harness.
    #13
  14. Seth S

    Seth S Will _____ for _____

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    I have a 690 now...the harness is junk..it works but they use very small wires that like to break and overheat and none of the connectors are water resistant in any way. Crankshaft's last 950SE got rewired by a friend and it was a much simpler harness...took up less space, better routing etc. I have plenty of wire at home to build a harness but I would'nt want to sign on for building one at the moment. If I had my own 950 sitting in the garage at the moment I'd try. The 950 harness would be a bit easier than the 990 as there are no computers to deal with.
    #14
  15. Chuckracer

    Chuckracer Jerkus Maximus

    Joined:
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    8,700
    Location:
    Lowville, NY
    Sometimes I sure wish I lived over on that side of the 'Daks.


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    #15
  16. Seth S

    Seth S Will _____ for _____

    Joined:
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    sanity?
    Is this the same one you were going to sell?
    #16
  17. zedtours

    zedtours Been here awhile

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    Surrey
    Don't know how you can work in bare feet, my floor would be covered in blood after 10 mins!
    That top end oil leak is probably just the oil pressure switch.
    #17
  18. Chuckracer

    Chuckracer Jerkus Maximus

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    Yep. :D

    Decided to give it a whole bunch of TLC instead.
    #18
  19. MortimerSickle

    MortimerSickle Semi-Adventurer

    Joined:
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    Location:
    Rainville, Orygun, where moss is a road hazard.
    I found the same thing in a 990 I got. It was from a California bike that ended up in Ohio. I don't know whether the deposits came from fuel additives, or something else.

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    I used a gun bore cleaning brush on it, but got only part of it.

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    But, when doing a valve check after running on Oregon 10% ethanol gas for 10000 miles, I found the deposits were pretty much gone. (I wish I had taken another pic.)



    I don't know whether it cleaned out because of the fuel, the climate, the change to carburetors, the way the bike was run, or some other reason, but gone for whatever reason is good enough for me.
    #19
  20. Orange Toaster

    Orange Toaster Been here awhile

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    All good reasons. Not that you really needed any :-)
    #20