950/990 Breakdowns and Trailside Fixes

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by MissFortune, Dec 1, 2013.

  1. MissFortune

    MissFortune mostly right-side-up

    Joined:
    Mar 13, 2013
    Oddometer:
    131
    Location:
    Okanagan, BC
    What have you broken or what has failed when riding offroad and how did you fix it? What tools or parts did you need or wish you had with you?
    #1
  2. HeatXfer

    HeatXfer Bad knees

    Joined:
    Feb 18, 2008
    Oddometer:
    796
    Location:
    S.F. Bay Area
    Clutch master cylinder seal blew, lost enough fluid to lose clutch function. I always carry a little bottle of mineral oil; pulled the piston, rotated it, filled it back up and "field bled" it. That was back in March this year. Haven't touched it since.
    #2
  3. Apple Jam

    Apple Jam Forest Flyer

    Joined:
    Aug 26, 2007
    Oddometer:
    7,062
    Location:
    Mt Hood mud flow
    When I was too cheap/stupid to buy an SS relocator and put a 1" x 3" HOLE in the bottom of my motor, my riding buddy had JB Weld, and it got us the 400+ miles home!!

    [​IMG]

    Three weeks later, I had a local-ish ADV weler/metal guru, peterman, weld a piece of diamond plate over the hole. Bike still works fine now.
    I went and bought my own JB Weld, and hope to pay it forward someday

    [​IMG]

    On the right, above, is the right side mirror mount that breaks off of the brake master cylinder when you get upside down.
    $12.95 for a new bar mount mirror clamp saves that from happening.
    #3
  4. Orangecicle

    Orangecicle On a "Quest"

    Joined:
    Apr 24, 2007
    Oddometer:
    3,922
    Location:
    West Des Moines, IA
    [​IMG]

    Ziptied the 990 brake lines down to the inside of the forks and rode another 500 miles. But, I could watch from above and see how close the brake lines were to the new knobby. :huh I've since rerouted them to the outside of the forks in case something like that happens again. And then I crash tested it. :lol3

    [​IMG]
    #4
  5. Apple Jam

    Apple Jam Forest Flyer

    Joined:
    Aug 26, 2007
    Oddometer:
    7,062
    Location:
    Mt Hood mud flow
    Oh yeah, that ^^^ fender trick happened to me, too !! :norton

    [​IMG]
    #5
  6. rburkat

    rburkat Been here awhile

    Joined:
    Feb 5, 2010
    Oddometer:
    306
    Location:
    Chilliwack, BC
    I also recommend JB weld quickstick. This happened to my buddy on a trail.

    [​IMG]

    I had a jb weld quickstick. good to go!

    [​IMG]
    #6
  7. Apple Jam

    Apple Jam Forest Flyer

    Joined:
    Aug 26, 2007
    Oddometer:
    7,062
    Location:
    Mt Hood mud flow
    That's EXCACTLY how the gaping hole in my case looked,
    I just forgot to take pics of the hole, only the chunk-o-metal left over after a piece was welded over the hole!! I was 40 miles from nowhere, JB Weld stick (and my riding buddy) saved my ass from walking a loooong ways !

    [​IMG]


    Get those SS relocators, people, this is real !!
    #7
  8. Steve Hunt

    Steve Hunt Adventurer

    Joined:
    Jan 2, 2011
    Oddometer:
    75
    Location:
    Fleming Island FL
    Paint me a picture, how does this happen? are you saying the engine case fatigues over time and your bike is sitting still on the side stand and then fails or does a bitchin ride through a rock garden hit the side stand somehow and cause the failure? thanks

    SH
    #8
  9. Apple Jam

    Apple Jam Forest Flyer

    Joined:
    Aug 26, 2007
    Oddometer:
    7,062
    Location:
    Mt Hood mud flow
    For me, it was a small 15-20mph fall (MY version of a small fall :D ), where the kickstand somehow hit a rock pointed up only about 2" off of the dirt road bed. I've read about guys that had a rock bounce up and do similar damage, or more often just a crack around the flange base that leaks oil, compared to the gaping hole that we got. I did have the stock skidplate at the time (Weld86 now) but even the aftermarket plates do not cover the entire kickstand for it's full length.

    You see the 2" long flange (the broken piece) that the kickstand bolts to in the pictures above?

    Think about grabbing a carrot half-way through, and twisting downwards.
    That carrot snaps off VERY easy....and so does that soft cast aluminum flange when you hit the kickstand anywhere on it's length :eek1



    I believe this could still happen with ANY skidplate.
    I believe normal road riders might still experience that in a road fall.
    I do think that stock mounting is strong enough for normal stirrup type mounting, by normal sized riders, if the bike is not overloaded.
    ................
    I also believe that any relocator is VERY cheap, compared to....:eek1
    They would likely all protect against a hit on the kickstand itself.


    PLUG:
    I like CJ's relocator best (had the Black Dog), because it relocates completely to behind the left peg, and the bike is significantly better balanced on the stand with heavy panniers on. With my bike admittedly overloaded for a big trip with wifey, the Black Dog's stock location allowed my bike to tip over towards the rear in a strong wind, bending the BD relocator. It and several other relocators also still sits right against those protruding flanges for absolute protection with just the wrong smack against the top of the kickstand mount, although this upper area is better protected with aftermarket skidplates.
    #9
  10. Jdeks

    Jdeks Accepting and supportive of everyones feelings.

    Joined:
    Aug 30, 2009
    Oddometer:
    1,523
    The only thing that's ever left me stuck at the side of the road was when the fuel pump timer failed. I've swapped for a Dr Bean kit now, so not an issue.

    Other things I carry.

    -Water pump seal and shaft. Small to carry, absolute necessity if yours shits itself miles from nowhere.

    -All case seals (Countershaft, gear shifter, clutch rod, breather shaft). They're pretty small and light, why not carry a spare.

    -Spare chain link and rivet tool.

    -Spare clutch and brake levers.

    -Wheel bearings if I'm going somewhere really remote.


    Good tool lists here:

    http://www.ktm950.info/how/Orange Garage/Tools/Tool_bin_index.html
    #10
  11. DELTATANGO

    DELTATANGO Motorcyclist and Dog Walk

    Joined:
    Nov 27, 2005
    Oddometer:
    14,266
    Location:
    Alabama
    Note to self: Get side stand relocator ASAP.
    #11
  12. Apple Jam

    Apple Jam Forest Flyer

    Joined:
    Aug 26, 2007
    Oddometer:
    7,062
    Location:
    Mt Hood mud flow
    And JB-Weld!!
    For the future hole in the radiator snout from a stick that finds it's way in, or maybe for the dork you are riding with (I was that dork, once) that didn't buy the SS relocator......
    #12
  13. HellsAlien

    HellsAlien a has-been that never-was

    Joined:
    Nov 16, 2004
    Oddometer:
    2,609
    Location:
    Baja Sur winter. PDX summer (that's like 6 wks!)
    The McGyver-roadside fix for failed fuel pump that I have used is to connect my $9 chinese electric airpump to the tank vent of the LH tank and pressurize the tank from time to time. Ziptied the switch/pump up by the clutch lever. Close the petcock to the RH tank, refill the LH by gravity from sidestand if needed. Close the gas cap on a baggie or something if you have done a gas cap vent-ectomy.

    I rode almost 400 miles with this setup once. Best part was when a shiney pork biker pulled up alongside in Yakima and took a WTF-look at the mess on my handlebar. I turned it on, told him it was a supercharger, he watched the little gears and rods spinning on the open pump. I hoiked a grande wheelie as the light turned green. :lol3
    #13
  14. Hipster

    Hipster Long timer

    Joined:
    Aug 31, 2004
    Oddometer:
    1,953
    Location:
    Mpls, Mn.
    It could probably happen even if you don't ride off road; Bike on center stand with rider on board and side stand down, by moving the bike off the center stand (w/side stand down) the suspension may compress enough that the side stand could bottom out hard enough to damage the stock case mount.
    #14
  15. xTomKx

    xTomKx Been here awhile

    Joined:
    Jun 11, 2009
    Oddometer:
    195
    Location:
    NJ
    Just when I though I may get away without the sidestand relocator for a while, looks like I'll be ordering one today.
    #15