KaptinKaos' 2013 990 Baja Build-up

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by kaptinkaos, Apr 17, 2013.

  1. triplenickel

    triplenickel Long timer

    Joined:
    Jul 9, 2008
    Oddometer:
    2,509
    Location:
    Campbell River, BC. Fantasy Island
    Sounds like a good win there.
    #21
  2. mikeegee

    mikeegee Been here awhile

    Joined:
    Sep 23, 2005
    Oddometer:
    309
    Location:
    Omaha, and I most definitely know why.
    I thought the only reason to remove the SAS on the 990 would be for the weight, since it's only used when the motor is not in closed loop.

    Not the same as removing it from the 950s.
    #22
  3. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Yep, mostly a weight issue and the leaner I can make the 990, the easier a transition from the 650 it will be for me. 5lbs, especially up high in the fairings, is a fair amount of weight. If all it takes me is a couple hours, 2 rubber plugs, 2 one way valves, a bit of hose, some beer and a K&N breather, I'm all over it. I will be tearing it down in 6 weeks when I get home anyway for other farkles, mods and the 1000km break-in oil change. It's just one more chance for me to get more familiar with the innards of the bike too, :D
    #23
  4. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    I really only got to play with the bike a couple of days. One was pure pavement and about -5C for 120 or so kms and another was a more decent 50/50 ride in +6C for 200kms including a wee creek crossing... Not enough to form any kind of opinion except, "Holy sh!t that's a lot of power." and "This suspension in standard setting is uber soft...", LOL!

    I did get the luggage rack/rear armor/soft bag support fitted:

    [​IMG]

    [​IMG]

    And yes, of course I know I will be having it off at least once to do the pipes and other small adjustments. :) Also got to fit some 2" risers which drastically enhance rider position for me and stand up riding feels almost normal now. I may have to get some longer lines and replumb some of the electrical for a bit more rise though... I still feel a bit forward of center and when dragging the rear end down a hill I feel like I can't lean back enough. Again, need to ride it more to really form that opinion. A soft suspension will make a guy feel unbalanced and until I tune that part of the bike to exactly what I prefer off road then I won't know what to do next.

    [​IMG]

    [​IMG]

    No other mods yet, :( I am 7000 miles from home and counting down the weeks till I get to fly home and ride this thing like I stole it, lol!
    #24
  5. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Compiling a list of doodads and farkles, etc I'll be ordering to arrive home before I get there:

    CJ Designs:

    - Bash plate and SS relocation bracket combo (Best by far imho for my needs)
    - Oil Tank Hose Kit (Did something similar on my Dakar to ease the process)
    - ECU Tune Cable (For future use)
    - Fuel Pump Rebuild Kit (For future use also)
    - Water Pump Rebuild Kit (Also future use, :) )

    Hammerhead (DS Warehouse):

    - Shifter with -5mm tip (I break these fairly often and it's always nice to have a stock one as back-up in the shop)
    - Brake Lever Tip - (the tiny stock ones are sometimes a bit fragile and I snap them off)

    KTM Parts (High Fender White Build):

    - Brake Hose Guide #60013025100
    - Brake Hose Guide Rubber Grommet #60013025050
    - White KTM Fender #7730801000020
    - Spacers For Fender x 4 #54808020000
    - Fender Bolts x 4 #0014060203
    - Black 85 Fork Guards #4700109400030
    - Bolts For Fork Guards x 4 #59001092050

    Mirrors:

    http://www.doubletakemirror.com/

    Meant to get a pair for the Dakar for sooooo long, lol! Now I will finally do it. I broke enough of those $28 mirror nuts off before constantly carrying a 14mm and 15mm wrench to remove mirrors on trail rides to know that these will pay for themselves in no time. I can live with a bit of vibration after coming from a single cylinder. It's no big deal to me.

    Wings Exhaust:

    Yep, changed my mind about the FMF's. I might pay a restocking fee on them, but that's what I get for not fully researching my choices. lol! Having removable db killers WITH spark arrestors is about the best thing ever when riding more than just dirt or pavement. I had this ability with the Staintune I put on the Dakar and I would miss it. Add to that the weight savings and lack of heat build up in the new pipes and it's worth even the price our Canadian dealer charges for them. Much less than Akra's too. I chose the NOS shape with naked tips. After thinking about it and looking at a lot of pics of the pipes I think the odd shape suits the angularity of the 990 better than the oval. On the Dakar the oval was great, but the lines of the bike are much smoother. I'll also be getting blanking plates with the pipes for the SAS removal/canisterectomy. I can pick up the one way valves and rubber plugs I need locally when I get home.

    Grip Heaters:

    http://www.adventure-spec.com/default/symtec-heated-grip-kit.html

    This will be best for me as I prefer the slimmer dirt style grips over other thicker options out there. I'll probably put these on when I do the bar swap to some ProTapers.

    Tires:

    Once I burn up the 908's that are on stock I'll fit Michelin T63's. I've had great luck with these tires in the last 4 sets I put on the Dakar. They wear great on AND off road and I was getting 10K+ kms out of a set. They are just the right amount of knob for where I ride, clean themselves out nicely in the muck and aren't as knob-flexy on pavement as the Dunlop 606's or 908's. Plus, they are 30% cheaper! :D They are, however, just as loud, :( I can source these locally in Calgary so I won't worry about this until I see belts poking through the 908's. (I'm kidding! Maybe...)

    Still on the drawing board:

    - Still eyeing the BRP Scotts damper + 1.25" risers. It would solve the bar riser issue plain and simple and at the same time I would have the ability to use the Scotts damper IF I wanted to, or not depending on what I'm riding. In the end it's not a bling issue and money isn't really that tight. It's an expense I could bear if I'm going to see some functional return.

    - Footpegs... Been scouring for a week now and haven't turned up anything really useful for lowered footpegs except these: http://www.motobau.de/ It's not a LOT of drop, but might be all I require once I get the proper rise to the bars that I like. The less I have to move my mass up on the bike while standing, the better! I had a lowering kit on my Dakar that substantially improved weight distribution when standing up and also kept my knees from cramping on long sit-down rides. If anyone has a better suggestion than those pegs (hopefully something in North America) then please, chime in! These are also these: https://blackdogcw.com/black-dog-sh...e-footpegs-for-ktm-machine-finish-detail.html which are on the list if I can't get lower pegs or the bolt on extensions that are common like: http://www.cjdesignsllc.com/products/ktm-long-foot-peg-extension/

    - New Chain Tool. I won't be using clip links on the 525 like I did on the Dakar's 520. I'm probably going to go with the Motion Pro tool http://www.adventure-spec.com/default/motion-pro-pbr-chain-tool.html. Still small enough to make it's way into my bag of goodies that lives in the bottom of my luggage and will allow me to rivet and break and all that good stuff.

    There's a bunch of other goodies that I never really got around to for my kit, but that's the bulk of the bike-specific stuff. This is kind of a list for myself to remember what I'm doing also, lol! I have a feeling I will be a very busy boy when I get home. I'm not going to consider too many suspension mods nor larger fuel tanks until I get to ride it more once the pipes are changed and the weather warms up. I have basically no opinions formed yet on those parts due to lack of time in the saddle and that is crucial for those parts. Crossing my fingers I won't need stiffer fork springs to air this girl out on some of the trails I ride.
    #25
  6. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Forgot to mention... My sucky time at work isn't all bad. +30C here at 13:00.

    [​IMG]
    #26
  7. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    All this nice weather and nothing to ride... Makes me serious miss my bikes. Made me reminisce about the Dakar and was going through old pics in between ordering goodies and reading The Pyndon's 950 thread. I'll share some memories to liven this thread up a bit, :D

    [​IMG]

    Got some orders placed and had some correspondence with dealers about a few other parts. Hope everyone is having a stellar day and riding!!!

    Joe
    #27
  8. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Took your guys advice and started looking into suspension, :) Found a place near home that this fall after a thorough beating and shake down that I could send my stock forks and shock to to have them revalved/reworked!

    http://www.ridersedgesuspension.com/index.html

    It's pricey, but will bring the stock up to 'S' standards. I think I may have a project (code named "Project Dakar Redux") that I may donate the forks out of the 990 to with a set of triple trees from Emig Racing to convert the front end of the Dakar into a KTM forked front end... Trying to convince my buddy that is buying the Dakar that it's really a great idea and he should do it, lol!!! That would also leave my trees open for some longer forks... 210mm stock is short stroke and even the 'S' with 245 or 265 is still not 300mm, :evil

    That will be a late this year or next year project. I don't want to waste this summers days off only working on the bike and after a season riding it I will know if it's a must-have for me anyway. Sounds like it might be after reading some more on these boards and the issues guys have been having with stock spring rates and valving for riding more than smooth gravel roads.

    AND... The Renazco seat is probably the solution I'm thinking is best for foot peg height issues. I can't lower them easily so best thing is raise my butt!

    This makes me smile, but miss home...
    [​IMG]

    Joe
    #28
  9. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    70 pages into Pyn's thread on the nine fiddy... Such a VAST wealth of knowledge. I'm lucky to have almost 10 hours a day to sit and read and absorb the info. Click linkies, read other info related, come back, read more Pyn thread, click more linkies, read more stuff, learn more stuff... rinse, repeat. Still at least 4 weeks out here which means I might know enough about it to be as confident in scattering it across my garage like any of the other bikes I've owned in the past, :D

    Starting to see parallels between the infamous Pyndon and I as far as shop/garage/bike habits though... I'm thinking my friends are right when they tell me I'm a tad OCD. Similar tastes in bike bits too. Engine Ice has been my favorite coolant for a decade now and I always think the simplest solution is the best. Now if I can find a place that has the K&N pre-filter in stock I'd be happy...

    Cheers!
    #29
  10. dirtdiver

    dirtdiver Long timer

    Joined:
    Mar 26, 2006
    Oddometer:
    2,219
    Location:
    San Diego, CA
    Crap Joe, You should re-name this thread, "990 All in!" :D

    I had to do my upgrades as I had money available, but I commend you in your enthusiasm and wallet!

    I enjoyed my Dakar and had some good riding. I remember the day I decided to get a more powerful bike. I had taken my wife out for a ride and at a stop light I wound my way to the front of the 2 lanes between a mercedes and a cadillac. All was well. The light turned green and I tried to get out in front of the pack. Well, with the two of us on the bike BOTH cars beat me in the first 30 yards and passed me.

    I told myself. Bullet proof yes. BMW yes. Cool red white and Blue yes. Better than 50 MPG yes. This bike has got to go. Yes. :wink:

    Anyway, I am enjoying your thread.

    DD
    #30
  11. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Lol... I was thinking of renaming it to something along the lines of "KaptinKaos' 990 Love Affair" or something, :D

    I've been socking money away for a few years now for Dakar upgrades... As I really only need one "go-to" bike that I spend a lot of time and money and effort on and with me handing the reins of the Dakar to a friend of mine in a month or so I figured it's saved money that should into this project, ;) I don't really see it as expensive either if it's going into making this bike perfect for myself and my riding... Yes, it's a lot of money, but I spared the expense on the Dakar 6 years ago and it's always been nagging at me since. I get a fresh start so to speak with the 990 and I'm determined to not go halfway this time!

    I love that Dakar... Sure, it has it's limitations, but it never let me down. It never puked oil on my shop floor. It never broke down in the middle of nowhere no matter how hard I flogged it. It didn't win any speed records and 3rd gear wheelies are out of the question unless you walk it from 1rst, 2-up travel is impossible and even some 1-up steep climbs at altitude were a struggle, BUT... It wasn't a KLR and it taught me a lot about riding heavier bikes without the abundance of power to hurt me bad or scare me off. I will miss it and it's first gear wheelies from every light in Calgary dearly... I still don't know how I'm really going to be able to part with the keys... Every nut, every bolt, every screw and every part on that bike has seen care and attention from me (except the water pump... it's a CHAMP!) There's even parts of the throttle body that I lent to a friend from the UK on his way through Alberta that traveled south on his bike and made their way back onto my Dakar via mail! Parts of this bike have gone further than I have and no one else has ever ridden it, lol!!!

    Lol, I've spent almost the entire last 15 years single :hmmmmm so I don't ride a lot of 2-up. The Dak was intended right from the get go as a 1-up travel machine with longevity, fuel mileage and comfort over time as the primary necessities. Somehow I ended up back at the motocross track with it a week after it left the dealer and proceeded to knock all the signals off and sky it out over the table top with about 10 riders stopped to watch... :lol3 Sure, I traveled on it, but in the end the stuff I wanted to ride didn't change from dirt to pavement with a bit of dirt. I primarily rode the bike like it was a 450 and had a ton of fun!!! It taught me a LOT about myself as a rider, as a mechanic and also what I really wanted out of a bike. Did I want more out of it? More power? More suspension? No... It is one of those perfect bikes with just some minor armor and suspension tweaks.

    You're right about one major thing though... I'm kidding myself and have been for years if I think for one minute that I belong in the fud crowd. The 3 core guys that I ride with always teased me about it and called me a yuppie, etc and they could get away with it. I constantly rebuked them and I was usually the lead rider on any given day unless we had a bunch of weekend warriors with us and I would hang back and make sure everyone was ok. I'm not big on forums and am more of a lurker and info searcher than anything... Riding is way more fun than typing tbh, lol! However, some of my best friends now, ex band mates and riders for life are from knowledge sharing here and on my local DS forum. I should put more back into the system and this thread is my start!

    Bulletproof bikes or not, I've never been a fud... I just literally couldn't afford the KTM 690A when I bought the Dakar. This year the sale of the Dakar, an insane overseas tax break and tax return, socked away cash from the last 2 years and possibly a little extra combined with the mindset that this 990 will be everything I want and then some for at LEAST the next 5 years... It only makes sense to me. I spend it now or wish I had them till I buy a new bike. Hopefully there's a bit more about me as a person there and I hope none of this thread comes off in a "tooting my money-making horn" kind of way. I've waited a long time and worked a lot/sacrificed a lot of time at home to be able to do this, :D In no way, shape or form do I think any of these parts, farkles or mods are going to make me a better rider... I do know that I will appreciate the benefits of having them when I'm in the saddle though!

    Cheers and thanks for reading and the encouragement! Helps these weeks in Albania go by a bit faster, ;)

    Joe
    #31
  12. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Whoops! Forgot to put a pic of the day... This is the guy that is buying the Dakar. That poor little DR got flogged just as hard as the Dakar and He's the only person I know that will ride it like I did and knows exactly where that Dak has been, lol!

    [​IMG]

    He was so PROUD! :clap
    #32
  13. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    4 hours of reading, many different posts and one hell of a better understanding of the 990's EFI and happy knowledge that removal of the SAS and a canisterctomy will take me all of an hour or so once I get a couple of plugs and resistors after I fit the Wings. This forum. It is the business.

    Thank you Orange Crush!

    Thank you FastEddy760!!! 990 EFI SAS Work-Bypass

    And much thanks cpmodem!!! Canisterectomy

    This just makes me itch for my shop and some tools and the 990 though...
    #33
  14. BykBoy

    BykBoy Meshuganeh

    Joined:
    Aug 21, 2003
    Oddometer:
    581
    Location:
    Reston, VA

    I can't say enough about the Rekluse EXP auto clutch. After the suspension upgrade from SPS and tires, it's right up there with the Scotts steering damper as the upgrade that had the greatest impact on my Dirty Dak's off road ability. :deal:clap

    Never having to feather the clutch or stalling in the tight technical stuff is pure bliss. :lol3
    #34
  15. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Really? Greatest impact on you? Or the bike? I know they work well (a friend has one in his 08 KLR) and I'm not going to bash the product, but for myself if I took away the necessity of using my clutch it would make riding boring... Sure, easy is better, sometimes, for some people. I just could never bring myself to do it on any bike, lol! It would be like modifying my soul... Riding more technical stuff more often makes a rider better at riding, not an auto clutch. It doesn't make the bike any better either, it just becomes a safety net imho. I know, to each their own and as I said, not bashing anyone or Rekluse in anyway. Just expressing what I prefer, :freaky
    #35
  16. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    Read enough today that I will NOT be ordering a windscreen for the 990 or thinking about changing the stocker until riding mine with it off for a few hundred miles and in some winds. I got to ride in some strong cross winds before I left and didn't notice anything really terrible... It was cold and rainy/snowy though and buffeting wasn't something I was concerned about, lol!
    #36
  17. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    That was with an Arai XD4 on with the brim also. I generally always ride with either a Bell MX or an Arai XD3. This year was time for replacing the street lid due to age and just the nasty smell of 5 years of sweat and dirt inside the old lids, lol! An orange/white/black Bell MX-2 and a white XD4 are the new lids of choice for my oddly shaped bean. Never had a white helmet before, but it looks sharp!

    [​IMG]

    The Rallye 2 suit has been a stellar performer in temps ranging from -15C to +50C with the right base layers. I have zero complaints with it and never saw the need for heated gear, but it fits my friend who is buying the Dakar and kinda just belongs with the Beemer. Might need new GoreTex liners as the cuffs and collars are frayed, but the shell is only faded a bit. This year and hopefully for many years to come I am gonna rock the Klim gear. Lots of vents, one piece GoreTex (no more liners in and out), lots of pockets and Kevlar/Cordura in the right places with full armor. I hope the leather in the knees stands up as good as the kangaroo on the Rallye 2 though...

    And a pic of the day to cool off this +30 spring heat here in Albania. This is a shot from a hill a few kms south of my back door. Calgary, AB. Was just dirt roads, small creek crossings and some slab to get a feel for the bike. Was a GREAT day!

    [​IMG]

    [​IMG]

    Joe
    #37
  18. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    So the suspension has been nagging at me for a week now... You guys started this!!! :evil

    This was always an issue with the F650GSPD for me... I got the suspension work well enough with progressives and an oil weight of 12.5 in those little spindles they call forks, but I know now that I should have spent the money in the first place for triple trees and forks, etc... Now, the way I see it, I have two choices.

    A. Ride it this year with stock suspension and live with that banging noise of the suspension bottoming out (I know this will happen as I still bottomed out the Dakar even after jacking it up and weighting everything hard...) and then ship it to PSP this fall when the snow flies for a revalve, etc.

    OR

    B. Mail Pyn back with my decision on 320mm... I can do the brake lines in the front end no problem and I'll weld and extra few cm's in the center stand. I've even already sourced an "S" sidestand...

    The projected future of riding for this bike... It will definitely see some slab. I have friends that travel and they do so on adv bikes, but they chose to ride more tarmac than dirt. It makes me sad, but I like my friends so I'm not gonna push them to do something they are uncomfortable with. HOWEVER, I travel alone a lot and when I do I'm 90% off road. Gimme gravel, gimme dirt, gimme dust... Anything but pavement. Do I race? No. Not yet anyway. I have in the past and it's always been my idea to get into something a bit more competitive with my riding. We have local hare scrambles and small rallies that are a ton of fun and I would definitely use the 990 for those events. Am I Lyndon? No. Will I do the Baja? No(At least I have no plans to do it YET). But I wouldn't mind riding the route at less than race capacity. The bike will also see mountain trails, LOTS of mud, lots of high speed gravel, and I'm hoping to get it to some dunes.

    I know what you're thinking... Am I just trying to justify this to myself? But I'm really asking if the 320mm is overkill. I'm not a super heavy guy... 170lbs geared. I'm no pro-racer. I would say my riding level is above average, maybe amateur race level. Is 320mm too much?

    Right now I don't see any cons other than I will need to ride it a lot and enjoy it a lot and probably quit my job to marry it...

    Smile of the day provided by a friend of mine Alex, different hole, different bike, same result!

    [​IMG]
    #38
  19. FakeName

    FakeName Wile E Coyote SuperGenius

    Joined:
    Jan 1, 2007
    Oddometer:
    2,045
    Location:
    San Diego
    I just had to make the height decision myself, and surprised myself by choosing R height rather than S.

    Even at S height, the seat is almost two inches lower than my RFS bike, so I know I can tolerate it. But this weighs a lot more, and I'm more likely to be loaded with gear and fuel, making it top heavy.

    Further, according to SPS, most of the increased performance of the reworked suspension is a result of the springs and valving- the height is of far less benefit.

    But here's the kicker for me- I find the seat-to-foot peg distance on this bike way too short for me. Increases the effort required to stand up- more knee pressure and more time in transition.

    I want a taller seat, but a taller seat AND way tall suspension on a heavy loaded pig is too much for recreational riding. Recreational riding means I'm certainly capable of riding faster, but I strongly prefer to avoid injury and contribute to our happy home.

    So. That was my choice- bike comes apart today.
    #39
  20. kaptinkaos

    kaptinkaos Just some nOOb

    Joined:
    Mar 9, 2008
    Oddometer:
    1,128
    Location:
    Airdrie, AB
    That is my worry... I lose the recreational aspect. I am in no way a Dakar Rallye racer. I dream big, but alas... My pockets aren't deep enough and my skill is less than pro. I am solving my arse to peg height isue with a Renazco. Hearing you say what you have leans me toward 265mm instead of 320mm. I too need to avoid injury if I can as my career depends on my health and that has always been the main reason I don't go further with my bikes. Cheers and tyvm!!!
    #40