My 950 Refresh or Mission Creep...

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by sakurama, May 5, 2009.

  1. Slider_Over

    Slider_Over Hooligan

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    Amazed at watching the progress on this....love it! Excited about the "choke work" too. Can't wait to see an FCR with choke solution:clap

    I just got my full Akra exhaust installed with the header. I can't believe how much this wakes up the 950...just amazing!! It looks so good as well...and the sound...wow!! I can't wait to add some FCR's...and then I'm done...:evil
  2. Flanny

    Flanny Flanny-it-up!

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    No such thing. :evil
  3. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>How repeatable is this? Not can you do it again but how much quicker/more economically can this be performed?

    It will be a much faster turnaround for more but I would ideally do them in batches of a few at a time. As of now official turnaround and pricing are TBD.

    >>If the key, I would have thought it would be safer to have the two sprockets fixed to each other?

    Keyways are specifically designed for transmitting torque on shafts so why try to reinvent the wheel? A 7/8" long key has a pretty large shear area compared to a couple of screws or dowel pins.
  4. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    Alcohol helps. I prefer tequila and beer at times like this.
  5. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    Well, its looking like the narrow 520 chain will be required! These are the 420V _rivet_ connecting links that finally arrived.

    [​IMG]

    After a lot of phone calls and digging, according to DID they do have rivet links for the 420V chain but nobody has ever bought one so they are not stocked even though they are listed as 'in stock' by many online vendors! DID US need to call DID Japan and see what a minimum production run is. Since that is a sure sign of scarce availability it is best to switch to parts that are more universally stocked.

    The 520VT chain seems to be carried by a lot of vendors and if we use it then a clip link can be used on the 420V short chain. It may seem like a tiny detail and it is but that 1.5mm means instead of a light grinding on the inside of the frame we would need to break through the wall thickness of the tube. That's not an option so we have an 11th hour change in parts. Its not the end of the world but just as I'm about to go and test it sucks. Now I need to get one of these chains in and on Gregor's bike for testing. Does anybody know if the rear sprockets/carriers for the KTM singles and twins are the same? I can machine the front sprocket to suit but the rear sprocket on Gregor's bike is hard as hell and chips every one of the inserts I try when cutting it on the lathe. If necessary I'll do it on the mill where the interrupted cuts from the sprocket teeth are nowhere near as much of an issue for the cutter as they are on the lathe, but would rather use an OEM part for for easy and cheap replacements.


    Arrrrgh.
  6. Head2Wind

    Head2Wind MotorcycleMayhem

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    The smaller KTM rear sprockets are similar in bolt pattern/count and the ID works too, however they use smaller diameter counter sunk bolts. Some people have switched to 520 on the 950/990s successfully by re-machining the bolt holes to accept larger bolts. Last time I asked, Sporting Wood had a 520 setup
  7. sakurama

    sakurama on an endless build

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    That's a tool steel sprocket and it is hard. I wouldn't try machining it. Is there a way to use clips throughout? For ease of use on the trail I like using clips if possible although I know they're not as secure as a rivet. I think a chain tool for 420 might hard to come by and space is limited.

    Gregor
  8. Head2Wind

    Head2Wind MotorcycleMayhem

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    There is a cross over from the Aprilia that will work as well as the 520 CS sprocket from the RC8 will work as well, the shaft is the same.
  9. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>Is there a way to use clips throughout? For ease of use on the trail I like using clips if possible although I know they're not as secure as a rivet. I think a chain tool for 420 might hard to come by and space is limited.

    Haven't you been keeping up? Needing to use the 420V clip master is pushing us to the 520VT2 rear chain. Anyway, the 420 chain is only 30 links long so keeping a spare onboard is easy.

    There are 520 front sprockets available for the SuperDuke, SM, RC8 and the Aprilia Mille, is that what you are talking about?
  10. Head2Wind

    Head2Wind MotorcycleMayhem

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    Yes, 520 for the CS for the aforementioned applications will fit with little/no mod, however the rears for the same will not fit. Will need to use a rear from a 530 application and machine the holes to accept larger dia bolts to fit the LC8 rear drive carrier.

    http://www.drivesystemsusa.com/

    specifically: http://www.drivesystemsusa.com/p/55...lled-countershaft-sprocket---ktm-950rc-8.html
  11. DRjoe

    DRjoe Long timer

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    Having to drill out rear sprockets isn't ideal.

    I'd rather a hard to find rivet link for the front wheel drive chain rather than a custom rear sprocket.

    But saying that you do what you've got to do.
  12. MortimerSickle

    MortimerSickle Semi-Adventurer

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    Why is that?

    I have had good luck doing it on my XR600. Even easy to get a nice clean cut, since I discovered step drills.







    Edit: Hey Chris, am I allowed to say "step drill" in this thread? or is that heresy? :D
  13. DRjoe

    DRjoe Long timer

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    Because when the owner of the bike is in butfucknowhere and is sprocket goes to shit its sometimes hard enough to find a sprocket let alone have it drilled out to match bolts.

    Not impossible but not ideal.

    Chris I do have plenty of 520 ally hub rear sprockets to try that I can drill out so if we have to go down that path it won't be a huge issue.

    I'll have to check but it might also be possible to swap sprocket hubs between the 520 and 525 two peice ktm sprockets.
  14. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>I'd rather a hard to find rivet link for the front wheel drive chain rather than a custom rear sprocket.

    If I heard back from DID I'd just buy a bunch of the rivet links and be done with it but nothing yet.

    There are a few alloy rear sprockets for the 950 for a 520 chain size and drivesystems.com says AFAM are a couple of months away from production of a steel one. I prefer the steel rear for durability reasons, especially with the narrow 520 chain.


    >>Hey Chris, am I allowed to say "step drill" in this thread? or is that heresy?

    Since you did it supporting my approach I'll overlook it this time..... :D
  15. StevenD

    StevenD Hmmmm, dirt!

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    Talon 520 labeled for Honda Xr600, lc4, exc. Direct fit with the lc8. And so is every other Xr600 sprocket, they have the same patern and 10mm holes.
  16. sakurama

    sakurama on an endless build

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    That's really good info.

    Forgive me for not keeping up on my bike but do you need to machine the actual rear sprocket or just the carrier? The carrier seems like a better solution if the idea is to move the assembly inboard and it's just aluminum. Okay back to my other life...

    G
  17. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    The carrier needs to be machined regardless of what chain is used. For these first couple of sprockets I guess we'll have to use the Talon aluminum ones StevenD mentioned. Once AFAM starts on their steel 520s we can switch to those for durability. I've been trading voicemails with Sporting Wood about his 520 experience, which in the brief messages exchanged so far, seem to work fine.

    I also spoke with DID about what is the best chain for the application. After getting through the 'well we recommend not going under manufacturers' recommendations' firewall I got a tech guy that said the 520ERV3 is their best narrow 520 chain. It is rated for 750cc sportbikes so using on a 950 twin is not a stretch (he he). Its used on GP bikes and by the current Dakar race teams. It is rivet only, as most high strength chains are, and seems to be commonly available. Coincidentally, I also received an email from DID Japan saying that they can ship 420V rivet links in about 4 weeks. I will purchase a handful to have but think going with the 520 rear chain is the good move anyway. This way we'll be able to use the clip or rivet link on the smaller chains. If the clip is used on the 420V chain it has to be done with the clip side facing the engine cases. If not, it will machine a groove through the lower frame rail.

    Some progress but still dying to get this beast rolling.
  18. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    So are we but with the amount of thought going into this project it'll probably be 99% perfect from the word go. I'm already saving to add this to my bike.
  19. PowerCell

    PowerCell Manufacture

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    Good lord... and I thought I had issues with leaving things stock... :huh



    .
  20. Unhingedlizard

    Unhingedlizard Been here awhile

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    I started reading the thread this morning, the missus asked what I was reading. told her.

    She came home after shopping, hairdresser, catching u with friends. "whatca reading hon"

    "Same thing"

    Now I have finished and I want more!