My 950 Refresh or Mission Creep...

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

  1. Achtung

    Achtung Wicked Pisssah Adventurer

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    Great Thread! I would love to see that shop someday. I'm sorry if I missed it but waas the 990 a bolt in deal or did you have to fabricate new motor mounts? Thanks again for taking the time to post this!
  2. sakurama

    sakurama on an endless build

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    Chris YOU have the nice MV. Mine is but a modern pretender. A fast pretender mind you, but not the same as yours.

    Atchung, then engine is a complete direct swap. The only thing you have to change is the timing gear which I show a few posts ago. I can already tell it's got a much lumpier idle and can feel the hit of the pistons a bit harder so I'm very curious to see what it makes on the dyno.

    Hopefully by Sunday we'll all know and I can spend the rest of the week putting the FCR flat slides on.

    Gregor
  3. Deadly99

    Deadly99 Fast and Far

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  4. sakurama

    sakurama on an endless build

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    Look, I'm just going to say it Deadly. I'm going to paint my bike white and yours was a big inspiration. I'm just going to come out and say it now. The whole thing with the flatslides and 990 is mostly to piss off Flanny...

    G
  5. Flanny

    Flanny Flanny-it-up!

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    It's not working....:mully

    The Brutale on the the other hand.....
  6. O.C.F.RIDER

    O.C.F.RIDER Loose nut behind h/bars

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    Yer gonna make me blush. :lol3 Thanks!

    I can only imagine what a snotty SOB your bikes going to be with that motor in it & flat-slides. I'm a green/orange with envy.
    You still have a dirt-bike on this side of the continent? If so, the invite is always open for you & whomever you'd like to bring along for a ride up here.

    Hope to see you again one of these days.

    Chris
  7. Xtremjeepn

    Xtremjeepn Motorhead!

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    :evil


    Love this sort of mechanical holiganism!!
  8. Deadly99

    Deadly99 Fast and Far

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    Why do I get the feeling you won't use a five dollar rattle can like I did :rofl
  9. Flanny

    Flanny Flanny-it-up!

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    :rofl:1drink:freaky
  10. buffallodan

    buffallodan Long timer

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    Great thread :clap.
    Any updates :ear.
  11. sakurama

    sakurama on an endless build

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    You know, I used to think it was pretty inconvenient to have to cross two rivers to get to my shop but now that I live in Portland and work in NYC and my shop is in NJ, well, it's just a whole lot worse. That and the fact that I have two little ones means that every time I book a flight for work I don't want to stay any longer than I have to and shop time suffers. J and I are hoping to find a place to buy in Portland this summer and then I'll move my mechanical wonderland across country and finally be living the dream - my own shop next door.

    But that isn't the story. The story is that I'm finally updating this thread. So, we left off that I finally got my SMR engine into the frame and got it all hooked up. It was leaking here and there but I managed to get the big beast strapped to the dyno and...

    ...it made 10 LESS hp. Seriously...

    It made 88rwhp whereas my old 950 made 98rwhp. It was also lean off the charts so that is what you'd expect. I wasn't going to spend the time to jet the old carbs to the bike since I had no intention of using them which brings us here - installing the FCR carbs. I spoke to Flanny and he said that stock they were really rich - which is exactly what I'll need. We'll see.

    So I managed to get a weekend here in NYC and I wasn't going to waste it drinking or visiting, no, I was going to spend it in the shop. I went straight from the airport and got to work - cleaning and trying to find all the parts to this project. I had to do two simple things - make a bracket for the TPS and bore the inlets open as the 990 has a much larger port.

    [​IMG]

    That is the inside of an FCR - on the slide you have to remove the two set screws and a roll pin to get the shaft out.

    [​IMG]
    You have to also remove the worlds smallest Jesus clip on the end of the linkage - named because when it slips out of your pliers and falls on the floor that's what you'll say.

    I asked Flanny to send me a photo of his TPS bracket - not because I needed it but I just wanted to know how nice his looked so I could make mine a lot better. Since Flanny used steel I started with a block of billet:

    [​IMG]

    And I spent way too many hours on my mill:

    [​IMG]

    At the same time I was waiting on a parts order from McMaster so I was going between the mill and the lathe. I made this tool to indicate my inlet true - if you have a lathe you need to make this little bearing tool as it will make your life much better.

    [​IMG]

    Then I set a taper of 6.5° on my cross slide so I could open up the venturi from 39.7mm to 46.7 on the engine side.

    [​IMG]

    I finally got my new boring bar with a C-5 insert for aluminum and spun the lathe up to 1200rpm and managed to get a very nice finish.

    [​IMG]

    The goal being that the inlet tapers up to meet the widest opening of the carb boot.

    [​IMG]

    And there you have it - about 12 hours of work to do something that should have taken two.

    [​IMG]

    [​IMG]

    [​IMG]

    I finished that up at midnight last night, cleaned up my mess and headed back to the studio. The goal for tomorrow is to get them installed, run the bike on the dyno to see if I can find those 10 horses back and then start pulling the exhaust up to fabricate the new one.

    Gregor
  12. sakurama

    sakurama on an endless build

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    Today isn't working out too well. I got it to idle but then broke an elbow on he throttle cable. It was the elbow that is threaded 6mm x 1 on one side and 6 x .75 on the other - who uses that thread? No one. The die is $40 and will take two days. I need another solution.

    Oh, and only one accelerator pump is pumping.

    G
  13. sakurama

    sakurama on an endless build

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    <iframe frameborder="0" scrolling="no" width="425" height="240" src="http://api.smugmug.com/services/embed/1763108610_NH4GF6t?width=425&height=240"></iframe>

    Okay, this video tells me two things: 1. I'm going to get (even more) horrible gas mileage and 2. I will save lots of money on front tires.

    Gregor
  14. Deadly99

    Deadly99 Fast and Far

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  15. Flanny

    Flanny Flanny-it-up!

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    What he said!
  16. 1Bonehead

    1Bonehead Fearless of Falling

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    :clap:clap:clap:clap I love it!!!
  17. pchGS

    pchGS Mark

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    Safari Time, and that might get you from one gas station to the next... if you're lucky!
    :D
  18. ktm950se

    ktm950se Banned

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    Any chance you made a dimensional drawing of the TPS mount?

    ktm950se
  19. sakurama

    sakurama on an endless build

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    No, but the FCR's are gonnna come off so I can make one. I spent the entire day trying to get the accelerator pump in the second carb working and it never did so the carbs are going back to someone - either KTM Twins or Sudco.

    Well, my entire day wasn't wasted. I'll update later.

    G
  20. adiablolex

    adiablolex Lost again

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    the TPS mount did not suck at all :D

    nor did the sound of those FCR's sucking in the hydrocarbons :eek1

    well done Sir