Odyssey PC545, a work in progress (pics)

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by uk_mouse, Feb 4, 2007.

  1. Armadillofz1

    Armadillofz1 Retarded Motardian

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    i was thinking of adding that same battery. I was also planning on moving the Fuel pump behind the airbox. there seems to be plenty of realestate there from the Ectomys. another thought on fuel pumps, i have a spare FZ1 yamaha pump that looks like it might be a nice fit and seemingly far more reliable. i think i'll give it a try.
    #21
  2. cpmodem

    cpmodem Orange Caveman

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    Humn, only thing I can think of has to do with being as low as possible. These pumps need to be as low as possible to function well.
    #22
  3. uk_mouse

    uk_mouse Aquatic adventurer

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    As far as I know, fuel pumps can "push" quite well but can't "suck" much. If the pump was mounted at the level of the airbox, it might have trouble raising the fuel to that height when the level in the tanks was low.

    I'm afraid I can't comment much on the OEM pump, mine failed (due to water ingress) soon after I did this conversion. Whether the failure was influenced by the new mounting position I can't say, but I doubt it, the pump basically filled with mud through the breather tube.

    I replaced the pump with a Facet 40105, mounted on the left hand side of my new battery box, with a couple of bolts welded onto the side of the box. The instructions for the Facet specifically state to mount it below the tank, or as near as possible.

    The shape of the Facet makes it fit better than the OEM one did into the space available on my bike, actually.

    I'm pretty pleased with this mod, the battery box has survived several rough off roading expeditions, including the Red Kite rally a couple of weeks ago (18th place :D ) where I was basically going balls-out for 130 miles of dirt. Which used 24 litres of fuel, my worst ever mpg! :D The Facet pump has also so far survived being submerged in some pretty dirty water.
    #23
  4. Armadillofz1

    Armadillofz1 Retarded Motardian

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    has anyone tried running the pump breather up to a higher position to avoid the mud/water problem?
    #24
  5. cyborg

    cyborg Potius Sero Quam Numquam

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    Any pix of your Facet pump setup? Thx.
    #25
  6. uk_mouse

    uk_mouse Aquatic adventurer

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    Here's the Facet pump, as requested :)

    [​IMG]
    #26
  7. cyborg

    cyborg Potius Sero Quam Numquam

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    Thanks!
    #27
  8. uk_mouse

    uk_mouse Aquatic adventurer

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    Dammit, there's still bits of grass stuck to my bike, it's so hard to get clean! :D
    #28
  9. HappyGoLucky

    HappyGoLucky Goeie Grys Giftige Gert!

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    is that piece of gear in the first photo belong to an old series Landrover? (the step up bar replacing the bumper?)
    #29
  10. uk_mouse

    uk_mouse Aquatic adventurer

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    Heh, you're right, it's the rear chassis member I had cut away from my Defender (same as on a series model though) before welding on a new one. My introduction to welding had a pretty steep learning curve :)
    #30
  11. Ricardo Kuhn

    Ricardo Kuhn a.k.a. Mr Rico Suave

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    Wow Don Raton the el Reino Unido...

    Great job on the updated battery.

    I'm going to read the whole posting right now and learn a few things in the process.
    #31
  12. HappyGoLucky

    HappyGoLucky Goeie Grys Giftige Gert!

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    Yipee!!!!!!!! MARS bar for me :D:D:D
    #32
  13. Pointman0853

    Pointman0853 Unregistered Gun Owner

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    Life Phases of the Stock KTM 950 pump...

    1. It pumps...:D for a while, or until you submerge it...

    2. It quits (always at the farthest distance from a new one...) :huh

    3. This is now the 'sucking' part.. :eek1

    4. Now you're getting to the pushing part...:cry

    Viva Facet!!!:clap

    Pointman, of the 40105 Cru'
    #33
  14. camel990

    camel990 Adventurer

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    Any thoughts of two odyssey 310s in parallel with one under the seat where the ladies aid goes?
    #34
  15. MotorOlly

    MotorOlly Sand basher

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    Hi

    First post :wink: Wanted to add something to this thread I found after doing my own 535 conversion. The battery problem on the 990 might be even worse than the 950 given that the EFI shuts down and needs to reboot when cranking it over with a weak battery, not to mention running the pump.

    I fitted a 545 in to 1050 Tiger with no problem when the battery failed in the cold after only 6 months. After 2 years my 990S Adventure went the same way so rather than fit the same battery I swapped in the PC545 but as UK_Mouse says its not as easy! :cry

    UK_Mouse can you update on your battery? How has it been over the last few years? I spoke to someone with a blue 950 who had swapped in the Odyssey battery and used the metal case as a battery box, he said the vibrations knocked the end off the battery eventually! Could it have been the same bike? :ear

    Anyway here are some pic of my own conversion keeping the vibrations problem in mind! It mounts on to the existing rubber mounts using the two captive bolts with some top hat spacers which allow the whole box to sit higher up between the cast aluminium brackets. This means the bottom of the box doesn't get close to the bash guard so the rubber mounts still get to do their thing. The box is also lined with about 8mm of sticky foam (two layers of adhesive wood flooring underlay) as is the back of the lid which clamps the battery in place. Fuel pipe is routed the same as UK_Mouses after I found the nice plastic clips in some of the pics hit the bash guard! The original accessory mounting plates were straightened out a little and bolted on the sides of the box, rubber pads put under the contacting areas and then zip ties run under the box to stop any vibrations. Everything is then installed and clipped on to these plates as it originally was. Funnily the bit I'm most pleased with is the rubber stopper off a table leg I cut down and drilled a hole in the side of to feed the positive wire through and protect the positive terminal from shorts :clap

    Hope this is of use to someone, thought it was about time I put something back in to the forum! I'm working on casting a new seat foam for the bike, will post when some pics soon.

    Attached Files:

    #35
  16. MotorOlly

    MotorOlly Sand basher

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    Don't seem able to post more than more photo at a time so here is another...

    Interestingly I found you can also fit a one of the tiny ATV winches in there which got me thinking; off centre hole in the front of the bash plate letting wire out through a fairway, battery relocated with solenoid under the seat.... or maybe just put the winch on the forks like I planned :rofl

    Attached Files:

    #36
  17. MotorOlly

    MotorOlly Sand basher

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    Just a short follow up, battery started to fail after 4-5 yrs of use in some pretty hard condition s so replaced it , same again. But this one lasted less than a year so I got in touch with odyssey to ask about their 2 year guarantee. Not a peep back. They only list one email address and either don't pay attention to their customers or ignore enquires so as not to honour their warranty. Really disappointing, think I'll be looking for another manufacturer next time..,
    #37
  18. uk_mouse

    uk_mouse Aquatic adventurer

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    Wow thread back from the dead!

    Olly - yes it was probably me you spoke to. The Odyssey I fitted lasted a year or two (it was ages ago, can't really remember) but was physically destroyed, presumably by vibration. I'm now back to using a stock battery.

    I replaced the standard plug between the reg/rect and battery with a waterproof one, and the main fuse holder with a waterproof item, and haven't had any charging problems since.
    #38
  19. rossguzzi

    rossguzzi 990 Adv.

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    Any chance you could tell / show what fuse holder you used?

    Cheers.
    #39
  20. uk_mouse

    uk_mouse Aquatic adventurer

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    #40