Rallye bike build - Kiwi Safari Team, Bro 1

Discussion in 'New Zealand' started by JayBo1, Mar 10, 2009.

  1. JayBo1

    JayBo1 Long timer

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    Hi all.
    I've talked about it for a while, so now is the time to start the bike preparation thread for my Rallye version of a KTM 530 EXC. I've had a few bits and pieces arrive recently (MD roadbook, ICO, cam chain tensioner) but I'll wait until the Mecasystem gear arrives this or next week before posting a few pic's of all the bits.

    So the first step, surely, in a bike preparation thread must be to actually buy the bike! So here it is - a blank canvas as far as I am concerned, just waiting for a few goodies to get it ready for the Yilgarn Rallye in late April and then more goodies for the Australasian Safari in early August. After that, who knows?

    [​IMG][/IMG]

    Note the best number plate in WA! The dealer (thanks David at Causeway KTM & Ducati in Vic Park) had it arrive a few months ago and kept it under his desk for me. Good thinking Batman!

    [​IMG][/IMG]

    I'll probably take it out for a gentle ride this weekend to run it in and do an oil and filter change. Then it'll be limited time to get it set up for the Yilgarn Rallye and hopefully a shakedown ride or two to make sure all the nav gear is solid.

    I'll keep the thread alive with progress as I can, similar to my previous "Kiwi on Safari" thread with my 640 build.
    Catch ya later.
    JayBo
    #1
  2. NordieBoy

    NordieBoy Armature speller

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    Is it finished yet?

    Hit any roos yet?

    :lurk
    #2
  3. Padmei

    Padmei enamoured

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    Don't know nothing about KTMs but why the 530? - what was wrong with last years bike? -Have you got too much money?- CAn I have a ride?

    Sorry for noobquestions but what is IMO & MD roadbook & I take it the meccano stuff is serious aftermarket stuff?

    :ear
    #3
  4. NordieBoy

    NordieBoy Armature speller

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    I'll get this one...

    530 'cause the 640 was a bit heavy/overkill.

    Not anymore.

    Unlikely but ask Topo what it was like when he gets back :evil

    IMO - speed/distance (little display usually in pairs on top of roadbook).
    The roadbook is a roadbook :doh:
    Meccano Systems is serious aftermarket stuff...

    Anything else?
    #4
  5. bikemoto

    bikemoto Tyre critic

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    The 640 is a 10+ year old road/trail/dual-purpose bike. The 530 is the most recent of several iterations of the mofo open-class enduro race bike.
    #5
  6. JayBo1

    JayBo1 Long timer

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    Nordieboy and warewolf have it all reasonably well covered but I can add a little.
    Last year I used the 640 Adventure and it was a great bike. Set up for the Safari, as mine was, it was very capable. The first few days I really appreciated many things about the bike. As the event wore on and I started to suffer from lack of sleep and had a few minor problems, mostly the occassional "drop" crossing rocky, dry creek beds, I started to find the 640 too big and heavy. By the last day when I drowned the bike in a deep crossing I was really wishing I had a lighter "enduro based" bike - especially when dealing with drying the motor out. I lost well over an hour at that crossing while undoing all the fairing, fuel tank, seat and air filter cover bolts. A good friend of mine, and fellow ADVRider "Rallye", was the first "big bike" home on his 690 Rallye and, despite owning a $45k specialist Rallye bike, he was largely the one that convinced me to build a 530 based bike for this year. So last year I raced the bike I loved, this year I'll race the right "tool for the job" and hopefully perform better.

    I definetely don't have too much money, although these things tend to be relative. I work hard and have a high pressure job with high technical knowledge that is in demand. This enables me to perhaps spend more than most people on my sport, but faaaaar less than some others I know.

    Refer to the above response to your previous question. Nothing to stop you building an identical bike and riding it to your hearts content.:lol3

    I'll post up some piccies of the MD roadbook but basically it's the unit that mounts in the cockpit that holds the route chart that the event organisers give you to navigate by. The roadbook has little electric motors that scroll the route instructions for you. The motor is controlled by a toggle switch mounted on the handlebar so the rider can scroll the map while riding using his thumb or forefinger. I'll also post some piccies of examples of the route sheet.

    The ICO is basically a trip meter with nice large display so you can easily see the numbers while riding at speed off road and navigating. The route sheet has the distances between features used for navigation so it's important to know the distance you've travelled from the last feature. A set of buttons are mounted on the handlebar to enable the rider to "increment" and "decrement" and "zero" the reading of the ICO. Often riders use two ICOs - one for monitoring the "partial" distances (feature to feature) and one for the total "stage" distance. If one fails, the other becomes the backup.

    Yep - the Mecasystem stuff is serious aftermarket Rallye preparation parts. Made in France the stuff is extremely well made and is developed specifically for the likes of Dakar Rallye so has withstood the ultimate test. I have ordered an aluminium rear fuel tank, navigation mounting frame, fairing, lights, high output stator and regulator, four way fuel tap and a few other bits.
    This is the general idea of what it's planned to look like:

    [​IMG][/IMG]
    #6
  7. JayBo1

    JayBo1 Long timer

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    So now the questions have started I'll get some stuff down here.
    First up is the IMO. (Only becaue the MD Roadbook is in the shed and I can't be stuffed going out to get it just to get a photo for you lot:lol3 ). The ICO came from RallyPanAm in the USA, the team that Jonah Street rides for. (In case you didn't follow the Dakar this year, he's seriously fast being the privateer that was showing all but one factory rider how to ride for a fair chunk of the Rallye by running second to the half-way rest day). The ICO kit comes with sensor cables, power cables, handlebar mount switches, brackets and sensor and the actual ICO unit itself. This is top of the range stuff that virtually all the top Rallye competitors use.
    [​IMG][/IMG]

    The ICO itself. This is the VR Lite unit which means it has a backlight so you can see the digits in the dark for those early morning pre-dawn starts -and maybe if you have a bad day and are still out on the course when it gets dark at the other end of the day.
    [​IMG][/IMG]

    This is an example of a route sheet, and specifically the start of a "Special" section. The header gives you some useful information like the total stage distance and the average speed required to meet the expected time. The target time is displayed so you can check your time card has been marked correctly by the starter and the distance to the next refuel is handy as it gives you an idea of whether you can afford to make any navigation errors. As you can see here, this was a reasonably big stage. To the left is shown the total stage distance and the partial distance, being the distance from the previous Tulip point.
    [​IMG][/IMG]

    This is further through the same stage and includes a "Caution". Riders each have their own method of colour coding and marking their route sheets. Often people don't mark single Cautions, but in the case of a solid object like a water trough, I do. I'll spend some time explaining my colour coding and some of the tricks I've learnt to maximise the value of a glance down while minimising the time to both mark it up the night before and to read it while flying along off-road.
    [​IMG][/IMG]

    That's it for tonight. It'll be a long trip getting the bike sorted so might as well not overload on the first session.
    Cheers all.
    JayBo
    #7
  8. NordieBoy

    NordieBoy Armature speller

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    Cool.
    It's just like being there but cheaper and less injuries :D
    #8
  9. cooneyr

    cooneyr terra firma rider

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    Dont know about that. Riding round the great red doging roos would be a pretty hard experiance to beat.

    Keep up the good work on the bike and reporting Jaybo. Really keen to hear how things are going.

    Cheers R
    #9
  10. NordieBoy

    NordieBoy Armature speller

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    Just need to head off through the Maungatapu with some digeredoo tunes playing on the 'pod. Every time someone hits a drum you jump off the bike.

    Just the same.

    Except for the desert bits and the heat of course.
    #10
  11. Padmei

    Padmei enamoured

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    thanks for taking the time to explain guys.:ear
    #11
  12. JayBo1

    JayBo1 Long timer

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    No worries Padmei. Stick around - there's plenty to come. I should be able to keep everyone reasonably informed right up to the start line. After that it gets a bit difficult to update here but then the "RallyRAIDio.net" service will kick in with links in the Australasian Safari thread.

    The Mecasystem gear has arrived in Perth and is with Customs, has been for a week, but I can't seem to get to it:huh . The tracking information shows it "on hold" because some information is missing. I rang Customs and they can't tell me anything unless I quote a tracking number. I quoted the number that the French postal service show on the on-line tracking service but it's not the number Customs is looking for because it starts with a letter other than "N" or "W". They told me to ring Australia Post. I rang Australia Post and pretty much went through the same process ending with the advice to contact the vendor in France. This is starting to sound like a saga!

    I emailed Mecasystem last night with the tracking information I had and they replied overnight. Coincidentally they had received an email from Chronopost (Frances postal service I think) requesting my telephone contact details. Maybe this is all the information that was missing? I would have thought I'd get something from Customs in the mail as the package is addressed to me so they must have that information surely. It's been a week now. Plonkers!!! Worst part for me is it's another weekend without the gear to bolt on and get ready for the Yilgarn Rallye. Ah well.

    I'm off to the KTM shop (Causeway KTM & Ducati in Perth) to pick up the $1,000 worth of HardParts stuff I selected as the promotion deal on new '09 450/530 EXCs. I might bolt some of that on and then head out for a gentle "run-in" ride. I've had fantastic runs out of my last several KTMs with the same run-in sequence:
    - idle for 10 minutes then let it cool completely down,
    - first tank full of fuel used on road riding with varying engine loading,
    - oil and filter change,
    - first half of second tank gentle off-road ride then
    - pull the trigger and ride it like it was designed to be ridden, including pushing the suspension through their ranges and working the brakes,
    - followed by another oil and filter change, valve clearance adjustment and change the fork oil and instal new springs both ends.

    I'll sort out the Roadbook piccies tomorrow and include the new bits from the HardParts catalogue:clap .
    Ciao
    #12
  13. JayBo1

    JayBo1 Long timer

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    Some shopping today, plus I got the MD roadbook photo I promised you.
    First up the roadbook. It's not a great piccie because the protective shipping tape is covering the clear perspex cover and the rollers inside. The bit sticking out the end with "MD" stickered on it is the drive motor. When I open it up and have it mounted I'll get you some photo's of the inside with the little drive belts and pulley wheels. In the mean time this is the box and all the brackets, cables and mounting hardware.
    [​IMG][/IMG]

    In Australia at the moment KTM have a promotion special for the '09 EXC's and you get to choose $1,000 worth of HardParts from a list of items available. It's a pretty restrictive list and I wasn't early enough to be offered a 21.5 litre tank or the 13 litre tank as they went weeks ago. I did select the Barkbuster handguards
    [​IMG][/IMG]
    the adjustable bronze triple clamps
    [​IMG][/IMG]
    and the clutch case saver that I fitted straight away.
    [​IMG][/IMG]

    I also picked up a set of the PHDS (Progressive Handlebar Damping System I think:huh ) clamps
    [​IMG][/IMG]

    and a Barret end cap (supposed to be good for 2.5 HP increase and a heck of a lot cheaper than an Acro slip-on).
    [​IMG][/IMG]
    Looks nice on and sounds okay - I hate loud bikes!
    [​IMG][/IMG]

    I'll do a few other things tomorrow. I'd like to fit the PivotPegz before going for a ride and might fit the triple clamps and steering damper too - although it'll be the MSC damper at this stage. I have to wait for the Mecasystem stuff to clear Customs before I can look into mounting up the Scotts unit underbar.
    That's it for now then. Ciao:freaky
    #13
  14. Ducatijim

    Ducatijim Hopeless Poseuer!

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    I am truely amazed.....................................................................!
    #14
  15. JayBo1

    JayBo1 Long timer

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    You're amazed Ducatijim? I'm amazed! - amazed I still have a wife after spending yet another weekend in the shed!:lol3
    So I got a few things done on the Rallye bike today. Unfortunately riding it wasn't one of the things:cry . I do get immense pleasure from working on bikes though, so I don't feel bad about it - but I'd better get a few k's in next weekend.
    First up I fitted the BarkBuster Handguards. I went and visited the workshop of the guy that's preparing all the KTM hire bikes and a few "specials" for some selected "guests" - very fast guests! I was very impressed with the happenings there and if anyone reading this is one of the lucky people that have bought a prepped bike from this dude, you ought to be pleased! The reason I mention this is we got into a discussion about various set-ups and one thing that brought a few laughs were the way people have their hand-guards set really low to protect the levers. "They are handguards! Have them set high to protect your hands. Protect your levers by learning to ride without falling off and buy the hinged type levers if you can't manage that." So I've been carefull to set the handguards nice and high:norton. (Although the angle of this photo doesn't look it).
    [​IMG][/IMG]

    I also fitted the billet alloy throttle tube with grip heater, although I haven't wired them in yet. I'll wait for the Mecasystem fairing and dash assembly so I can work out where to mount things like the control switch and resistor.
    [​IMG][/IMG]

    Then to wrap them up nicely and keep my delicate office worker hands pristine I fitted the Rallye foam grips from pro-Grip. (Model No. PG785B in case you are wondering). I used these on the 640 last year and they were magic. I bought four sets in case I needed to replace them during the Safari and the original set still looked great at the finish.
    [​IMG][/IMG]

    The clutch side got similar treatment. I also started fitting the ICO buttons and relocating the standard switch block and backup ICO button set.
    [​IMG][/IMG]

    Finally I also fitted the HardParts adjustable triple clamps and the PHDS bar damping clamps. I have to say fitting the bottom bearing on the steering stem caused me a few drama's. I've done a few over the years but this one was a pain! I used the heat gun to warm it up and it slipped nicely over the top of the stem. Then I realised I'd forgotten to put the bearing seat ring on first. Getting the bearing to slip back off the top of the stem was a little tedius. Then got it back on after the seat ring but then couldn't get it to retain enough heat to stay big enough to slip over the bottom of the stem. It was taking so long the heat transferred into the stem itself and was making a nice interference fit. Had to resort to the evil pin punch and careful tedius tapping around it. This takes forever as you have to use a very small punch so you don't damage the bearing outer ring or put any pressure on the rollers themselves. Got it in the end but it took me ages. Anyway, it looks good now.:clap
    [​IMG][/IMG]

    It is of course missing the Scotts damper but that'll have to wait until the Meca stuff arrives as the spigot clamp is integrated into the nav tower mounting frame. I'll also need to do some homework on the dimensions to get the PHDS to clear the damper. Bro3's (Indo2002) setup probably won't work for me because the HardParts triple clamp is a little different to the standard clamp and so I'm missing about 7mm of height. I'll sort that after I've got the spigot so I know what to aim for. I might "borrow" his while his bike is in my garage and he's in hospital, just to confirm my thoughts and see what my options are.

    That's it for me tonight. Got dishes to do, cup of tea to make, and a fax to a power company to get away ... oh and some sleep might be good before work tomorrow too:lol3 .
    Keep it safe out there.
    Ciao
    JayBo
    #15
  16. kiwipeet

    kiwipeet Uber Cyber Loafer

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    I'm looking forward to seeing it at Condo :thumb
    #16
  17. pampaX

    pampaX Been here awhile

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    Hi JayBo1, I followed your previous thread with real plesure and already enjoying this one, keep it coming.

    I guess you're fully recovered of your encounter with the wildlife, how r u talking your training/fitness side of things?


    That bike looks awesome, I want one :D ... huh I guess I should know how to ride properly rather than barely make it across the easy tracks ...

    Cheers,
    PampaX

    #17
  18. JayBo1

    JayBo1 Long timer

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    Hiya PampaX. Thanks for the interest and feedback. Knowing people are out there actually reading this drivel is encouraging and keeps me at it:lol3 .

    Good question on the fitness side of things. Some background for anyone that hasn't kept up on other threads. I have a bad history over the last three years that result in me being "behind the eight ball" before big events. Ten weeks before the ISDE in Taupo I completely smashed my right foot, ending with multiple fractures to seven bones. Then, almost exactly a year later and the very same weekend that I bought the bike to base my last years Safari bike on, I clipped a log ending with a posterior dislocation of my left shoulder with almost the whole rotator cuff (the tendons that hold your shoulder together) torn, a fractured humerous head and a few other minor things. I'm still recovering from the shoulder reconstruction now, almost 18 months later, and recently got a new referal from the surgeon for more physio to get me more movement before the '09 Safari. On to the latest drama was a coming together with the local wildlife in the form of skippy - a reasonable size skippy by all accounts. I was unconcious for around 6 minutes and got myself three fractured ribs and a ruptured spleen. I rode about 40 min's back to the car, my mate drove us back home so I could change, use the toilet and get the missus to drive me to the local hospital. Several weeks of bed rest followed and I escaped without surgery. Very, very, very lucky!

    So that was in October or something so I rested a fair bit. The Doc said stay off any exercise, no lifting over 5kg until Xmas, no pushbike until January and no dirtbike until March/April. So I had a holiday back in NZ:clap . Upon re-starting work in January I eased back into cycling the commute by doing a couple of days one week, then a few weeks of 3 days cycling and now I'm easily doing it 4 to 5 days per week. It's a 65km round trip and takes me just over an hour in the morning and about 1'10" on the way home (always head wind and very slight overall incline). So my leg strength is coming good and cardio fitness is also geting there. 20 weeks to the Safari so I'll be good by then. Just need to hit the home gym more to build the shoulder strength up. No worries!!

    Errrr ... I'm not going to Condo:cry . I figured I'd be pushing it to get the bike ready for the Yilgarn as it is and also wasn't sure of whether my fitness would be okay by then to make that comitment as long ago as I needed to in order to enter and arrange the transport. Also financially I just can't do it. I'm hoping if I go well in this years Safari I can maybe be in a good position to get some sponsorship for next years season.

    Catch ya later.
    JayBo
    #18
  19. JayBo1

    JayBo1 Long timer

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    The courier service dropped of a little package at work today. The Mecasystem stuff cleared customs at long last (just had to give them my credit card number with no limit!!) and a carton about the size of my couch turned up:eek1 !!! (Actually about the size of the box a 28" TV gets shipped in). I couldn't wait, so right there in the office in the aisle between cubicles I cut it open and started pulling out shiny bits. I didn't have my camera so you'll have to wait a few days for some snaps but it was very exciting. The whole office came to have a nosy and rib me about how expensive it was and there's no engine!

    First impressions are the fairing pieces are incredibly light. Might only be fibreglass but it is very, very light and looks well made with a beautiful finish ready for paint.

    The aluminium frame for the headlights, on the other hand, seems incredibly heavy and ridiculously solid. It'll be interesting to see why when putting it together but I need not fear 'roos with a 'roo bar like that at the front!

    The rear fuel tanks are an absolute work of art. The welding is first class and the finish of the tanks is without blemish. Seems a shame to put it on a dirtbike.

    I have a club meeting tomorrow night and other stuff for the rest of the week so won't get photo's for you until the weekend probably. Suffer like I have for the last week waiting for the Customs issue to be resolved!:lol3
    Ciao
    JayBo
    #19
  20. NordieBoy

    NordieBoy Armature speller

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    Is it the weekend yet?

    :clap
    #20