950 Rehab

Discussion in 'Dakar champion (950/990)' started by MadM, Jan 8, 2017.

  1. Seth S

    Seth S Deleted

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    Yes

    Just think....you dump the stock mufflers and they both weighed more and added to higher cog. Several modern bat choices for min weight. Always hated having the battery down there.
  2. MadM

    MadM Dreamer Supporter

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    Thanks!

    The main reason for moving the battery for me was, getting the electrical stuff out of mud, water and other crap. After only one year of use, the battery looked worse than on my 450EXC.

    Weight distribution is just added bonus and when funds are available for a lighter battery it should be unnoticeable.
  3. MadM

    MadM Dreamer Supporter

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    Crankcase breather, attempt nr. 2

    Last year, whend I did the swap to ITG filter, I routed the crankcase breather like its natural bends allowed, back and down. Well that proved like a big mistake, because I got a oily mess allover left side of the engine.

    So for the second take on this matter, I ordered a check-valve from a 990...
    [​IMG]

    ...and routed the pipe straight up as fars as possible.
    [​IMG]

    Since now, I have a hot regular up here too and I don't want my bike to catch fire from any oil mist, I turned the hose with filter away from the regulator and towards ITG filter.
    [​IMG]

    With everything mounted, there is still enough room between all the parts (filter, regulator and glove box)
    [​IMG]

    Almost ready for first fire up in 2019 :clap
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  4. MadM

    MadM Dreamer Supporter

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    Now it was time for some goodies to add to the bike.

    First off, a set of TripleClamp Moto 950/990 HDPE covers for the engine. Great quality, perfect fitment.
    [​IMG]

    Next, my second attempt at a oil drain hose. This time I had it made a little longer and from a bit thinner gauge hose than the first time around a few years back.
    [​IMG]

    A little trimming of the centre tank support was necessary, nothing that would hinder structural integrity.
    [​IMG]
    [​IMG]

    All nicely tucked in and away. Should make oil changes a 30min affair without disassembling half of the bike.
    [​IMG]
  5. MadM

    MadM Dreamer Supporter

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    With that out of the way, it was time to see of this beast still has any life in it. Lets just say that it was a bit of a struggle to get it starting with a dead battery after sitting for 7 months of so. But with a set of jumper cables and my girls car she roared to life.
    [​IMG]

    So with that out of the way, I could dig a bit deeper and fine tune the beast. Out came this nifty tool...
    [​IMG]

    Yes, it was TPS adjustment time. I connected my cheapo voltmeter to it, and the reading was a bit low, but in spec.
    [​IMG]

    I adjusted it to the upper limit as suggested in H.O.W., but had my doubts about the correct reading of that cheap 5€ voltmeter. So I called in a favour and got my hands on the "big guns", professional, calibrated measuring instrument.
    [​IMG]

    The reading says a lot. I really enjoy working with quality tools. I didn't take the picture of the upper limit, just because I ran out of hands to hold all the stuff :knary So with TPS set at 0,6V-3,6V as per spec it was time to move to the other part of the carb work.

    [​IMG]
    Who knows what I am doing?

    It was carb balancing time and let me just say that it was quite a PITA job to do. First off, I have to give credits to @DirtyADV for his great idea for the cheap carb balance tool. And a word of advice to all that might want to try this on their own:
    1. If you have previously adjusted TPS, make sure you reconnect the cable! I didn't and my idle was allover the place, making carb balancing a long and stressful job.
    2. Use as thick oil as you can get in the pipe for a more precise and less sensitive inputs from adjustments.
    3. If you have ITG filter, you will need to remove the base plate if you want to reach the adjustment screw.

    So with idle adjustments all over, I rev'd the engine to around 3000rpm, where the oil has settled so that I could adjust the balance. Balance should be good, engine even sound different, nicer, now.
    [​IMG]

    Soon it will be time for final assembly and test ride :ricky
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  6. nk14zp

    nk14zp Long timer

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    I synced mine at 4000ish rpm.
  7. MadM

    MadM Dreamer Supporter

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    I would love to sync mine at 6000rpm, but with open Akrapovic pipes and our quiet neighbourhood, they would hang or deport me :gerg
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  8. MadM

    MadM Dreamer Supporter

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    Work continues...

    Since I had to change the burnt out ignition lock a while back I was carrying 2 different key with me all the time, one new for ignition and one old for the seat and fuel tank caps.

    Seat lock was easy to take care off, took it off, stuck in the new key and grind off all the pins that stick out too far. A 5 min job on a grinding wheel. On the tank caps, that seemed a bit too intrusive, since they are a lot more expensive, so I opted for the second cheapest option.
    [​IMG]

    I had to take a weight measurement before mounting new tank throats, since they felt quite heavy and they are. Weighing in at 622g for each neck and cap.
    [​IMG]

    Like with everything liquid, it is worth installing new gaskets every-time you take it apart.
    [​IMG]

    OEM gas caps have all those additional holes for safety bolt and breather where as the race throat is flat on the bottom. That means front breather connection is now useless, you can just cap it off.
    [​IMG]

    Here is how they compare:
    [​IMG]

    Like I said before, this throat blocks OEM tank breather and tanks need to breath. So supplied in the order you get a nifty breather caps. No those are not one way valves you see on EXC/SX/XC models, it is just a stylish cap with a hole through it so the tank can breath both ways.
    [​IMG]

    Those will stay on for a while now, until I figure out where to route vent tubes, like on a proper race machine.
    [​IMG]

    Small steps, as soon as the weather improves I will be riding this beast again :) I might even have to take it with me to Rally Albania, since I can't get my 450 back to life for last 3 weeks...
    Manny U likes this.
  9. RedRupert

    RedRupert Brit in the Soviet Union

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    The aluminium part at the bottom is a one-way valve - it allows the engine to exhale, but not inhale. What do you expect the black bit on the other end to do?
    MadM likes this.
  10. MadM

    MadM Dreamer Supporter

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    It is just a small air filter from LC4 SAS system. A small precaution from inhaling unnecessary dirt.
  11. RedRupert

    RedRupert Brit in the Soviet Union

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    It won't stop oil vapour, so you'll still get an oily mess under the glovebox tray. Better exit that breather pipe in the base plate of the filter.
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  12. MadM

    MadM Dreamer Supporter

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    I will find a better solution for this as soon as I have time. This was just to get the bike through the MOT :)
  13. MadM

    MadM Dreamer Supporter

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    I have a short post to make. A good week back I finally did first 100km on the 950ADV, loved every single kilometre on it. Going on a group ride on Satorday, so maybe a bit more to report after that event :-)
    [​IMG]
    [​IMG]

    Ohh, before I forgot, got some extra 5hp from the bike using those awesome stickers
    [​IMG]
    [​IMG]
  14. juames

    juames Have Fun, Don't Die!

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  15. MadM

    MadM Dreamer Supporter

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    Hey all!

    It has been a long while since my last post in here. No I haven't forgotten about this thread or sold the 950. Last 2 years I was mainly focused on my 450 and Albania Rally I participated in last year. I did a few good weekend trips with 950, but unfortunately just didn't have time to pose them (will in the future).

    Now I am bringing the mighty 950 out of the shadows and putting it up front for my next endeavour (that will stay a secret for a little while). So first off, the suspension is all in pieces, front and rear a re getting a service, re-valve and stretch. But yesterday I made a bit of a progress on something different.

    I have reticently sold my 60CSX for an upgrade to a Montana 610 (just because of the bigger screen) and now I needed to get in mounted to my 950. Since I already have a KTM PowerParts GPS bracket on it, I decided to make my own anti-vibration mount for AMPS cradle. Stared off with measuring everything and designing a holder in 3D.
    [​IMG]

    About an hour time with hacksaw and a drill and first prototype was made. With the same rubber dampers as on 130€ Touratech mount
    [​IMG]

    It actually fits nicely.
    [​IMG]
    [​IMG]

    Now to connect it up the the bikes powers supply and some adjustments to the mount are needed.

    Stay safe all!
  16. MadM

    MadM Dreamer Supporter

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    Now, here comes the big modification/upgrade. I have been planing this for quite a long time now and I finally had all the parts and the €€€€ to do it. And that is a proper suspension service with re-valve, re-spring and lengthening to "S" spec at 265mm suspension travel.

    First off, I took care of the shock. I bought a 130/265 spring, the appropriate spacer to make it longer and a whole lot of shock shims for valving.
    [​IMG]

    Next, I delivered it to a suspension shop for the rest of the work. I would love to do my own shocks, but with the nitrogen refill it needs, it is just easier to let a pro do it. I did ask him for some pictures, so here they are.

    Shock getting torn up
    [​IMG]

    Inside, there was carnage... 16y and 96.000km of work without any proper service the shock was basically "dead" inside.
    [​IMG]
    [​IMG]

    But the tuner did his job well and saved all that he could. Rebound adjuster and needle were beyond help though. After bringing it back to life it was time to valve it for my style of riding.
    [​IMG]

    I specifically asked for SKF seal head and he got the job done as asked.
    [​IMG]

    There it is, one fresh and alive rear shock for my ol'950.
    [​IMG]

    When the postman delivered it, I just couldn't wait and mounted it right away :D
    [​IMG]

    I like the new orange spring and can't wait for the first test ride. But we are still a long way from there.
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  17. MadM

    MadM Dreamer Supporter

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    Toolkit

    This quarantine thing is slowly getting to me... so to pass the time today, I decided to check out the OEM toolkit and build my own version of it. Now this toolkit isn't the "ultimate" adventure toolkit, the idea was to have a small toolkit permanently on the bike, sort of a "get me home" toolkit, for when I just grab my helmet and jacket for a day ride.

    Since the OEM kit that came with the bike was missing a few things, I first looked online for a base line. I found a great post from @mookymoo H.O.W. page. Short version is below:

    The 950 Toolkit contains:
    Sockets: 6, 8, 10mm
    Open-ended spanners: 8/10mm and 10/13mm
    Ring Spanners: 24mm, 32mm - still haven't found the reason for 24 spanner :dunno:hmmmmm
    Hex/Allen: 5mm, 6mm (by way of T-handle), 8mm (for subframe bolts) - T-handle was missing from my kit, into play cam 1/4 drive stuff
    Phillips/Flat screwdriver
    =================
    Extra tools you might need:
    3mm Hex / Allen key - for carb drains & carb horn adapters - also front screen bolts
    4mm Hex / Allen key - to remove the seat lock so you can get all the panels off!
    7mm open-ended spanner - for carb heater earth connection - don't have heaters, don't need the wrench
    11mm open-ended spanner - for brake bleed nipple - only for front calipers and this should be done at home not on the street
    12mm Hex/Allen key (950 toolkit owners) - for Shock mounting bolts - same as above, not reason to carry it
    13mm socket - for exhaust header nuts (required for access to water pump seal) + rear pannels and front brake calipers (I changed some hardware on my bike)
    14mm open-ended or ring spanner (950 toolkit owners) - for brake banjo bolts, sidestand removal - stand should be on the bike, no sensore on mine to break and need fix in the field
    17mm Socket/Ring spanner (950 toolkit owners) - for shock high speed adjustment, centre stand removal - won't be removing the centre stand on the road and your shock should be adjusted properly by now
    19mm Socket/Ring spanner - for engine oil drain plug - you are gonna change the oil in the middle of a day ride? :D

    First off, I checked all my tools and laid the out as per list
    [​IMG]

    Next I started thinking of what I actually need with me, check commentary in orange at each tool. I also added a few thing that I like to have with me, to ease the work.
    [​IMG]

    When all was packed in OEM tool bag, it was only half full
    [​IMG]

    So with that in mind, I also added pliers, safety wire and a pair of spark plugs in there. Pliers will be swaped out for a small vice grips and side cutters that are more useful that regular pliers.
    [​IMG]

    And it still fits snugly behind the battery under the seat.
    [​IMG]

    Do you have any suggestions? any other tools I didn't think of, for a day ride? I would be happy to hear your opinion.

    Stay safe all!
    Manny U and Frostguiding like this.
  18. juames

    juames Have Fun, Don't Die!

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    Don't see any tools for flat tire repair...do you keep them elsewhere? Also some consumables like duct tape, safety wire, zip ties, etc?

    BTW...Love the thread! Glad you revived it!

    :lurk
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  19. Frostguiding

    Frostguiding Been here awhile

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    the 24mm ring fits the fork pre-load adjusters...unless you have bleeder valves, which mean you need a 24mm open spanner. I wondered if cutting the 24mm ring to make an open would be worth it. But maybe lockdown boredom is getting to me too.
    The underseat storage is brilliant and under-rated. I got a Rade underseat tank so lost the storage. I fitted a bashplate toolbox but that meant the tools were always wet and filthy and my KTM toolbag shredded itself in there.
    MadM likes this.
  20. MadM

    MadM Dreamer Supporter

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    Thanks for the kind words, it was long overdue to pull the 950 out of the darkness ;)

    As for the rest of the tools, I don't carry anything more on my day rides (day rides as in a couple of hours seat time after work). When I go out on a proper ride or multi day ride, I have a separate toolkit that I carry.

    So, one more useless tool I don't need to carry :D I have forks apart on my table and that was the only thing I didn't check.

    Under seat storage is nice, I lost half of the box, because I moved the battery there, but I am slowly working on getting some space back under there. When I am done, there will be so much space I don't really know what I will put in there yet :hide
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