Going Walkabout on an 800xc through Russia & Central Asia...and maybe beyond...

Discussion in 'Ride Reports - Epic Rides' started by GuiltyParty, Apr 9, 2013.

  1. loxsmith

    loxsmith Good ol days my arse

    Joined:
    Apr 10, 2006
    Oddometer:
    594
    Location:
    Ex. Little village called Brisbane, Australia
    Exactly where is the fall sensor located, it a little hard to tell by the pic
    I have been curious since I bought the bike as to it's location

    Do you know what strength or shock spring that is?

    I get a new one fitted tomorrow here in Austin, Texas. I'll let you know how it goes
  2. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    Thanks for the tip.

    It's under the rear rack with the tail light wiring. It's a handy storage space if you haven't used it before. I always put the 'hope I'll never use' stuff in their like co2 canisters and volt meter. The space is big enough that a spare tube can even fit in there. When I say 7mm bolt I mean a 7mm head. Maybe it's an M4 or M5.

    I'll find out about the shock and get back to you.
  3. loxsmith

    loxsmith Good ol days my arse

    Joined:
    Apr 10, 2006
    Oddometer:
    594
    Location:
    Ex. Little village called Brisbane, Australia
    I think 7mm head size is what is used on the Airbox cover? I ditched them the first time I checked the Air Filter and replaced with Phillips head screws

    Why on Earth would you use 7mm and then scatter Torx headed bolts throughout the bike?
  4. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    The air box bolts will be going to. The side stand switch is a T25, which is a different size to the torx heads on the shock and rear brake electrics. My kit is getting lighter and lighter without all these extra bits!

    Using odd sized bolts is a British thing apparently.
  5. yokesman

    yokesman Long timer

    Joined:
    Sep 12, 2008
    Oddometer:
    2,776
    Location:
    SW. Idaho
    it has been a common practice to ditch the side stand switch as it was failing during a rain or for ant other reason,just one less switch to deal with ,my clutch I wanted to ditch but suzuki decided to make it a primary support for the fueling to ecu communication.?
  6. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    I'm not doing anything ground breaking with that idea. It needs to be done though because luckily it's just an easy relocation unlike the Suzuki you had trouble with. Methodically I'm going over the whole bike and changing what I can and what needs doing
  7. Cabriolet

    Cabriolet Adventurer

    Joined:
    Jul 13, 2012
    Oddometer:
    58
    Location:
    Blackpool, England, UK.
    If you have the nerve to explore the wiring towards the front end of the bike, I would be interested in seeing if you can locate a break point in the loom with a male to female cable connection that carries the feed for the headlamp main beam.

    I must be the ying to your yang. You are happy hacking bits off your bike that you don't like and changing things to the way you want them to be. I am the total opposite, I still bolt bits onto the bike, but I always want them to be totally removable. I have no idea why, I must have been dropped on my head as a baby.
    I want to wire up a feed for a relay to control some extra lights, but I don't want to cut the loom. At all, not even a scotchlok (wire tap or whatever you call them).

    If you find a connection point in the loom that contains the feed for the high beam, then throw a picture up so I can try and identify the type of connectors I would need to order to make an interconnecting loom with a tee off to control a relay for my lights.
    I have not found anyone else that has had their bike in enough pieces to find the relevant connector.
    Keep up the good work, I can't wait to hear about your next adventure on it.
  8. loxsmith

    loxsmith Good ol days my arse

    Joined:
    Apr 10, 2006
    Oddometer:
    594
    Location:
    Ex. Little village called Brisbane, Australia
    Installed an Eibach spring 0800.225.1000 today ie 1000 pounds per inch or about 18.5kg rating (more than double the stock rating)
    Race Tech valving to suit, what a difference

    Can't call it the Pogo Stick anymore :clap
  9. PHILinFRANCE

    PHILinFRANCE Long timer

    Joined:
    Aug 8, 2010
    Oddometer:
    1,572
    Location:
    S W France my little bit of paradise
    What cani say

    TIGER TIGER BURNING BRITE THAT ROCKIE TUMBLE LOOKED FUCKING SHITE

    Unbelivable guy ,and there's me thinking i'm fortunate going to Georgia (Black Sea)

    :clap Phil :freaky
  10. Ant23

    Ant23 Wantings Enduroness

    Joined:
    Jan 5, 2010
    Oddometer:
    31
    Location:
    Staffordshire, UK
    I don't really reply to threads on ADV, I'm more of a lurker. But there are a few threads that stand out in the greats, for instance

    colebatches
    the dude with the beemer that looks like johnny five in Iceland
    radioman
    luke and nick
    round the world on a drz
    the ducati guy - antihero
    noah

    and ive added you guys to the list. top stuff. loved it. and kudos for sticking with a smashed up bike. look forward to seeing it finished.
  11. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    I'll take a look for you. The wiring harness is covered in a black plastic from a point around the ignition coils to somewhere further along and I won't be taking that bit off, but past that around the headlight some wires were damaged in the accident so it's covered in tape. I'll take a look for you and report back.

    I'm hesitant to do anymore to the wiring loom in terms of cutting. I had to walk away before any drastic action was taken.

    Wow yours is almost double mine. Mines an eibach 0800.225.0550 (550 pounds or 9.8kg) with race tech valves as well. No idea how it feels yet but when it's all together the shock guys will measure the sag and adjust as necessary.

    I can't find any concrete info anywhere on the rating for the stock spring but I saw it mentioned somewhere it might be a 550. I dont know if that's right or not. The guys took my weight and all that jazz so I doubt they took out a stock spring and replaced it with the same rated one.

    How are you finding yours? You have a pic? What weight, riding style and luggage have you set it up for?

    I told the guy I'm 78kg and mostly ride with minimal luggage off-road but there will be times I do two-up with slightly more luggage. I don't need to set it up for a trip like we did before.

    :lol3 is that a song or you just made that up? Thankfully it wasn't burning bright though, not quite.

    Ahh Georgia is great mate. Crazy drivers and the country looks like it's been invaded by cows but otherwise it's a blast. Wish I could join you!
  12. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    :eek1 wow thanks.

    Have you read the Borneo equator expedition? That's the thread of all threads. When that guy rides it's not him moving, it's the world rotating on its axis under the force of his tyre.
  13. blacktiger

    blacktiger Tigers R great.

    Joined:
    Nov 14, 2005
    Oddometer:
    4,023
    Location:
    St.Leonards on Sea, England.
    Why don't you use the plug under the tank that Triumph kindly put there to supply their accessory fog lamps?
  14. Cabriolet

    Cabriolet Adventurer

    Joined:
    Jul 13, 2012
    Oddometer:
    58
    Location:
    Blackpool, England, UK.
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>

    <o:p></o:p>
    A very good point. <o:p></o:p>
    I already have the Triumph accessory lights. I switch them on and off as I see fit. <o:p></o:p>
    I also want even more light when on main beam. So I want use some additional lights (mounted to the Hepco and Becker tank bars). I don’t need any external switches to control them, I only want them on in addition to the main beam, and go off when using dipped beam.<o:p></o:p>
    I want to supply a relay with an input signal when the headlamp pass light trigger switch is pressed or the Hi/Lo beam switch is in the high position. <o:p></o:p>
    <o:p></o:p>
    I don’t want to chop/splice/solder the loom. That’s just my own irrational OCD.<o:p></o:p>
    I guess there is a main plug on the headlamp assembly, but it might have lots of wires going though it or be a unique connector? I was wondering if there was another point on the loom with a headlamp related signal wire passing through a smaller more common connector. Maybe from the handlebar switchgear? Or the instrument cluster for the dash warning light? Or a signal to the ecu perhaps? <o:p></o:p>
    <o:p> </o:p>
    If someone has removed the loom from the frame for themselves they must have unplugged all the connectors and might be able to offer advice as to what they look like and where they are situated on the frame. <o:p></o:p>
    I can then try and source a matching male and female connector and make a simple pin-for-pin pass through loom with a spur off to control my relay.<o:p></o:p>
    <o:p> </o:p>
    I was just trying to save having to strip my bike down twice, once to find the connector and then rebuild it so I can use it to get to work and back while I try and find a supplier for the relevant connector. Then strip it down a again after making the loom to fit it. <o:p></o:p>
    <o:p> </o:p>
    If no one knows where these connectors might be or what they look like, I will eventually have to go looking for them myself, but was just trying to take advantage of the totally exposed wiring situation as this one gets rebuilt from the ground up.<o:p> </o:p>
  15. loxsmith

    loxsmith Good ol days my arse

    Joined:
    Apr 10, 2006
    Oddometer:
    594
    Location:
    Ex. Little village called Brisbane, Australia
    The Race Tech dealer mentioned that the stock rating was 8.9kg so mine is more than double the stock rate. The suggested new spring rates were between 18 and 22kg, the 18.5kg spring was in stock at Race Tech so that was what went in
    The gross load inc rider and pillion is about 200kg. Preload is now set to about half and rebound is spot on. Measurements were taken unloaded, loaded and loaded with both of us on the bike. This guy knew what he was doing
    It's never going to handle like a Track bike but it's miles ahead of what I was fighting before
  16. blacktiger

    blacktiger Tigers R great.

    Joined:
    Nov 14, 2005
    Oddometer:
    4,023
    Location:
    St.Leonards on Sea, England.
    I wired my extra lights (2 of http://ledrider.com/shop/?model_number=LR4 ) in with one of these http://ledrider.com/shop/?model_number=BD1 It has a main beam bypass so that you can have the lights on dim (or off when the switch is just past "on") but when you switch to main beam they come on at full brightness. I soldered the bypass wire into the main beam inside the LH switch cluster. Maybe take a piggy back off the headlamp relay for the supply.
  17. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    I didn't get a chance to work any more on the wiring harness other than plug a few plugs in, but did blacktiger give you the answer you need?

    This weekend I'll play with it more and might even get it fired up. Time is against me as I want to take it to a rally on the Easter weekend and there are still some critical things to do like wire in the light, fit the brake lines and mount the high fender.
  18. Cabriolet

    Cabriolet Adventurer

    Joined:
    Jul 13, 2012
    Oddometer:
    58
    Location:
    Blackpool, England, UK.
    I guess I just need to start unplugging things myself until I find something I can work with. I'll post my results in the tiger 800 accessories/modifications thread. Cheers.
  19. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    This is the plug at the headlight.

    [​IMG]

    Do you have a copy of the wiring diagram to see where these go? If not PM me and I'll send it to you. A signal is going to the ecu, instrument panel, switch assembly and a relay. The only accessible plug is the one coming from the switch assembly or in the assembly itself. I don't think there is any easier solution than that but take a look at the diagram and let me know what you need photos of and I'll do it.
  20. GuiltyParty

    GuiltyParty drifter

    Joined:
    Jul 17, 2008
    Oddometer:
    318
    Location:
    London
    I took my wheels in to get checked for flat spots, damaged spokes, smooth out sharp and rough edges, alignment etc.

    I could tell just by looking at the front one there was a flat spot and I remember every single detail of the rock that caused it...

    As it turns out it had 9 flat spots but that's nothing unusual for a dirt bike with 21" rims, especially a big fat dirt bike with lots of weight on it. He could only tighten a few spokes though as the rest had seized up. The lubricant on the stainless steel nipples had washed out and caused them to seize. Despite that though it ran reasonably true and it's still a perfectly fine rim to use. On the rough stuff I wouldn't notice the flat spots anyway.

    The rear was fine.

    Refitting the rear. I could get used to a longer swingarm

    [​IMG]

    Starting to look like a bike again

    [​IMG]

    Fitted a SW Motech side stand pad. Looks badass, if it's possible for a side stand to be badass.

    [​IMG]

    Cable tied the headlight on just to see how it looks. I could have trouble with the tank when it's fitted...

    [​IMG]

    Fitted some Pivot Pegz. I've got these on the KLR and can't live without them. A nice and easy install.

    [​IMG]

    Replaced the torx bolts on the rear brake. Should have done this before the trip so it's one less tool to carry.

    [​IMG]

    Ooh shiny stepper motor

    [​IMG]

    In preparation for fitting this bad boy, a unifilter outer filter (?) picked up from the bargain bin at the local bike shop. On this trip despite servicing the bike as required the stepper motor still played up and it takes a bit of the buzz out of the trip when you have to service the bike just because of the stepper motor so I thought I'd do something about it. It's an easy fix for a bit of peace of mind.

    [​IMG]

    I had to cut a couple of holes in it to fit around the bracket for the stepper motor where it attaches to the throttle bottles and another hole where the electrical plug goes in.

    I covered it in a very light soaking of filter oil before fitting it. In most cases the stepper motor won't cause any issues but having this in place will stop the bulk of dust getting in.

    [​IMG]

    Snug. There is still plenty of space in there for the arm to move.

    [​IMG]

    I think it likes it's new home (from the side looking under the air box). That should stop the bulk of the dirt.

    [​IMG]

    The Safari tank arrived :clap

    [​IMG]

    After undoing the bolts and giving it a little twist the filter slipped out from the old tank easy enough. I almost choked over how dirty it was :eek1 The black thing at the bottom is the filter.

    [​IMG]

    [​IMG]

    The fuel sensor on the left and the O-ring on the right. The O-ring will go back in and not leak provided the tabs are around the right way.

    [​IMG]

    The fuel sensor is mounted to the inside of the tank on a bracket by three tabs. You can feel around inside the tank to find these tabs then push them through and it will come right off the bracket.

    [​IMG]

    The service manual says it's a sealed unit and must be replaced as one unit. There are three or four tabs on it though that would allow you to pull it apart but I didn't try in case I couldn't put it back together again. They're worth $630 new so I wasn't game to try. It's not a matter of will this fail it's a matter of when, so I found one from a wreckers for less than a third the price. I'll carry that with me until this one fails.

    Before I put it back in I gave it all a clean with a cotton bud and blowing into it using my mouth. I didn't want to use a compressor in case it damaged the filter.

    It took a bit of time getting it all fitted. The first problem was the fuel sensor sat on top of the fuel pump inside the tank meaning that when I do finally get it started it wouldn't register the fuel, so I had to undo everything and bend the fuel sensor bracket a few degrees to get it away from the fuel pump. Then fitting it to the bike the mounts wouldn't line up properly so I had to bend them in a few degrees. It's not difficult to do, but it took time assembling it, disassembling it then reassembling it. But damn it looks good!

    [​IMG]

    It was then I discovered the headlight at full lock is in fact brushing against the tank. I sat and pondered for a while the quickest and easiest solution and settled on some brackets that lift it 5cm and out 3 cm to get it clear of the tank. I took the idea to a local machinest who will make them up for me. I also left him with a blue print for the fork mount.

    Hopefully this week I'll have more news.