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Discussion in 'Dakar champion (950/990)' started by Pyndon, Jun 23, 2006.
Keep an eye on this bike and when Pyndon puts it up for sale. It is gonna be the one to own.
Well, got home from work and would you look at that, a box of tricks for Pyndon!
wonder what it is??
Can you tell what it is yet?!? If its what I think it is it will put a smile on my face for sure!
Yep, received my tripple clamps today (Thanks to Paige at Emig Racing). Very nice girl, knows exactly what she is talking about and tells you exactly how it is. "Youll receive them on Tuesday she said" and low and behold here thay are on Tuesday
I went for the 20mm off-set for stability more than anything and a Revolution II damper to go with. I also got the super high (3¼") bar mounts since I very much like standing up and I am 64" tall (I even have 35mm risers in my CRF250R, this makes it much more comfortable for me).
The quality of the product is excellent, everything fitted together like a dream, no problems at all.
You get a new lower bearing with the 20mm offset tripple clamp set so I knocked the old one out of the frame to replace it with the new one. I got a punch to it
.a couple of shots either side and it just fell out. The old bearings were in great shape, well gresed and not really warn at all. When I cleaned the bore ready for the new lower race to be installed I noticed why it fell out after a couple of hits, the bore was badly scored, machine scores.
When I looked at it closer, the machine has obviously boobood in the factory and taken a dirty great gouge out of the bearing bore. The bore was oval when I measured it, not good at all! It definitely wasnt wear so I took lots of pictures and am going to report it somehow to KTM. I am very dissapointed with this and cannot believe how the quality control in the factory let this one go! Nevertheless I installed the new one and found that at least the base part of the bore was just (and only just) supporting the bearing race so I shouldnt have any problems, it has been ok for 12,000 miles anyway. You can see the gap in the following pictures. At the right hand side of the first picture!
I will definately keep my beady :eek1 on it if I'm riding it heavy off-road, make sure the race doesn't crack or anything.
Greased the new bearings up.......
.......and slotted it all together like a glove.
Before and after:
Notice the black damper below (allbeit not fitted properly in picture), I thought a little touch of black would be a nice contrast since the bike is orange and black.
Well, next up was the carbs. I decided to strip them all down and give them a clean. I also knew that they needed richening up a little since the bike was at 3000ft before and I am much closer to sea level.
First thing I noticed was, to some what of a shock, the rear carb had no clip on the needle.........
I looked and looked and eventually found it sat in the base of the slide just trying to make its way into the engine!
STEVE!!!! Did you have anything to do with this?!? I'm sure it will run better with a clip on the needle, how it ran as smooth as it did was a mirracle, I can't wait to ride it now!
Anyway, I then established that the carbs still had the stock needles in so, I ran upstairs to get the Factory Pro Jet kit that I got with the bike and noticed that half of the stuff in the kit had not been used. Why buy a jet kit and leave half of the nice things you get in the box?
Anyway, changed the needles to the Titanium ones (and set them to where I think they need to be), richened the mains and the air screws a little and well see where we go from there. I also replaced the standard float bowl screws with the stainless steel Allen screws you get in the Jet Kit.
I've just got the vent pipes to replace on the carbs now. I hope to get it dynod just as soon as I get everything done. Good news is that the carbs were spotless inside, no dirt whatsoever.
Thats it for today, time for some .
Your attention to detail is phenomenal. Are you from Japanese or German ancestry?
Anyway, one of my specialties is Finish work. I suggest you take a look at reapplying a clear coat finish to all of the aluminum pieces you cleaned and shined? Theres some really bombproof urethanes out there that hold up for years against the most corrosive elements, i.e., salt, snow, etc.
I think it will eliminate a lot of the elbow grease that will otherwise be needed to maintain the aluminums new factory appearance.
Mother of God !!!!!!!!!!!!!!!!!!!!!!!!!! I thought I took good care of my bikes. :eek1 I feel like the torturer of my ktm compared to you............Great work.
I know there endless posts are on the factory pro jet kits, but my experience with them was not a good one. The stock jets lifted one notch with the remus pipes worked perfectly for me. Try both. Very nice documentation.
I probably wouldn't have even looked! All the one's I have done have been a bit of a fight to get out. Now I feel better. I have to admit that I haven't done my 950 yet. Any chance you want to borrow my bike for a few weeks
If you ever tire of instrument engineering and aviation stuff
I think you have a good business waiting for you out there in the patient blueprinting, assembly and re-assembly of these bikes mate.
The oval steering head bearing seat is a shocker.
Your not joking.."a shocker", I was pretty narked when I found it. The bad thing is, if it's gonna be a problem, it will be a problem with me riding it for sure!!
I guess we'll find out when we get out on the rough stuff. Got a trip in planning for Arizona/California on Thanks Giving weekend. Mostly off-road, mostly 525's etc, fancy it on the 9fiddy's?
We'll get out before then though, maybe Colorado?
Lets rock and roll !!
I have to pick up my VOR from Dallas SMS Racing week after next so maybe we could meet and conspire for Co. then. I'll throw the 950 in the truck and maybe we could get a quick scoot in somewhere or just use the VOR.
I am trying to work a plan with some of Mikas' contacts over NEW Year for renting an Africa Twin in Lisbon to see the PD and park the family at some nice hotel on the Algarve. It has to beat Loughborough in the rain (sorry Blue)
I am also booked on the IOM Steam Packet 2nd-11th of June next year.
Ideally I'll rent a "fireplace" in London or better still rent a van and borrow an enduro bike to get around the back way doing my poor impression of Dave Knight-we eat the same food and weigh about the same-er that's it.
IOM on a dirt bike is a great way to go but you go through about 10 sets of tires doing a Stephan Chambon impression round the TT course .
Will call you sometime to discuss, bring it on! .
Lordy.....Pyndon is more anal than my old man was........great write up and I would buy a used Yugo from this man as I know it would be good to go for at least 100k.........
Great job and great documentation!!! Thanks for a superb reference manual!!! You should be rewarded from KTM USA!!!
P.S.1. You didn't think a little hole at the bottom of the swing arm end would be a good idea to let the water out or are you plannig to empty it every now and then??
P.S.2 If you need to report any of your findings to KTM factory, in Austria, pm me.
Respect !!!!!!! if only our dealer mechanics were so dedicated, brilliant thread Pyndon wish you were my neighbour you would have to be my bestest buddy haha.
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Hope you enjoy all your hard work now, you certainly deserve to.
Awww...that's a shame!!
An enduro bike on IOM has to be the way.Buy a map from the shop at the ferry crossing which will detail all the legal lanes which should make it a doddle to find your way to the best sightseeing spots for the racing!!
Been working on the bike all day today, it is starting to take shape and look very.......VERY nice!! I'm starting to smile lots and lots now the hardest work is done.
Lots of pictures, as usual and I will try and get them posted within the next few days with report. Key focus at the moment is getting the bike finished so I can go riding with buddies on Sunday!
Tease! You had better have a ride report. My 620 will be down for about 3 more weeks. I am still waiting for a piston.
I don't have anything KTM and I still think this is a great thread. I guess a gear head is a gear head. Keep it coming. Thanks for posting this.
Thanks for the excellent report Mr. Pyndon sir! I will definitly be using it for guidence when it comes time to strip down my beloved ninefiddy. Or better yet if your ever in Southern California, I would be happy to trade free room and board.......... . Just kidding thanks again!
Hey don't knock it, your just jealous!!
I wondered how long it would be before somebody had a good dig at Stevo!
I would be happy if he just sent me the parts he promised almost two weeks ago. He did'nt even reply to my PM :uhhuh ! He has a good excuse for the parts not been sent though, fancy argueing with a deer on a BMW! Had he of been on the KTM the deer wouldn't have been able to catch him to knock him off .
I wish you all the best Steve and a speedy recovery.
PS. The bike is great, I love it!
Day 7: Comfy Bum!!
Hmmmmm, well I got my Renazco seat today after posting the add in the Flea Market. I also got a KTM tank bag from the same guy (Thanks CISCO). The Renazco seat and the Tank bag are exceptional quality, I am very impressed with both items and they are both in as new condition, great .
I knew the Renazco was a slightly taller seat but didnt realise if was 1.5" taller.......this is good for me though .
Well, I left work early today to drive over to Dallas and collect my Suspension form Curtis at CTS. Unfortunately I could not get any 5.0 or 5.2 springs for the front so Ive had to use the stock 4.8s which I am not too happy about. I am looking at getting some Eibach springs, I think they can make the longer spings in a 5.2 rating, these will suit the early S model like mine with extended travel. I will keep everybody posted on what I finish up doing. The rear shock is back to its full travel so that should be good for me now. I also got an O-ring fitted to one of the fork legs so that I can monitor the amount of travel I getting on the front and identify if the forks have been bottoming or not.
Before I started work I had to fuel up for the journey so I made myself some Sesame Chicken with noodles and peppers to set me up for a long nights work
First up was the usual clean up. I detailed the shock and forks and fitted the forks with some WP Suspension Racing carbon look protectors, these make them look so much more sporty I'm sure you will agree .
I also got some TKC 80s for the bike but am not going to fot them until the Pirelli Scopions are shot that are on it at the moment. The TKCs are great, they look very aggressive and the new 150 section dual compound rear is awesome. You cn really feel the differnet coumpunds too, the center being much harder than the edges.
I fitted the suspension and got it all torqued up to the correct values.
Then, now I had the front forks in I was able to finsh the tripple clamps up. I set them up true, took all the free play out of the steering bearings, torqued everything up and fitted the steering damper .
Since the entire exhaust system was off the bike I got a full set of new seals for the headers and the silencers.
I then fitted the headers loosely, it is imprtant to get the full exaust system in place loosely before you tighten everything up. This enables you to line up the mufflers correctly and ensure their isnt a build up of stresses in the pipes than could induce cracks and breakages as the exhaust heats and cools, in particular when you ride through water etc. and the pipe wants to contract as it cools :eek1 .
Next I got the front brakes all finished up, put the pads back in, greased all the pins etc. and got them mounted on the bike ready to put the pipework back on.
I decided to run the lower fender on the front for a while as you only need the high fender in really muddy conditions (something we do not have in Texas in the summer!).
After draining the entire brake fluid from the remainder of the brake system I cleaned everything up and replenished the system with some racing fluid and bled it all up using a vacuum pump curtesy of a friend (Thanks Lucas - possibly a future ADV Rider here once the crotch rocket goes!).
Cleaned all the wheel spindles up and coated those in anti-seeze compound. Also removed the chain adjusters from the swing are and gave those some anti-seeze treatment also, it is very common for these to seeze up. Fitted the wheels.........it's a roller!!
Thats was it for this evening, it is now getting on for midnight so time to call it a day. I have the day off work tomorrow so I hope to get a good bit done then.
It's taking shape now, expecially since it has wheels. I can roll it around now.
More to follow......................................