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Old 01-17-2008, 10:52 AM   #1
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
Oddometer: 3,951
950 S-new look, new mods, new year

It's 2008,

My 06 950 ADV has been a great bike for trips, commuting and misc screwing around. No regrets. Thanks to all the help from the great members on ADVrider my 950 has been transformed...some good, some not so good. Learning all the time, none the less. This WI winter season has been pretty poor for riding. We got dumped on w/ snow early in Dec. and we've been getting snow/sleet/rain off and on since then. Last year I was able to ride most of the winter, but this year the roads never dried up long enough to be safe from ice. My plan for this winter was to go through the bike and give it a once over. It's been through a lot this past year. It deserved some TLC. A week into it, the opportunity to head back to Mexico popped up again, so the complete tare down has been postponed, it's just getting a good look over now.

It started w/ an oil change. Then I figured I have the time and all the posts about water pump issues finally got to me. Last year at about 10,000 miles one of the coolant hoses sprung a small leak so the system has been drained and flushed under warranty. I went to order parts but the stuff was back ordered from KTM. Willnevergrowup came to the rescue w/ a full rebuild kit, so I took that on. Thanks.


Figured almost 30,000 miles, so what the heck. At least now it has the updated parts and I have some piece of mind.

The shaft was scored and the seal lip surface had some darkening to it, almost like it was burnt. Thanks to Pyndon's great rebuild report, that service was no problem. I checked the bearings and they were fine so I just swapped the shaft and seal. "If it ain't broke don't fix it" I'll change those in the next 30,000 miles...maybe.

BTW, We have a BMW 1999 F650 in the stable too. Last year it blew a head gasket so I looked it's entire cooling system over. Sure enough, at about 12,000 miles it's shaft was scored and need replacing too. Looked just as bad as the KTM's. The BMW parts were much more $$$ than the KTM replacements so I made my own shaft, we'll see how long that holds up. 3,000 miles and still going. So there...It's not just KTM's.

Next project I was into was adding the tripmaster switch, but I did my own kit from a post on ADVrider.

I used this one.

http://www.advrider.com/forums/showt...ht=mode+switch

But this one the most.

http://www.advrider.com/forums/showt...o+shack+switch

Post #7 Jaydee1445 mentions the smaller swtich from Radio Shack. That's these. Thanks Jaydee.
"radio shack PN 275-1571"

I don't like taking my hands off the bars to toggle through the functions, we'll see how this hold up in the long haul. So far so good. Looks stock.






UPDATE: 7-30-11
I now have 95,000 on the bike and these buttons are still working great. My MODE button on the Instrument no longer works though..... :/
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cjracer screwed with this post 07-31-2011 at 10:26 AM
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Old 01-17-2008, 10:56 AM   #2
aurel
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Joined: Sep 2006
Location: Toulouse, France
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Quote:
Originally Posted by cjracer
I like it !!!
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Old 01-17-2008, 11:10 AM   #3
J.W.Mudd
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Joined: Jul 2006
Location: Pacific Northwest - Washington
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Thumb Top Notch Job

Very well done, looks like a factory install
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Old 01-17-2008, 11:19 AM   #4
KTMSER
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Location: Six feet from hell Phoenix AZ
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Dam, Where is the (that pic gave me wood smilie)......


Nice install on the switches.......
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Old 01-17-2008, 11:47 AM   #5
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
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thanks guys.

Next up was the dash.

I use a Garmin 60cx GPS 90% of the time I'm on the bike. This setup has not failed me yet and is plenty stable for off road use, but I was getting sick the Garmin cigarette power outlet wiggling out of the power socket. I bought a cheap cigarette lighter power plug off ebay for about $8 shipped and wired that in. Now I still have the Garmin power cord for the truck and this one can stay on the bike all the time. I like having the full size power plug for charging MP3 players, Cell phones and using my tire pump when needed, so that stays. Both plugs are wired to the all time 10Amp fused power leads under the dash and routed behind the headlight. I drilled a hole in the base of the Ram mount and threaded the power cord through that.


The oval plug is for my heated gear and battery charger.

So why did that one come out small like I wanted? Hmmm..
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New product updates here! Wordpress BLOG
click www.cjdesignsllc.com for the full line of products. FREE STUFF!!
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Old 01-17-2008, 11:59 AM   #6
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
Oddometer: 3,951
This has gotten beat up pretty good and bent against the chain, so the Jury is still out on how useful it is. I do know I've hit some pretty good rocks w/ it and it's still there, not sure how well the plastic one would have survived. Only time will tell.



Then I thought I'd add a little color.





I swapped a new set of sprockets and chain on. If I was riding around here I would have let them go for another 2-3,000 miles as the chain had about 12,000 miles on it. Down in Mexico is not the place to have a chain fail, so a new one goes on. I put a Regina 525ZRP/120 X-ring chain on at around 15,000 miles.(needs to be cut to 118 links) It has held up well. It is rated for larger bikes than the stock chain is actually and is plated to help prevent rust. The stock one took a lot of maintenance to keep the rust at bay when I commuted almost everyday. I like the Regina so I got another. One other thing I learned lat sprocket swap is stick w/ the KTM ones. They are pricey but the hold up well. I run JT sprockets on my LC4 640E w/ good luck so I thought I'd try there 950 42T rear. The rear bolt are held from spinning by the flange on the sprocket. The JT flange was not the right size and too soft. I had to use a vise to hole the head of the bolt to keep it from not spinning. NO FUN. I bought new bolts and nuts and from now on KTM sprockets only.

Last year I ran 16/42 in Mexico. Two up travel w/ Gobis and tail bag for two weeks. This year I'm going w/ 16/45. We travel w/ KLR650's. 80mph max would be fine. No problem for the 950.

I had put the 950 SE chain guard on some time ago. Both side for about $15 is a good deal I figure. They include frame guards integrated in them and have held up very well to MX boots and mud. Plus it's nice to be able to see at a glance how the front sprocket is doing and the nut is tight.

I checked/cleaned the clutch oil jet again while I was in there. First time it was clean, this time it was clean too.



If you look close you will see that I have the clear hose that comes from the bottom of the air box plugged too. Now that I run the UNI prefilter, air is only coming in through there. I'm sure it doesn't make that big of a difference, but there has to be a slight draw on the end of the hose too, so no dust is getting sucked up through that now.

Head2wind's jet kit has worked great. Thanks for all your hard work.
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My 2006 950S thread. 2006 950s update
New product updates here! Wordpress BLOG
click www.cjdesignsllc.com for the full line of products. FREE STUFF!!

cjracer screwed with this post 01-18-2008 at 05:30 AM
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Old 03-29-2008, 11:38 AM   #7
Gert
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Location: Dawsonville, GA
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Plug

Quote:
Originally Posted by cjracer
thanks guys.

Next up was the dash.

I use a Garmin 60cx GPS 90% of the time I'm on the bike. This setup has not failed me yet and is plenty stable for off road use, but I was getting sick the Garmin cigarette power outlet wiggling out of the power socket. I bought a cheap cigarette lighter power plug off ebay for about $8 shipped and wired that in. Now I still have the Garmin power cord for the truck and this one can stay on the bike all the time. I like having the full size power plug for charging MP3 players, Cell phones and using my tire pump when needed, so that stays. Both plugs are wired to the all time 10Amp fused power leads under the dash and routed behind the headlight. I drilled a hole in the base of the Ram mount and threaded the power cord through that.


The oval plug is for my heated gear and battery charger.

So why did that one come out small like I wanted? Hmmm..
CJ,
where did you get the dashmount SAE(oval) plug??
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Old 01-18-2008, 07:45 AM   #8
willnevergrowup
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Location: Green Bay, Wisconsin
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Quote:
Originally Posted by cjracer
Willnevergrowup came to the rescue w/ a full rebuild kit, so I took that on. Thanks.
Wow...that willnevergrowup guy sounds very cool and good looking!!

Did you get your tail rack powder coated or just paint bomb?? Bike is looking good!!
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Old 01-18-2008, 07:51 AM   #9
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
Oddometer: 3,951
Quote:
Originally Posted by willnevergrowup
Wow...that willnevergrowup guy sounds very cool and good looking!!

Did you get your tail rack powder coated or just paint bomb?? Bike is looking good!!
He sure is.....or somthing like that.



Black anodize.
__________________
My 2006 950S thread. 2006 950s update
New product updates here! Wordpress BLOG
click www.cjdesignsllc.com for the full line of products. FREE STUFF!!

cjracer screwed with this post 01-18-2008 at 08:03 AM
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Old 01-18-2008, 09:09 AM   #10
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
Oddometer: 3,951
I wanted to try one of those Kings tires when my next Scorp AT was shot. I put the 5.10-18 on and this is how it looks.





It is a tad thin for this rim, but otherwise looks good. We'll see how long it lasts come this summer. Kinda of an in between TKC and Scorp tire.

This is where I'm at now, Not sure how long the decals will work on these tanks, we'll see.









Hopefully this will help w/ car drivers seeing me.



This weekend I'll try and get some shots out in the snow. Once the rear panels get done in white and blue it should look a little more complete.

That's all the mods until after I get back from Mexico. I'll report on what worked and what did not.
__________________
My 2006 950S thread. 2006 950s update
New product updates here! Wordpress BLOG
click www.cjdesignsllc.com for the full line of products. FREE STUFF!!

cjracer screwed with this post 01-18-2008 at 09:16 AM
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Old 02-17-2008, 05:11 AM   #11
forsyth793
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Oddometer: 205
Tires Look Great!!

Quote:
Originally Posted by cjracer
I wanted to try one of those Kings tires when my next Scorp AT was shot. I put the 5.10-18 on and this is how it looks.





It is a tad thin for this rim, but otherwise looks good. We'll see how long it lasts come this summer. Kinda of an in between TKC and Scorp tire.

This is where I'm at now, Not sure how long the decals will work on these tanks, we'll see.









Hopefully this will help w/ car drivers seeing me.



This weekend I'll try and get some shots out in the snow. Once the rear panels get done in white and blue it should look a little more complete.

That's all the mods until after I get back from Mexico. I'll report on what worked and what did not.

Could you give us a Link.....

Thanks
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Old 01-21-2008, 07:22 AM   #12
willnevergrowup
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Joined: Jun 2006
Location: Green Bay, Wisconsin
Oddometer: 1,668
Quote:
Originally Posted by cjracer
He sure is.....or somthing like that.



Black anodize.
Wow...you can see my 6 pack abs...bulging biceps and pecs through the jacket!!!
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Old 01-22-2008, 07:14 AM   #13
cjracer OP
AWD please!!
 
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Joined: Sep 2005
Location: Mukwonago, WI
Oddometer: 3,951
Screwing around this weekend.



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My 2006 950S thread. 2006 950s update
New product updates here! Wordpress BLOG
click www.cjdesignsllc.com for the full line of products. FREE STUFF!!
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Old 01-22-2008, 10:40 AM   #14
willnevergrowup
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Location: Green Bay, Wisconsin
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Hey...I've been there!! Did you make any snow angels any where??

Looks really nice!! When do you get the painted pieces back??
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Old 02-16-2008, 11:42 PM   #15
DakarBlues
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Joined: Dec 2005
Location: The pink lake less circled
Oddometer: 1,280
CJ clutch cover

Quote:
Originally Posted by cjracer
Screwing around this weekend.



A gorgeous Urban Assault Vehicle you got yourself here CJ.

By the way where did you get your clutch cover?
Is it glass-window or just molded (make believe)?
Or is it home-brew, made in CJ?
If so how much?
If not where, how much?

Thanks
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