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Old 06-28-2006, 12:21 PM   #46
Hambone950
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Pyndon's Progress

Lyndon,
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.
H
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Old 06-28-2006, 05:17 PM   #47
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Big Rides!!!

Hamish,

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 !!

Lyndon
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Old 06-28-2006, 05:31 PM   #48
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Co

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.
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Old 06-28-2006, 06:09 PM   #49
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Iom.....!

Hamish,

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! .

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Old 06-28-2006, 06:35 PM   #50
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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.........
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Old 06-28-2006, 08:18 PM   #51
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Congrats for the service manual you wrote!!!

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.
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Old 06-29-2006, 12:48 AM   #52
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Quote:
Originally Posted by Kat00m
wow nice post
Respect !!!!!!! Ė 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.

Hope you enjoy all your hard work now, you certainly deserve to.

Joe
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Old 06-29-2006, 03:35 AM   #53
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Quote:
Originally Posted by Hamish Nicol
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.

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!!
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Old 06-30-2006, 08:15 PM   #54
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Not forgotten!

Hi all,

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!

Back soon,

Regards

Lyndon
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Old 06-30-2006, 09:27 PM   #55
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Quote:
Originally Posted by Pyndon
Hi all,

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!

Back soon,

Regards

Lyndon

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.


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Old 07-01-2006, 06:27 AM   #56
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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.
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Old 07-01-2006, 10:28 AM   #57
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Thumb You are a wrench God!

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!
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Old 07-01-2006, 09:16 PM   #58
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Refund!!

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!
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Old 07-01-2006, 09:27 PM   #59
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Day 7: Comfy Bum!!

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 didnít realise if was 1.5" taller.......this is good for me though .









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Old 07-01-2006, 10:03 PM   #60
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Day 8: An evening after work!


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 Iíve had to use the stock 4.8ís 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 ĎSí 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 80ís for the bike but am not going to fot them until the Pirelli Scopions are shot that are on it at the moment. The TKCís 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 isnít 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 .





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!!



Thatís 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......................................
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