ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 08-28-2008, 04:17 PM   #46
brents347
Trusting my Cape...
 
brents347's Avatar
 
Joined: Mar 2006
Location: Where the hell is Truckee, CA?
Oddometer: 3,497
I know I went months between posts on my 660 build, but I have to ask...

"Is it done yet"?
__________________
07 Yamaha R6
07 KTM 950 Super Enduro
04 KTM 250exc- plated two-stroke

01 Kawasaki KE100
74 Honda MR50
brents347 is online now   Reply With Quote
Old 08-28-2008, 06:09 PM   #47
neduro OP
Addict
 
neduro's Avatar
 
Joined: Jul 2003
Location: Colorado Springs, CO
Oddometer: 11,784
Before we get started, I was digging through my smugmug and came across another set of pics of the bikes, from a trip I took to Dumont Dunes in 2006. I'll keep sprinkling them in as appropriate, but here's a few that I thought were neat:







As I work on the rebuild, it's been cool to have been around these things pretty much from the moment of conception.

Before we can get into the build, the starting point is what we're after. GP and I had discussed this over a long candlelit dinner manly beer, and come to the same conclusion.

The strengths of this bike are that it's reliable, lightweight, has a ton of gas without losing it's balance and composure, is comfortable, and cool as hell. Neither of us want a mantlepiece, so we're not after a rebuild to original spec to freeze the bike in time at it's moment of glory. Rather, we both think these things will be outstanding bikes to tour the backcountry with, in all likelyhood south of the border where gas matters.

To that end, there were some admitted shortcomings in the original bikes that we aren't going to repeat, probably the biggest of these being the skidplates, which were a last minute "we're out of time so this will have to work" type of affair.

The chassis is pretty straightforward- they raced with 660 front ends but those are unobtainable so we're going with stock RFS stuff. Otherwise, they were well sorted and we'll just going to use what's there.

The engine presents a lot of options. After extensive research, we both decided that the most desireable option would be a stroked 525, for 552 in displacement. This will make a torquey motor that will happily pull tall gearing and lope along at 70mph, but without the questionmarks that the big bore motors carry with them (which need revs to breathe, which is where RFS motors go to die). Unfortunately, KTM stopped making the cranks needed- More on that later.

Our approach is the same, too. Get the thing back together and running, then piece by piece address shortcomings or updates.

To that end, here has been my shop for the last month:



I had lofty goals of having a running bike when Gaspipe arrived. Clearly, that was not to be.
__________________
Doubletake Mirrors- Folding D/S mirror that is both useful and indestructible.

Dual Sport Riding Techniques DVDs: Clear instructional DVDs to improve off-road skills.
neduro is offline   Reply With Quote
Old 08-28-2008, 09:03 PM   #48
meat popsicle
Ignostic
 
meat popsicle's Avatar
 
Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
Oddometer: 14,147
Quote:
Originally Posted by neduro
...

Neither of us want a mantlepiece, so we're not after a rebuild to original spec to freeze the bike in time at it's moment of glory. Rather, we both think these things will be outstanding bikes to tour the backcountry with, in all likelyhood south of the border where gas matters.

...
A brand new bike, all beautiful and shiny, is only potential - and there's nothing worse than wasted potential!

You probably have so many resources at yer disposal, and still no stroker cranks... none of the rally blokes like these have em?

http://www.scotlandtodakar.com/bike_spec.html
http://www.rallymanagementservices.c...mrallypro.html

etc.
meat popsicle is offline   Reply With Quote
Old 09-10-2008, 10:19 PM   #49
gaspipe
Wandering Soul
 
gaspipe's Avatar
 
Joined: Jul 2004
Location: Pickwick Lake, Tennessippi
Oddometer: 11,342
This is far from dead - in fact, I'm just starting to turn my attention to this project. I'm accumulating bits here and there (and a whole 'nother '05 525EXC bike...) to get this bike going again.

I've spent a good deal of time thinking about various aspects of the things I need to fabricate and procure, and I'm beginning to get a handle on it now.

And when it's done, it should be a reasonable facsimile of it's former glory, but saddled with rider of significantly less talent than the former pilot of old #98, Mike Krynock.



Back to work, but some pics soon.....
__________________
gaspipe [the original]

Hair of the dog....
gaspipe is offline   Reply With Quote
Old 09-11-2008, 12:09 PM   #50
neduro OP
Addict
 
neduro's Avatar
 
Joined: Jul 2003
Location: Colorado Springs, CO
Oddometer: 11,784
I've been THIS close to getting mine running for about 3 weeks now, which I guess means my judgment of what's left is off, but I think I knew that already.

Anyway, a funny story from the trenches: I'm really bad at wiring and electrical "stuff". I'm looking at the harness and absolutely can't make heads or tails of it, so I give in and call Niles (team mechanic) for advice. As it happens, we were living in parallel yet opposite worlds- as I called, Neil Diamond was blaring in the background. Niles had the Kinks going, working on a Virago 750 or somesuch, we discussed and agreed that Diamond and a Rallybike was almost perfectly the opposite of his situation.

I digress.

I asked Niles about the harness and he started laughing.

Apparently, the harness is weird to start with becuase the Baja Designs stator runs everything on DC. Then, to make it extra special, Charlie wired everything with only one color wire (I already knew this) and for some wires, ran extras parallel for use if there were a short on the primary (this had me pretty confused).

Niles' advice? "Start over".

I think I've got it sorted far enough to start it, but I'm going to need help with this. Any electrical gurus in the front range? I pay in Beer and Pizza!

__________________
Doubletake Mirrors- Folding D/S mirror that is both useful and indestructible.

Dual Sport Riding Techniques DVDs: Clear instructional DVDs to improve off-road skills.
neduro is offline   Reply With Quote
Old 09-11-2008, 12:35 PM   #51
mud
I just wander.....
 
mud's Avatar
 
Joined: Apr 2003
Location: Roseville, MN
Oddometer: 1,648
Could you just start with a stock wiring harness?????? Tons of bikes being parted out over on you know where.
__________________
2007 Factory Husaberg 380FE
2007 Montesa 4rt
1984 Husqvarna 500AE
mud is offline   Reply With Quote
Old 09-11-2008, 01:18 PM   #52
borsiin
Gnarly Adventurer
 
borsiin's Avatar
 
Joined: Feb 2008
Oddometer: 132
Quote:
Originally Posted by mud
Could you just start with a stock wiring harness?????? Tons of bikes being parted out over on you know where.
Nope it wont fit with the special stator they use.

I guess that the bajadesigns DC stator+reg+rec is used.

Then it´s quite simple, start by opening all cable wrapping and think.
Then first wire ignition which should be easy since nothing should be changed since original. Then wrap all ignition in own tubes separated from lighting, so that you wont mix it up with lighting when you stand in the middle of nowhere trying to locate an electrical problem.

Then comes lighting and since it´s a bajadesigns everything is fed to the reg/rec and from there to the battery. From the battery you should feed it to a nice heavy duty fuseblock easily accessible.

From there I recommend that you make 6 groups:
1. Front lighting
2. Navigation
3. Backup to navigation
4. E-start
5. Rear light
6. Indicators

By this method it´s easy just to remove the fuse from non necessary groups and just limp home with working navigation and perhaps lighting in case that something breaks down.
borsiin is offline   Reply With Quote
Old 09-11-2008, 01:23 PM   #53
Mercury264
Once you go Triple...
 
Mercury264's Avatar
 
Joined: Nov 2005
Location: Masshole
Oddometer: 21,807
__________________
'12 Tiger 800XC
'07 TE510
'02 Sprint ST
'99 XR650L
'99 Speed Triple
Mercury264 is online now   Reply With Quote
Old 09-11-2008, 01:43 PM   #54
InfoManiac
Always Learning
 
InfoManiac's Avatar
 
Joined: May 2006
Location: San Antonio, TX
Oddometer: 5,889
__________________
"Goin' to "The Farm" - wherever it may be - makes JM what it is. It ain't the basement - more like a foundation...... and it's better with rough edges." ---DireWolf
"Knowledge is an unending adventure at the edge of uncertainty" ----- Jacob Bronowski
"I have sworn upon the altar of God, eternal hostility against every form of tyranny over the mind of man." -----Thomas Jefferson

Smugmug coupon ----- 5w5TPcXpTtBdw --- Save $5.00!!
InfoManiac is offline   Reply With Quote
Old 09-11-2008, 02:25 PM   #55
sixer
I suffer from Ainrofilac
 
Joined: May 2006
Location: CenCoCal
Oddometer: 1,220
__________________
"There are no such things as accidents—just two people competing for the same point on the space-time continuum."

Support your local Search and Rescue Teams.
sixer is offline   Reply With Quote
Old 09-11-2008, 03:55 PM   #56
joenuclear
Planning.....
 
joenuclear's Avatar
 
Joined: Mar 2007
Oddometer: 6,122
GP and Ned,

Reading about both of you finding and fixing problems could be a great learning experience.

Or it could just confuse the mortals....
joenuclear is offline   Reply With Quote
Old 09-11-2008, 05:34 PM   #57
gaspipe
Wandering Soul
 
gaspipe's Avatar
 
Joined: Jul 2004
Location: Pickwick Lake, Tennessippi
Oddometer: 11,342
Hola Ned,

The big issue is that the KTM runs the lighting on AC, and the bike is equipped with only a little AC regulator for that. The easy way out that costs $$ is just setting the whole bike up for DC power. If you want to spend money, Baja Designs' wire harness add-ons for the dual sport kit and the DC rectifier/regulator will do it. You need the HD R/R.

I'm not sure how I'm going to do it yet. I might just make my own harness. I'm likely going to rewind my stator to get around 200 watts, so it'll be similar to the BD one you have.

We probably ought to talk on the phone on some of this, since I'll grow a beard trying to type it all.
__________________
gaspipe [the original]

Hair of the dog....
gaspipe is offline   Reply With Quote
Old 09-11-2008, 06:24 PM   #58
Jeff@TheQuadShop
TAT survivor
 
Jeff@TheQuadShop's Avatar
 
Joined: Nov 2004
Location: Crestwood, Kentucky
Oddometer: 4,578
I forgot to tell you GP, I already did the DC mod with a TrailTech reg/rect. I've been running a HID lighting setup.
__________________
1998 RMX 250 singletrack bike
1999 DR350SEX Dual Sport bike
1996 XR600R adventure bike
KY state Vet A offroad champion
TAT, KAT and TWVT survivor
Jeff@TheQuadShop is online now   Reply With Quote
Old 09-11-2008, 08:58 PM   #59
gaspipe
Wandering Soul
 
gaspipe's Avatar
 
Joined: Jul 2004
Location: Pickwick Lake, Tennessippi
Oddometer: 11,342
Quote:
Originally Posted by Jeff@TheQuadShop
I forgot to tell you GP, I already did the DC mod with a TrailTech reg/rect. I've been running a HID lighting setup.
You've saved me a bunch of time Jeff!

__________________
gaspipe [the original]

Hair of the dog....
gaspipe is offline   Reply With Quote
Old 09-12-2008, 06:29 AM   #60
neduro OP
Addict
 
neduro's Avatar
 
Joined: Jul 2003
Location: Colorado Springs, CO
Oddometer: 11,784
Quote:
Originally Posted by gaspipe
I'm likely going to rewind my stator to get around 200 watts, so it'll be similar to the BD one you have.
Bear in mind that one of the few weak points of the 05 motors is solder that melts at too low a temperature. The Baja Designs unit addresses that shortcoming as well as providing extra power.

I've got the BD R/R already. I think the bike is generally wired like borsiin helpfully suggests (thanks! I may have questions later) except I haven't figured out the exact logic of what goes where, and, I'm going to simplify a bit from true rally format in that I don't need some of the equipment it's currently wired for (Sentinel, ASO GPS, etc).

I'd like to look at the BD Fuego HID 4" lights and see if those are an option to replace the stock 640 lights... figuring out lighting is on my list but pretty far down right now, so hopefully you'll beat me to it and I can just copy what you do. :lookingatneighborstestandfillingintheiranswers

__________________
Doubletake Mirrors- Folding D/S mirror that is both useful and indestructible.

Dual Sport Riding Techniques DVDs: Clear instructional DVDs to improve off-road skills.
neduro is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 09:39 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014