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Posts from the ‘Motorcycle’ Category

5
Oct

KTM Duke 390 2017+ Carbon Screen version 2

I’ve had quite a few KTM Duke 390 owners now running the 3d printed brackets.  They have used all kinds of screens which is great to see.  I decided to make some improvements to the design to allow for larger screens and installation easier.

The major change is that the two brackets that mount to the back of the TFT display are now one connected bracket.  This means is much stronger and less able to flex.  I have also made the screen brackets fit into a notch for alignment.  It improves installation a fair bit.

Parts List

2 x Screen brackets (left & right)
1 x TFT bracket
2 x Plastic TFT bracket spacers
4 x M6 Bolts 10MM
2 x M6 x 20mm bolts
2 x M5 x 25mm bolts
2 x M5 Washers

Manual

A full installation manual is available to download here

Fitment

These brackets are designed to allow the fitment of screens from the previous versions of the KTM Duke 125 and 390 from before 2017.  It has been tested with the Zero Limits carbon fibre version, but others that match the stock part should also fit.  Here are some links to various different screen choices.

Zero Limits

Moto Composites

Carbon King

Tyga Performance

I will be making and selling these brackets for anyone who would like one.  Please contact me for more info.

4
Apr

KTM Duke 390 2017: Black out

I’ve done some more colour changing on the KTM Duke 390 2017, it’s now a lot more black.  The side panels and headlight surrounds are painted a Porsche Volcano grey metallic colour.

Also changed is the front mudguard for a carbon fibre Ducati scrambler with a custom bracket I designed and made.

17
Feb

KTM Duke 390 2017 Carbon Screen

One of the issue with the new 2017 is the poor availability of screens for it.  Along with those that are available being both expensive and ugly.  I set upon trying to find an good alternative.

What I came across was a Carbon Fiber screen for the older 2011-16 models.  It fits in around the display on these versions.  I took a punt on this hoping that I could make some kind of bracket to make it work.  I got this screen from Zero Limits they were great during the buying process and sent me lots of info.

Parts List

2 x Screen brackets (left & right)
2 x TFT brackets (Left and Right)
2 x Plastic TFT bracket spacers
4 x M6 Bolts 10MM
2 x M6 x 20mm bolts
2 x M5 x 25mm bolts
2 x M5 Washers

Fitment

These brackets are designed to allow the fitment of screens from the previous versions of the KTM Duke 125 and 390 from before 2017.  It has been tested with the Zero Limits carbon fibre version, but others that match the stock part should also fit.  Here are some links to various different screen choices.

Zero Limits

Moto Composites

Carbon King

Tyga Performance

I will be making and selling these brackets for anyone who would like one.  Please contact me for more info.

Manual

A full installation manual is available to download here

 

 

The carbon screen arrived quickly.

A quick test fit to make sure it is going to work.

Next I spent a lot of time 3D modelling and print off multiple brackets for testing.  Believe it or not this is only around 50% of them in this picture.

The final bracket is a 6 piece design and deals with all the angles etc.

Doesn’t look half bad just the bracket.

The final screen in place.

From the riders seat.

16
Feb

KTM Duke 390 2017 with black wheels

One of the first things I wanted to change on the KTM Duke 390 is the amount of orange.  Whilst I like the orange I feel there is just too much of it.  I researched powder coating and other options, but in the end the easiest and cheapest option seemed to be obvious.  Get a pair of Duke 125 wheels.  These come in black as standard and from my research they should be identical.   After a bit of ebaying a got a barely used set for very reasonable money.  I was worried that the whole plan was not going to work, but it was all fine.  There were three differences between the 125 and 390 wheels:

  1. Colour
  2. Front disc size
  3. The rubber bits seem to be a different design.

Apart from all those they are the same wheels.  Result

Pics:

I still want to get rid of more the orange.  I’d love to get the frame painted black, but that just not going to happen.  I think the next stage is to swap the orange headlight side panels for black ones, and sort the white rear section out.

14
Feb

New motorbike. KTM Duke 390 2017

Well, after all the fun with my Z650 I decided it was time for a new motorcycle.  KTM were doing amazing offers over black friday with a 1/3 off a new KTM Duke 390.  It would have been rude not to bite their hands off.

I’m still running the bike in, but it is so light a nimble compared to my Z650.  I love it.

I intend to make a few changes to improve the bike.  These include a tail tidy and new mirrors and some other parts.

14
Apr

Rewiring Progress on the Z650/KZ650

Well some forward progress was made on the wiring. I took a couple of days of work to start making real progress. Unfortunately the British weather was well British which slowed things down.

I got out the tarp again to make some form of shelter to work under.

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First job was to get the Dyna Coils in place. I had to order some nylon spacers from ebay and sand them down to the right size, but they now fit perfectly.

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I also managed to get the battery and M-Unit mounting into place to make sure it would fit. Luckily it did!

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Next up I fitted the Dyna S ignition. I’ve not set it up fully yet, but it’s in place.

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Other jobs included a new mounting point for a new brake reservoir as the previous one was leaking. I knocked this up in aluminium, Also I had fitted the new switches from Highway dirtybikes. These mount directly onto the brake levers. Sadly the left one doesn’t fit so I had to use a different switch setup from the previous switch setup. It’s still cool looking but I wanted two identical ones instead of similar ones.

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I’ve broken the back of the main rewiring, it’s just the final fitting into place of the main loom. I am fed up of seeing and working on cables and connectors now, but it will be worth it.

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With a lot of the loom work I tried to merge things together to simplify things and make routes to the main loom easier. Such as this section of front indicators/horn and brake switch.

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I’ve had a play with the M-Unit and it’s a great bit of kit.

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My final completed job was to make a mounting point for the Motogadget M-Lock. I’ve put it down the side so I can easily get to it. It may move when I finally decide what to do with the side panels. As I think a hidden setup would be best.

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Using the key is awesome, I need to get the glass vial fitted to my glove asap.

Video:

Not going to get more done this weekend, but hopefully I will get the final wiring done soon as I want to ride it!!

 

 

24
Mar

Shorai Battery box

A quickish update. I’m still waiting on parts to start the rewire. I’m hoping my birthday tomorrow brings some shiny treats for the bike….

The Shorai Battery arrived and I was blown away by it’s size and weight.

New vs Old

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Next to the m-unit it also looks so tiny.
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In the meantime I got to work building the battery mounting box. I’m fabricating this out of sheet aluminium. After a couple of sketch drawings I got to work using the bending brake.

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A quick test fit.

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Next I made the attachment strap out of aluminium as well.

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Looks like this should work. I need some longer mounting bolts and some sheet rubber for protecting the battery from the metal, but it’s a start.

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Next job will be to drill the holes into the frame for the battery box to mount to. I’m not looking forward to that bit!

15
Mar

Z650 Update and Rewire

So it was about time I updated this project log. I’ve ridden the bike a few times, but I’ve been suffering constant electrical gremlins. I tried replacing the regulator with a Shindengen SH775 ,but that didn’t fix things.  As the weather has been foul I’ve not had a chance to do much work on the bike.

For some time now I’ve wanted to do a complete rewire so finally I said sod it and got started. First off I wanted to do it properly and easily so my first purchase was a Motogadget M-Unit

Motogadget M-Unit

Motogadget M-Unit

Motogadget M-Unit

Motogadget M-Unit

It’s an amazing bit of kit, it makes life much easier for the rewire. To go with it I’ve order lots more kit that is arriving shortly I hope. In the mean time I started removing the old crap wiring.

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The bike looks much cleaner with out all that rubbish hehe

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When the rest of the kit arrives I can start planning the next phase. Here’s some of my shopping list:

Dyna S complete coils/ignition kit
Motogadget M-Unit
Motogadget M-Lock
Shorai Lithium Battery
New Spark plugs
Loads of wiring bits.
Uni Clamp On Air filters
Starter Relay

10
Nov

Picture of my KZ650 so far.

I need to keep working at it until it’s done.  However here it is at the moment.

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14
Aug

Carbs fixed but now something new

So I promised an update. Well Tim worked his magic on the carbs and timing. He got it so the bike stopped surging at mid revs and re-jetted so that the power was actually smooth line as the revs increased. Test riding it round the lanes and it was transformed into an amazing ride.

However as with this whole project my luck sucks, I rode in the center of town feeling very happy however on my trip the bike completely cut out with no warning. I managed to get it restarted, but the same thing happened three more times in less than a mile. I managed to get to my destination, but I was pissed off. Interestingly when I started the bike to go home it worked fine all the way home.

Once home I checked things through and with discussions with Tim, I think there is a dodgy connection to the coils. I will be checking the wiring through and changing old dodgy connectors.

I took a couple of pics of the shop
My bike hiding amongst many others. So many spares in this corner.
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Some drag bikes
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Another job I did before the trip to Tim’s was to sort two things on the rear of the bike.

1. A slow puncture
2. Replace the rear disc.

I managed to do both of these at the same time.

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Old disc
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New Disc
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New disc and wheel back on
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Now I’m back from holiday I can attack the wiring. I saw a camo Z650 when I was in the Lake District too.
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