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Posts from the ‘Motorcycle’ Category

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.

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

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Motogadget M-Unit

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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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29
Jun

Mudguard fitted & carb woes

Quick pre MOT update and mudguard pics.

I managed to create a mount for the triumph mudguard using aluminium pipe bent to shape and attached with P-clips. I had no idea whether it would work or not when I started. First I used the rear tire as a bending guide as it’s about the width that I needed. This gave me the front bracket which I attached to the mudguard as a test.
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That worked really well so I set about making the second bracket for the rear.

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What I had failed to think about was how to get the brackets and mudguard into place. I had hoped to leave the brackets attached to the mudguard and slide them on, but that was never going to work. So i had a very fiddly time trying to mount the brackets to the mudguard once they were in place. With a lot of swearing and dropping nuts I got there.

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I am so delighted in how it turned out. I never expected it to work so well.

Next it was time to refuel the tank and fire it up. This is where the headache started. The bike started ok, but sounded odd, I realised that it was pissing fuel out from somewhere. Not good. I also realised that one of the exhaust headers was cold not hot. Also not good.

I rapidly realised that there was probably a carb issue. I’ve avoided touching these so far as I don’t want to cause more issues than I fix, but needs must. I took them off the bike which was much easier than I was expecting. Thankfully I didn’t need to remove the tank either.

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I found some blockages in the carb that I thought was the problem and managed to clean them out. I’ve just put them back in and it seems to have sorted the issue out. Certainly it sounds better and is no longer pissing out fuel which is nice!

A job for this winter is a proper carb clean inside and out.

25
Jun

Brakes and other jobs

I’m so close the end of this….

I’ve made a chunk of progress though it doesn’t all show. The main jobs left to do from last time was sorting the wheel placement and fitment. I then also need to fit the brake calipers.

1. Front axle
I had the axle machined down to the correct length. This meant I could finally test fit the wheel and get the correct spacings

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2. Front axle spacers.
The local engineering shop also made up two more spacers for me, once I had worked out what size wheel spacers I needed. I got them to machine down the existing spacer as it was quicker for them. They then created the second one.

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3. I picked up some new caliper bolts as the calipers didn’t come with any. This allowed me to fit the calipers and see if it would even work!

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4. The original petcock was on it’s way out so I tried to find a suitable replacement. After much research it appeared a Suzuki GS450 one would work, so I ordered one. It turns out it will fit the tank perfectly, but you cannot get it the tank back on the bike! In then end I just put the petcock in with the tank in place. This creates future headaches when removing the tank, but it will have to do.

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5. Disc spacers.
With the axle and wheel spacers in place I could finally work out what to do with the discs. As they were touching one side of the brake pads on each caliper. It was around 1.5mm out. I tried to find some suitable disc spacers, but couldn’t find any. In the end I just made my own. In the end they worked perfectly and didn’t take me too long to make.

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6. Brake hoses
With the fitment of the brakes I could finally get the brake caliper hoses ordered. I went with some nice Venhill ones like I had used before.
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7. Mudguard mounts
I’ve not finished this yet, but after various attempts I think I’ve got the design sorted. It uses some round 6mm aluminium, I bent it to shape around the rear tire to get the perfect bend. I tried to hammer out mountings, but found it far to hard to be perfect. So now I am using some little brackets that I’m waiting to arrive. The pics give you an idea where it’s heading.

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8. Speed sensor
The final job I’ve done was to find a place to mount the new magnetic speed sensor. In the end I’ve used a longer cinch bolt on the bottom or the forks. On the extra end section I’ve mounted the Koso speed sensor using the p clip to get it in the perfect place, I then routed the cable using the brake hose as a path for neatness.

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