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Fast Orange & Black

270 posts · Started by loony888 · 16 Nov 2010

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Post 1 by loony888,

#1
hello, at the prompting of Bert be, I have started a thread to show the progression of my rebuild. the link to my photobucket page is below

http://s833.photobucket.com/user/loony8 ... 0Superduke



if you want to see the older pics or other stuff and i'll copy some here as well.
I'll probably be asking some questions about the bike too, like cable routing, wiring etc. so please help where you can, remember, i've never even ridden one of these and i didn't pull it apart in the first place!

so without further adieu, here's where i'm up to.

paul.

Post 2 by Bert,

#2
Thanks and *drool*.

Post 3 by loony888,

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Post 4 by MrZ32,

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Post 5 by Luigy,

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Post 6 by bic_bicknell,

#6
Love your Triple Eight!

I used to have a Superlight that I cherished.

Post 7 by superduke08,

#7
Why the rebuild. The pictures show a very clean internal engine When you are done it will look like a new bike..

Post 8 by Bert,

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Post 9 by loony888,

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Post 10 by loony888,

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Post 11 by loony888,

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Post 12 by loony888,

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Post 13 by loony888,

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Post 14 by samba,

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Post 15 by sunnbmx,

#15
Just love your attention to detail Paul. The engine all cleaned with your bits all sorted, really appeals to my obsessive side!

Cheers
Daniel

Post 16 by ktmguy,

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Post 17 by loony888,

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Post 18 by loony888,

#18
Got my oil tank on, the subframe is next, more pics to come, and the new mask is on the way so i'll get that assembled and wired in as soon as it arrives.

paul.

Post 19 by loony888,

#19
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Post 20 by RRR,

#20
hey Paul

goodluck with the build , its good to see so much attention to detail . where did you get the rocker covers coated/treated . is it just powder coating and if so will it hold up to engine temp ok . i appreciate there is not a huge extrnal surface temp so am sure they will be fine just curious . ta muchly

rich

Post 21 by loony888,

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Post 22 by RRR,

#22
Paul

cheers for the reply sooooo tempting would look cool with a motobox . its to easy to be a tart with these things . just as well that they go as hard as they do . ta muchly .

rich

Post 23 by loony888,

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Post 24 by RRR,

#24
ha ha no more than me or anybody else with a healthy fixation for these damn bikes . looks bloody good with a motobox . am feeling more tempted all the time to break out the paint .

rich

Post 25 by loony888,

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Post 26 by cdlabate,

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Post 27 by loony888,

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Post 28 by loony888,

#28
been plodding along, run out of parts now, waiting for orders.........and overtime!

paul.
Image

Post 29 by loony888,

#29
can someone tell me what this is? how and where it mounts please? perhaps with a pic?
cheers,

paul.
Image

Post 30 by RED ZX,

#30
That looks exactly the same as the speedo sensor from my old Acewell dash. It is a magnetic pickup, bolts to a stationary part ie swingarm, then a magnet on the wheel gives it a signal as it passes by.

Could be wrong though as I am as yet unfamiliar with the KTMs.

Post 31 by loony888,

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Post 33 by sunnbmx,

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Post 34 by loony888,

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Post 35 by DribbleDuke,

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Post 36 by DribbleDuke,

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Post 37 by loony888,

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Post 38 by loony888,

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Post 39 by loony888,

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Post 40 by DribbleDuke,

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Post 41 by loony888,

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Post 42 by troy,

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Post 43 by loony888,

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Post 44 by MrZ32,

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Post 45 by dougle,

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Post 46 by scamb66,

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Post 47 by loony888,

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Post 48 by loony888,

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Post 49 by DribbleDuke,

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Post 50 by loony888,

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Post 51 by loony888,

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Post 52 by loony888,

#52
thanks gezza, i'll mount mine in the middle so it doesn't get knocked.

I've finished my wiring mods for the new mask assembly, while i was at it i fitted the O2 eliminators and tidied up the rest of the loom. I also fitted the radiator, though i'm waiting for a guard before i bolt it up tight. I also cleaned up the akras using meguiars metal polish but the original decals were looking a bit tatty so i replaced them for these, what do you think?
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cheers,
paul.

Post 53 by samba,

#53
well, i've decided the tank will be as original i think, it just looks right i guess because most other bikes have a satin tank.
My wheels are stripped except for the cush drive rubbers and i was wondering if anyone has gotten theirs blasted and powder coated with the rubbers still in place? mine look fine but if i remove them they will be stuffed, do i have to? i think i read somewhere the bake cycle for the powder can stuff the rubber??
cheers,
paul.

Post 54 by loony888,

#54
not a great idea to PC the wheels with the cush drives in place - new ones are only ~£30, so even though it is quite possibly the worst job I've ever done on a car or bike, I'd still rather do them than bake the buggers only to find they're fooked and need replacing anyway

Post 55 by MrZ32,

#55
hmmm, no worries, i guess i'll have to pull them out, any tips?
30 pounds is fair, shame i'm in OZ where the KTM network love to gouge the aussies!

paul

Post 56 by loony888,

#56
what year tank do you have?

and what year engine is this again?

Post 57 by MrZ32,

#57
i have a 05 mate.
why's that?

Post 58 by loony888,

#58
trust me you are going to want to sort out some better fueling and bigger tank for the 05 model... as I borrowed my mates old 06 one day (before i bought mine to try one out... fell in love with it when i first saw it) and i emptied the lil tank (on the standard very rich fuelling) in 95km... ok i was pushing hard but that was ridiculous.

I wanted the 08 after i rode it because of the fuel range... which is important in australia as a round trip in aus is a good 400-600km of flat out riding... and 4 to 6 fill ups for a one weekend trip is ridiculous.

hence why i would suggest an 08 tank with some fuelling changes as you can just smell how rich the 05/6 models run

Post 59 by loony888,

#59
i hope that's an offer to help me set it up then mate??
if i can find an 08 tank i will use one but they're bloody expensive new!!

paul

Post 60 by MrZ32,

#60
oh yeah, nearly forgot, off for a ride over queen mary falls tomorrow, 8.30 at yamanto maccas, want to join us?

Post 61 by loony888,

#61
sorry mate... all roads seem to be closed from my direction to you.

plus im gonna be helping people in the city to clean up after the floods (although first thing tomorrow morn i will go up Mt G but cant get past the cafe due to road closure)

Post 62 by MrZ32,

#62
well it's raining so i didn't go. i tried my wheel bearing puller on the cush drive rubbers with no success, what's the best way to get them out?

paul.

Post 63 by loony888,

#63
drill out the rubber snd extract... somone did a thread on it a while back... hard work

Post 64 by loony888,

#64
something like this then, off to bunnings for a burr...

viewtopic.php?f=18&t=11230

Post 65 by loony888,

#65
well that was an absolute bastard of a job!why would anyone loctite the fukkers in there??? aaarrrghhh!

Post 66 by loony888,

#66
well xmas slowed me down a bit but i'm back in the swing of things, my wheels are at the powder coaters, my bodywork is being painted metallic black with orange candy, i've ordered my nichols kit and i've fitted my cox radiator guard. when i get my paintwork back i can assemble the mask and install it, i'll post up more pics when there's something to show.

paul.
oh, my SDR exhaust has arrived too!

Post 67 by loony888,

#67
Nice job your doing there. Keep up the good work.

Post 68 by loony888,

#68
thanks jue,
i have a question, for anyone with the nichols top clamp, what did you do to mount the handle bar clamps to it? the std bolts don't work, and i can't find any bolts with a short cap head so the bars will sit in the cradle.
suggestions?

i have some new stuff arriving so i'll be doing some more work and taking more pics, hopefully on the weekend.

paul.

Post 69 by loony888,

#69
I've got some stuff done at last, i fitted a ZipTy captive axle block set and fitted my nichols triple clamp, but i have to machine the allen head bolts before i can assemble the handlebars on the bike. I've got my painted bodywork back, and it looks AWESOME! which means the mask can be assembled, which was a fukken ball ache! but it is done. my wheels are back from the powder coaters in gloss black and i've pressed in new bearings and cush drive rubbers and rebuilt the sprocket carrier also.
I still have to sort the brakes and suspension, the rear shock will be sent off to be rebuilt and set up to suit me by MPE, they will also fit the ride height clevis while they're at it. once that is done i'll get them to do the forks and by then i should have my new brake lines on and plumbed/bled. i still need levers, number plate carrier, rotors (f&r) and that's about it, i saw a pic of a superduke and the ktm logo on the seat was kind of embossed rather than screen printed on, what is that seat? anyone have one?
cheers,
paul.

Post 70 by loony888,

#70
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Post 71 by MrZ32,

#71
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Post 72 by loony888,

#72
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Post 73 by loony888,

#73
mate, i can see right now that you are going to have a problem fitting the front mud guard.

as i believe that you bought on 07 onwards bottoms of your forks... different mounting positions for them. Have you got brakes to fit too?

Post 74 by MADDOG53,

#74
Just wondering loon , did you get the shock clevis set-up as well from tri-valley and what kind of set-up advice did you get from them looks "wicked"

Post 75 by loony888,

#75
cheers mate,
i have the shock clevis yes, i'm getting MPE to pull my WP shock apart as the body is quite discoloured and corroded so i want it cad plated again, if my weight will suit the std spring it will go back in, if not the correct one will be fitted, paul at MPE says he can set the sag specs and then adjust the overall length back to the std length. I'll do the same with the front and start with base settings and std geometry, i'll see what needs adjusting once i get to ride it from there.

paul.

Post 76 by loony888,

#76
took my forks and shock to MPE yesterday, says it will take a month to do what i want to them, got my handlebars mounted to the top triple but i've now decided that i want black clamps so they're not fixed tight yet, though the throttle cables are adjusted and the grips are on and lockwired. the master cylinders are on but i'm still waiting for new lines.....

Post 77 by loony888,

#77
got the bars on.......
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Post 78 by loony888,

#78
well, i've got my CRG levers and mirror on, i've also fiited my rizoma number plate kit and i've got my new brake and clutch lines, the clutch is apparently a bastard to bleed, any suggestions guys?

paul.

Post 79 by MrZ32,

#79
did i hear from paul at mpe that you got your forl nitride coated?

and i think that i got your old 160 rear spring... tell you what bike is running like a dream atm

liking your build mate.... where is the top of your nicholous triple?

Post 80 by Aussieduke,

#80
Mate
Paul at MPE is a guru, he's done two of my bikes and I have much positivefeedback from others about his talent.

You can't go wrong with him. Please organize a ride date to chrissen the baby! I'd love to be along when you do the maiden ride. We've all enjoyed following the build, so keep us informed.

Cheers
Rosco

Post 81 by loony888,

#81
bloody hell!
no secrets round here, yeah they're getting titanium nitride coated, the fork bottoms are black and the tubes are getting re done too. i haven't got anything back yet, not sure about the spring, it better not be mine, i was expecting it to be re used!
i know he's revalving the forks, replacing the fork seals and wipers and setting the air gap, i think he's using the original fork springs but i can't recall.

it's coming along rosco, getting close now, another couple of monts at the most and it will be done, shame, i'm enjoying building it.

paul.

Post 82 by loony888,

#82
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Post 83 by loony888,

#83
Hey Paul, still looking for a fast way to bleed the clutch? I did mine with a syringe from the bottom. Worked great. There is a blead valve on the master, thanks KTM who ever. Brake and clutch are two different manufactures, and take two different fludis. Minerial oil only in the clutch. I did a final bleed on the masters( both brake and clutch masters) by leaving a foot lenght of clear tube on the bleed fitting to watch the bubbles bleed off. Sure is nice to see the bubbles in the clear line. Hold the line upright. You can leave the line on over night to re-bleed the next day. I have to say I have been enjoying your build but you raised the bar soooo high.. I am also doing a rebuild, frame up, except I did not have to mess with the motor. Prev rider parked it in the side of a pickumup with less than 2k on the clock. Riding it today to work but need paint yet. Fricken plastic is wayover priced so I went the flea bay route and bought some race glass , uppper and lower for $150 + shipping. It sat on e-bay for a long time, guess guys on this site are afraid of making waves. Saved me some cash. I am buying up stock panels when I see it forsale on the cheap. Got ta go, work, work...

Post 84 by MrZ32,

#84
cheers for that doug, i reverse bled my rear brake and it took 2 mins! pushed the fluid through the bleed nipple with a syringe till it half filled the res, nipped it off then pumped the pedal up. i put some clear hose on the nipple and bled some fluid the regular way and no bubbles, good feel at the pedal so it's sweet!
now, this clutch.......i'll bleed it the same way and finish with a normal bleed at both nipples but i want some info on the magura "blood". I have red which i use in my husky but i think i read our bike takes blue? what's the difference? is it the viscosity? i read guys use ATF and regular mineral oil but i've seen mates get stranded with leaking clutches in the scrub and they all used regular oil or ATF so i'm not game to use it, my husky clutch has never failed me and i reckon it's cause i use the proper fluid.

good luck with your build doug, i've found the hardest part is scrounging up bits and pieces, especially here in australia, not very common and new parts are sooo expensive, still good fun though!

Post 85 by loony888,

#85
Don't want to stear you wrong on the fluid to use. Fill cap reads minerial oil. Magura blood? $$$ Magura is who makes the unit. Might be worth the worry to stick with Magura blood. Some fork oil is minerial oil. That is all I have to say about that. The hardest part for me to source, well I never did find one, was the elbow fitting on the clutch master. Don't brake the one you have. I made the broken one work by making the elbow a straight fitting. It holds no pressure. Had to make a new bracket to hold the resivor so the hose can work. Put over 100 miles on the bike yesterday.. My bud bought a new Adventure and was taking it e-z for the break in miles. I let him lead through his olld stompping grounds. Nice back roads. Kind of cool wet ride. Still fun. This bike is a keeped. Only trouble I see will be trying to keep my license. It wants to go fast everywhere...

Post 86 by MrZ32,

#86
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Post 87 by loony888,

#87
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Post 88 by loony888,

#88
snooping? no... i just love to know exactly how everything works... so i do ask a lot of questions to those who know.

it is how you work out all the little problems that these great machines can throw at you

Post 89 by cdlabate,

#89
well, i'm still waiting for my suspension parts, but my levers are fitted, my rear hose and clutch hose are on and bled up and i now have my SDR exhaust. other than fiddling and adjusting some small bits and pieces nothing much has been happening, i did fit my rizoma tail tidy though with indicators and number plate light and it was a fair bit of work for a kit that is supposed to bolt on!

paul.

Post 90 by sunnbmx,

#90
well, i'm STILL waiting! still waiting for my suspension, and the braketech rotors i ordered are back ordered as well, 90 bloody days! course, they only tell me that after i pay for them! bastards!
so if anyone is still following my build please be patient, i have to be, hopefully my suspension will be ready for pick up this week, which means i'll be able to get stands under it and fit the bottom half of the bike together, i'll put more pics up as soon as i have some more parts, it's oh so close...................

Post 91 by loony888,

#91
Its worth the wait dude. Its going to be a sweet ride when she's all done.

Post 92 by Aussieduke,

#92
We're all still watching with great interest! You are doing some great work Paul.

Post 93 by loony888,

#93
cheers mate, haven't been doing much work lately though, i'm getting a little impatient to be honest, i do love to tinker!

Post 94 by Aussieduke,

#94
Hey Paul

So after you get the bike finished what's the next project,? .......or is that divorce material...bwah, hahahah !

Post 95 by loony888,

#95
HE HE, my wife is a top woman, no such worries, yet! i haven't really thought about another bike, i want to get this one finished and enjoy it for a while, but the RC8R looks very tempting, although by then the new ducati superbike with gear driven cams should be out........

Post 96 by Aussieduke,

#96
Paul,
It'll be hard to let go of that bike after all the blood,sweat n tears that's gone into it! I imagine you'll get a few years before the bug bites again. Just enjoy it, I'll bet you're going o get plenty of lookers at every stop.

My wife is tops too! She has a Ducati S2R, I'm acquiring bits from a 996R to swap the front end to something adjustable with usable brakes. It will make it the bike it should have been.

After riding my SD, she loved it, and wanted one. But we talked as I was happy to trade hers on a SD, but she loves the S2R. So I decided to upgrade the front end.

Happy wife = Happy life.

Post 97 by loony888,

#97
i have the arrow shotgun set up on my S4R, it's bloody loud alright!
what exhaust do you have on your SD? would the wifes S2R800 be louder?

paul.

Post 98 by Aussieduke,

#98
The SD has slip on titanium Akras, no baffles and sound really nice. Not as loud as the wifes arrows though!!

It sounds deep and throaty, much more than an 800 has a right to sound ! She can ride it too and has embarrassed a few blokes up the mountain. So the front end upgrade will be a change for the better.

Post 99 by loony888,

#99
nice!
looking forward to hearing my akras soon!

Post 100 by loony888,

#100
Still no suspension.................

But! i did get my braketech rotors from www.motowheels.com , which were on backorder for a while, no front tyre yet though been too busy at work!

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Post 101 by Aussieduke,

#101
Very, very nice Paul. What are the rotors made of ?

Post 102 by loony888,

#102
they're ductile iron, braketech sent me instructions with them, they're coated with "gunkote" which protects the disc from corrosion i guess, so the friction surface won't stay black unfortunately. i have to use an old set of pads to scuff that off before replacing them with new ones and using them in anger.

paul.

Post 103 by bic_bicknell,

#103
Nice brakes! I sent these guys an e mail a few months ago asking which rotor material was available for the SD. They replied with some prices for the stainless steel and cast iron. They also had some road developed carbon rotors on their website but didn't mention that this was available currently. Did you look into this?

Post 104 by MrZ32,

#104
if you dont mind me asking... how much are they worth?

i ask as i looks like im going to need a new set of front rotors

Post 105 by loony888,

#105
hey bic,no, didn't know about them but carbon rotors for the road? not sure they're legal here but surely you would never be able to keep enough temp in them on a road bike??

hey james, they cost me $340 each and $60 freight, with the exchange rate at the time less than $700AUD all up, nice huh?

Post 106 by loony888,

#106
My suspension has finally been done, paul at MPE in caloundra has done a fantastic job on the refurbishment of these, new seal and O'ring kits, racetech revalve, Titanium Nitride coating for the front sliders and rear push rod, reanodizing of the outer tubes, powdercoatiing the rear spring and hard anodizing of the fork bottoms with the "WP" highlighted by buffing the proud lettering to expose the alloy. He also preset the sag, compression and rebound settings based on my weight and use of the bike, he says the sag will be right and the rest should only be a click here and there depending on my preferences, we'll see i guess but based on my husqvarna TE450 which he did it should be close. He also installed the nichols shock clevis and gave me a 3mm increase in rear ride height, just waiting on a preload adjuster now and it will be installed, but the forks are in, the brakes are on and connected, full of fluid but not bled, waiting on a front tyre before adding the front wheel and being able to bleed it fully. Nice to do some work on it, i was getting tired of just looking at it.......

paul.
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Post 107 by oafboy182,

#107
That Gold is beautiful.

Post 108 by Aussieduke,

#108
Mate that is HORN!.....sigh....I think a little bit of wee just came out.

Post 109 by Bert,

#109
*Drool*

Post 110 by Jermo,

#110
These forks are P0RN!

Post 111 by 2bigalow,

#111
Pure LUST. Better that the naked pis thread. We need more pics!!! (of your bike that is)

Post 112 by jambox,

#112
That is looking sweeeeet! Think you should get the calipers done black as well, then it'll look even sweeeeter!

Post 113 by loony888,

#113
cheers guys, i'm very happy with how it's coming along, can't wait to finish it and ride!!

paul.

Post 114 by MrZ32,

#114
Looks good mate, I should have that answer on the PC maps i the next couple of days.

Post 115 by loony888,

#115
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Post 116 by rocketchick,

#116
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Post 117 by loony888,

#117
Hey mate just looking for some non ktm clutch plates managed to source some from the sunshine coast.

Cheers Cam

Post 118 by Aussieduke,

#118
That's beautiful.... Looks great

Post 119 by loony888,

#119
well thanks to mike who has kindly circumvented the KTM embargo on selling to overseas customers i have a preload adjuster coming for my shock, the thieving bastards make enough profit on parts in the U.S, yet they still want to skewer smaller markets for obscene margins. pics to follow, whine over.

paul.

Post 120 by loony888,

#120
got bored today so i fitted up the front wheel and mounted the brake callipers, bled the system but it seems the master cylinder is knackered, won't bleed up! no air in the system but it won't build up pressure at all, looks like i'm up for a new one, oh well.
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Post 121 by scamb66,

#121
That front end gives me a horn............coming together nicely.

Post 122 by zoddas,

#122
I thought I had a tidy and clean garage.........

Post 123 by nampus,

#123
That is going to be one very nice looking machine!
Such a shame those rotors will not stay black like they are now.

Post 124 by loony888,

#124
thanks guys,
nampus, i wish they would stay black too, looks mean eh!
can't wait to get the rear shock on now!

Post 125 by omky756,

#125
How close to finished are you now loony..???
Been following along and I admire how it's turning out bro..

Post 126 by loony888,

#126
Hey Paul,

What did you do to the front fender? You just paint it, or is that a CF painted up? What the heck? My fender got wacked from the last owner and needs replaced or reshaped with a heat gun. Got a coment on the mirrors you can take or leave. I have those mirrors on my Duck ST4S which is more rounded than the SD. Are those made by CGC? Mine are. Anyway CGC has a new model that realy works with the SD lines. I got a set on my SD and I really like the look and quality. Arrow model. Mechanical male jewelry.

Post 127 by loony888,

#127
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Post 128 by omky756,

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Post 129 by loony888,

#129
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Post 131 by loony888,

#131
I seem to remember the Klinckmeister stated that an air pocket in the slave is possible from design flaw.
I am not sure if you reverse bled, but that may help. Also something about pushing pucks all the way into the cylinders prior to bleed procedure. I have the newer radial mounts and it took a fair bit more patience than any previous brake bleed I have performed. I used the old fashioned, two people, open-close technique and all was fine in due time.
Looks absolutly brilliant. What a great project. A man can find little better to spend his time on that gives the kind of pleasure you must get everytime you walk through that door.

Post 132 by bic_bicknell,

#132
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Post 134 by Stratkat,

#134
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Post 135 by Superdan,

#135
yess gotta love the cam covers, very Ferrarish! nicely done

Post 136 by omky756,

#136
This thread has somewhat slipped through my radar.

Nice job, some good touches.

Post 137 by omky756,

#137
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Post 138 by MADDOG53,

#138
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Post 139 by loony888,

#139
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Post 140 by Aussieduke,

#140
yeah, the iron ones will do me just fine i think......

Post 141 by loony888,

#141
What's wrong Paul, the money tree drying up?

After all the bike looks a million dollars,.......that's 1.07M USD....bwahahahah.

Post 142 by Aussieduke,

#142
money tree?
mate, i do not have a green thumb let me tell ya!
they're nice rotors, and i like that they have made them road friendly but $3200 for a set?? crikey mate.
but could you imagine how fast it would change direction with them and a set of forged carozzerrias??

Post 143 by loony888,

#143
Yeah, I'm just jealous with my stocky 07!

Just promise not to park near mine!

Post 144 by Aussieduke,

#144
Yep, this months a write off for me, far too much family stuff going on. But we need to organize September, will you be getting close to having the beast on the road then, or you may have to drag the Ducati out for a ride in the sun?

Post 145 by loony888,

#145
either or, but i'm looking forward to a good blast somewhere, on something, it's been ages since i've been out.

Post 146 by Aussieduke,

#146
I'm there to help a desperate friend in need! Call you soon.

Post 147 by Agent Orange,

#147
I'm in, it's been a long time here as well with new daughter etc..

Post 148 by Aussieduke,

#148
Yeah, Irish lives in the west so I can see a ride on soon. I'll check my roster and post a proposal soon for a get together. Maybe a ride with lunch at a pub, a couple of mid strength beers and ride home.will be in touch soon.

Post 149 by loony888,

#149
looking forward to it guys!

Post 150 by loony888,

#150
well, my rear preload adjuster arrived today,thanks maddog, love your work! i'll get it fit up and on the bike on the weekend, so it should come together a wee bit faster now.......pics to follow. nice bit of kit i must say!

paul.

Post 151 by MADDOG53,

#151
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Post 152 by loony888,

#152
there's a small problem though mike, it don't fit! Aaarrghhhh! it's 2mm too big and slides straight over the threads, what a bummer, so don't bother pulling your bike apart to fit it, just send it back cause we were led astray, but the GOOD news, my master cylinder is fine, i pulled the cyl. apart and the main bucket had rolled over on itself, i'm guessing because it was dry for a while, but with a bit of fluid as lube it went back together and bled up easy, SAWEEET!


PAUL.

Post 153 by MADDOG53,

#153
Good thing I put the paint pen down sent an e-mail , and packed it back up,,,bummer,,,, I have seen other's to fit other models however,,,and I'm investigating part # and such,,will send a few e-mails out,,,,there's gotta be one that fit's ,,,,sorry Paul,,,been looking at one of these ,,,,,,,,,,,,,,,,,,,
http://www.ktmtwins.com/elka-ktm-990-super-duke-shock

Post 154 by loony888,

#154
don't apologise mate, it's not your fault, can't help it if we're told it will fit and it doesn't, the elka looks pretty but from what i've read about it it's an average performing shock, lots say it's under sprung, which can be fixed easy enough i guess but the std WP has high/low speed compression damping, don't think the elka does, does it?
Anyway, for me at least, i'm happy with the std one, it's been set up for me and it's in now (bastard of a job)

paul.

Post 155 by loony888,

#155
So the shock is installed, it's on the front wheel with a rear stand under it and the engine frame is gone, geez it's tall!!!! pi$$ing around with the bastard battery box, trying to arrange the wiring and figure out what goes where.

paul.

Post 156 by loony888,

#156
more pics, got the exhaust system on, battery box, and wiring all done and tested, no horn as it's stuffed. KTM want $80 nah, i'll find something else thanks, all the other wiring tests ok so far, my mask/gauge conversion lights up and the alarm works, can't test much more till i start it and i need a tank for that. still waiting for said tank, carbon fibre hugger and heat shrouds for the exhaust, then it's a battery and chain and i'm done WOO HOO! well, soon i'll be done.

paul
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Post 157 by tripoddave,

#157
That looks Über Kool.

Post 158 by omky756,

#158
Really coming along Paul..
BUT I'm waiting for your parts to get there too...
in anticipation of the start up video...

Wanna hear it running..

Cheers..
Mike

Post 159 by MADDOG53,

#159
Gee Paul,,,now may be the time you put some bling on it

Post 160 by Aussieduke,

#160
AhHA ! Glad to see from the camera angle....some crap and clutter in the background. You've been making us all feel guilty as to the state of our garages.

BTW...bike looks great

Post 161 by loony888,

#161
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Post 162 by Agent Orange,

#162
Way cool bike Paul. From your task list the most fustrating thing left to do will be to mount your tank, if its anything like my 08SD. The plastic tank will want to move around ,(as in getting bigger) if its not mounted on the frame. You probly know about the new hinges you can buy which moves the tank towards the seat. I modified my stock hinges with a small chain saw file. Another mod I did was on the front tank mounting screw . I champhered the screw by chucking it up to the drill press and taking a file to it. I counter sunk the tapped hole in the frame. This will make it easer to align the screw when you try to shoe horn the tank past the forks top clamp. I also read in this form if you get the screw started to thread into the frame before you push the tank down on to the frame, you will cuss less.
Next on your list to cuss is the battery box / wires. Pure after thought design. My wires and connections are now covered with road grit and grime with only 3 months and 6k smiles on the clock. But what a fun bike, and yes it is a tall bike.

Post 163 by loony888,

#163
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Post 164 by loony888,

#164
Thanks for the tip A. Orange. Some poor soul ran the 08SD I have into the side of a pickup so I had to find another tank. I am not sure how long the tank was sitting around but my thoughts are they move around when not bolted down. I just got back from riding my SD to lunch and another thing to watch for is the pinch bolt on the top triple clamp is on a angle. If you turn the bars say 20 degrees to the left the gap between the tank and the clamp gets bigger. I had my bike up in the air on a work stand with the tiedowns holding the wheel straight and did not notice this feature when I installed my tank.

Post 165 by loony888,

#165
thanks for the tips guys, when i get the tank back i'll let you know how i get on.


paul.

Post 166 by Aussieduke,

#166
can anyone explain how the negative cable from the earth point on the starter runs back to the neg side of the battery please? mine looks to be way too short?????

Post 167 by loony888,

#167
thanks roscoe

Post 168 by Aussieduke,

#168
Sorry Paul have just got home now after working overtime 19:40.
Don't really have the energy tonight, but will be home at 3pm tomorrow, so will hopefully be able to take a look and shed some light then for you.

Post 169 by loony888,

#169
no worries mate, i fitted the chain today, one step closer!

Post 170 by ktmguy,

#170
Same here Paul, found your post too late. I'll see if I can get a look tomorrow before I go to work and mail you from there.
No promises as I need to leave 6 am.

Post 171 by No. 47,

#171
Are you sure you have the right earth cable as there's more than one and they are different lengths - have a look at the parts fiche.

Post 172 by omky756,

#172
On mine the neg cable is very short...Makes it hard to re-install the battery more than anything...Patience...
Eventually I will change it out for one a few inches longer...

Post 173 by ktmguy,

#173
Bugger, up too late will have a look tonight....
From memory from the starter down to the front of the engine in between the downpipe to the other side than in to the box.

Post 174 by Aussieduke,

#174
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Post 175 by loony888,

#175
yeah i think i will, does it run in the front of the box where the pos. goes in or does it go through the round hole in the back?

paul.

Post 176 by Aussieduke,

#176
Mine just runs along the rear top part of the battery box, then curls downward into the open window at the top right corner looking at the box, onto the neg terminal. Then the front box cover can go on leaving, I guess a little window in that corner where the earth lead goes in.

Mines 2007, can't imagine them changing this though.

Post 177 by loony888,

#177
yep, no worries roscoe, looks like i've ran mine too tidy and lost some length, i'm 2" short. i'm going to make a heavier longer one to replace it i think, thanks for the help guys, appreciate it!

paul.

Post 178 by Aussieduke,

#178
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Post 179 by loony888,

#179
i'm a lot more than 2" Short mate!
thanks for your help.

paul.

Post 180 by loony888,

#180
well, i got my tank back today, the painter whined and moaned about the rubberised coating on it and took a looooong time to get it off, then repainted it satin black with ceramaclear, he also fitted my power parts tank pad and i fitted up the pump and my bling filler cap. surprisingly (maybe??) it bolted on with no pain whatsoever, i do have the motohooligan hinges and as someone here suggested i mounted them loose and nipped them up last, all sweet.
looks awesome on the bike, i want to fit up the rest of the bodywork now but i still have to fill it with oil/coolant/petrol add a battery and start it......soon!

paul.

Post 181 by MrZ32,

#181
Paul,

You need a HM QUICKSHIFTER, just fitted mine awesome.

Post 182 by loony888,

#182
Have a look in the for sale section... I posted an eBay link that is selling them for 250 (HM qs plus) not the normal 460

Post 183 by samba,

#183
Glad to hear your tank went on with little or no problems. Hate to see you scrach it up with all the extra fine work you are doing Paul. Mine took a small beating, but I was getting kind of excited to ride the bike I pieced back together. Steady as she goes!

Post 184 by sunnbmx,

#184
cheers doug,
i'm going to fill it with fluids this weekend and fire it up, just have to organise a battery.

paul

Post 185 by loony888,

#185
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Post 186 by Agent Orange,

#186
You have to get some video of it firing up for the first time Paul.

Post 187 by loony888,

#187
it's aaalllliiiiivvveeee!!!!
mwoarharrarrr

Post 188 by nampus,

#188
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Post 189 by MADDOG53,

#189
still need a battery, and i'm waiting for my akra muffler heat shields and c/f hugger to finish it off, i have a mate with a dyne who is going to set it up and tune the PCIII for me, it looks awesome with some bodywork fitted up though

Post 190 by loony888,

#190
i'll take some more later today, bathurst is on so i'm glued to the telly for now.
a prezzy? you shouldn't have mike! what is it?? huh? huh?
paul.

it's come to life alright, needs the throttle bodies balanced, idle set then a decent tune, cause everything is different!

Post 191 by sunnbmx,

#191
Bathurst is run and done. Time for some pics Paul!

Post 192 by MrZ32,

#192
And what a bloody good race it was.. Man loundsey can drive... One more lap... But tander kept his cool an held out.

1,2,3 Holden ftw

Post 193 by loony888,

#193
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Post 194 by loony888,

#194
crikey i've been busy! here's the pics i've been meaning to post up, still haven't seen my battery arrive, and my hugger is on the slow boat so no further progress, but it runs, and after priming the oil circuit it fired up straight away. one thing i noticed immediately was how much heat the exhaust radiates, can't have anything anywhere near it at all!
I have a friend with a dyne who has a run in program that varies load and with that done he will map my PCIII for me. happy days!!
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Post 195 by Agent Orange,

#195
Looks awesome mate, congrats!

Post 196 by loony888,

#196
cheers mate, the photos are crap though and don't do it justice at all! once i get it in the sun the orange in the black should show in pics, can't wait to register it and ride it!

paul.

Post 197 by rob1botes,

#197
that looks friggin awesome Paul.....congrats on a really classy job!!! I love the look of the front end with the 'gold' coated forks, the black end caps & the black rotors...looks super trick. Not to mention the great orange on the frame & valve covers, accented by the orange brake lines & water pipes.
Again, really looks sharp!!
I'll bet you can't wait to get her out on the road.
Nice workshop set-up you have there too by the way...only way to go.

Cheers Rob

Post 198 by sunnbmx,

#198
Looking fantastic Paul!

Are you still waiting on your carbon exhaust guards?

Post 199 by lc4,

#199
Great job

Chain looks a bit tight

Post 200 by loony888,

#200
cheers guys, yep still waiting for c/f exhaust guards and hugger, as for the chain, i needed to have it tight to press the link, i'll adjust it with my weight on it before i ride it

paul.

Post 201 by bic_bicknell,

#201
Looks really good! Just ordered a set of those Braketec rotors for my spare set of wheels. Love them. When you order through the UK importer you get a choice of colour for the bobbins so I chose black as I'm not sure about the red. I went for the cast iron rotors - which are those?

Post 202 by AGRO!,

#202
Hey Paul have you pulled the flies and shafts out?
I have only just done mine and it does make a difference. Yep I was a sceptic
Also don't forget to wear high heals when you ride LOL!! You know its just not fair for us little blokes
By the way your bike looks great mate.

Post 203 by ktmguy,

#203
Great job Paul, looks awsome! Big thumbs up!

Post 204 by lc4,

#204
The front rotors look ala Moto GP , carbon fibre

Post 205 by MADDOG53,

#205
Looks the absolute dogs dinnger the front end is pure porn,,,,Brake tech irons are sweet

Post 206 by loony888,

#206
i'm so looking forward to the carbon bits arriving so i can register it and ride it, i CAN actually touch the ground on it, just, and it has to be level ground but i'm used to it with every bike i ride anyway, so no high heels for me! the rotors are iron, they still have the gunkote on them once it's ridden the pads scuff the gunkote off and i have to put my new pads in then.

paul

Post 207 by nampus,

#207
That thing looks awesome! Love the little orange details, valve covers, brake lines, coolant hoses, very nice!!

Post 208 by AGRO!,

#208
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Post 209 by stalker,

#209
tidy . . . .real tidy

Post 210 by omky756,

#210
Wow Paul..It's so close.!!
You going to get it run up on the dyno after break in..??? Be curious to see the charts..I'm guessing you will run the Tuneboy programs..???
Was gonna raz you against the common opinion but I just couldn't diss what you've done even in fun..You've put a lot of hard work, thought and patience
into your build...I want your pipes..!!! and when the time comes I'm going to powder coat my frame orange(maybe pink ) because of the single seat conversion I just mounted...
You ARE going to give us a start up video eh..????
Great job!!!

Post 211 by loony888,

#211
the bike has come up a real treat, and yeah it's so close now, just waiting for back ordered bits. A big big thank you to every forum member who chipped in with photos, advice, wiring diagrams etc when i got stuck. the mask conversion for example, i liked the new mask so much better and was really keen on doing the conversion, without the thread on here in the "how to" section it wouldn't have happened. sure, i could have muddled through and rebuilt the bike as it was, but the forum made it very enjoyable (and expensive!) with suggestions and help that had just as much to do with how it turned out as what i did, so again, thank you everyone.

paul.

Post 212 by loony888,

#212
That strap on the seat can come off..or not. It's not going to do anything for ya anyway. Don't see any pussy pegs. I allways 86'em before the seat has time to fade from the sun light. Gives it the more dirt bike look of the Katoom.....Put 40 miles on my 300exc yesterday Very nice job Paul. Thanks for raising the bar for my build.

Post 213 by loony888,

#213
i'm not game to remove the strap, it was out in the sun for a while so it will likely be faded a little, i fit up the chain guard and the battery, fit the lower cowl after securing all the wiring, all i need is the splash guard and it's ready to ride, sounds nice though.......

my alarm speaker is making some funny noises, sometimes it chirps, sometimes it farts, and not real loud. ideas?

Post 214 by indy84,

#214
Have you checked all terminal conectors?

Cleaned all the earths?

Post 215 by Bert,

#215
How old is the alarm? Does it have an internal battery?
I'm asking because a couple of years ago I head problems with a car alarm.
I opened it up to find that the internal battery pack (for backup power when they cut the wires) had started leaking all over the PCB.

Post 216 by loony888,

#216
indy, the alarm is factory one that uses the harness, all the terminals and earths are fine cause everything else works properly.

bert, the alarm is as old as the bike i think, so that would be 6 years now. do the factory alarms have a back up battery? i'll pull it apart today and see what i find, not liking the idea of battery gel getting everywhere!

paul.

Post 217 by loony888,

#217
more pics,
the alarm is ok, it just has a low voltage in the backup battery.

Image
Image

Post 218 by omky756,

#218
Nice Paul.!! Tell me you didn't just push it to the back yard.. you go for the first shake down run bro.??? Time for that video.!!!

Post 219 by loony888,

#219
no, not yet! it's killing me but i want to make sure it's right, the splash guard (hugger) is on back order and i don't want to chip up the shock! it's booked in to be run in on a mates dyno and the PCIII will be tuned after that. it's not registered yet either................

and for those who joined us late this is what i started with...
Image

Post 220 by nampus,

#220
You've cleaned it up quite a bit! Very nice job!
Just wondering: did you get it dynoed yet with the sdr headers and motobox?
I can get a new set of headers for cheap and was wondering if it would be worth it.

Post 221 by loony888,

#221
no mate, not yet, it will happen soon but i'm at the mercy of my pay check and it's all been spent lately.........
i promise i'll post up when i do though!
cheers,
paul

Post 222 by omky756,

#222
A project like your undertaking takes a lot of time, thought and fortitude..and a big game plan...
Oh ya...and usually rgwe budget we start off thinking always goes over!!!! Tell me about it..!!!! My stead was
bought straight from the showroom floor...It hasn't stopped yet..and you had a box ..or several boxes of
spagetti to spread out all over first.)) I'm waiting to hear Paul...I've mentioned video..will you do that for us
here on the forum bro.??? I think that is one of the big things about all of our Superdukes here...Few ride 'em very long before
we start small and end up with some great ideas..What for and how to's...I'm diggin this forum more all the time..
and I've enjoyed following along with your project for quite a while...

Mike

Post 223 by loony888,

#223
when it goes to the dynoo for it's run in and tune i'll borrow a video cam and record it, i'll post up the dyno results with the vid.
thanks for the kind words, it's been a great build, lots of fun with very little aggro, hopefully all will go well with the run in and dyno, as for the budget, lol, didn't have one, no point really. my first intention was to rebuild the engine then sell it, doing that properly i was unsure of how much it would cost, mine cost about $4600 in parts, machining and a bit of labour here and there. By then though i'd given in to OCD and had pulled it completely apart resulting in what you see in the pics. total cost? $21,555.04 blown the budget? YEP!

Post 224 by loony888,

#224
Well i'm going to sell my project SD, it's been a great build, and looks fantastic! but it's a bit tall for me..............
didn't know how tall when i started but really, i would have done it anyway. It's had a few heat cycles but needs a run in, and probably a tune, but other than that it's done, and as good as brand new. The thread tells the story but PM if you have any questions, i'll happily answer them.

paul.

Post 225 by sunnbmx,

#225
Holy Cow Paul!

Get some taller boots!!!!!!

You have put in way too much love and attention to detail to let someone else ride your bike!

Post 226 by AGRO!,

#226
I know how you feel mate I'm 5'6" and think the SD is a bit to tall at times and the R is slightly taller.DOH!!

Post 227 by Bert,

#227
Damn! After all that work and effort. I'm shocked!

Post 228 by omky756,

#228
dont do it man there is bound to be a way,

Post 229 by ktmguy,

#229
I'm caught off guard...it feels like Simo all over again..
Tell us it isn't true.!!!!

Post 230 by MADDOG53,

#230
Yo Paul, you might get use to the tall bike. Having both feet flat footed is over rated, if the bike is worth the effort. 98% of the ride your feet are on the pegs. I see kids riding full size dirt bikes. They slide off to one side to get one foot down and keep the bike balanced, but they are dirt bikes and made to take a nap now and then. I have and had tall bikes. My Triumph Tiger is a lot taller and top heavy than my SD. Had it loaded for a week camp trip and it allmost got away from me in the drive way as I was leaving. Well, you know what you need to do...I enjoyed the build. A little over the top for my pockets, but some have it, some don't. Maybe get a stock SD and ride the heck out of it. A guy like you might come up with a way to lower it. Enjoy and stick around.

Post 231 by TLS_Russ,

#231
MPE strikes again lol.

Post 232 by MADDOG53,

#232

Don't do it Paul! One of my mates is vertically challenged too and he has ridden higher bikes than this. He gets the seat trimmed an that is it.
You have an husky TE450 like me too, that is way worse...
If you need some inspiration look up Gaston Rahier. He is the Belgian chap who won dakar on this early BMW HP2! He unfortunately passed away a few years ago but he is one of my all time heroes!
He was short stuff but with a big heart and strong as an ox. Awsome sight to see him at the start geting away in amazon style one foot on the footrest the other on the ground and then mount the bike while he sped away. Didn't stop him passing all the other...

Post 233 by DribbleDuke,

#233

You could lower your ride height in the rear ,,,first,,,,,take a "bread knife" to your seat foam,,,there is a "lowering kit" on ebay,,,,,,,,

Post 234 by loony888,

#234
I think he is on a wind up

Post 235 by scamb66,

#235
BRAND NEW, NOT RIDDEN SINCE REBUILD...................??????

Post 236 by lc4,

#236
Someone is going to score a nice bike

Post 237 by One67,

#237
That sure is a beautiful bike, I hope you do as well as you can with the sale.

P.S. Where did you get those chain adjusters ?

Post 238 by loony888,

#238
cheers guys,
i got the adjusters from KTM twins.

paul

Post 239 by ktmguy,

#239
Still jaw dropped and gob smacked about it.... can't follow this.... spend months rebuilding it to better than new standard and then selling it?????

I'd say there is more to it and it calls for an "intervention"! All from Brissie and surrounding areas to Paul's man shed on Saturday for a SD seller anonymous intervention. Bring the urgent intervention kit like beer, rum, etc...

Whoever buys this bike must be in to win the lotto, wish I could justify putting another SD in the shed.

Post 240 by AGRO!,

#240
Guys,
Show up at Pauls with e-nuf gas and top his bike off. Duct tape his feet to the pegs and make him ride it 'till the low gas light comes on.
Let us know where to follow your next build Paul. Thanks again for the show.

Post 241 by omky756,

#241
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Post 242 by samba,

#242
I STILL can't believe it.!!!
Don't you get wood just looking at it Paul.???
I hope you guys talk him out of it..!!!!!! Bring the video camera.!!!!!
and...I shouldn't say..
but I only paid $14k for my '08 FULL PRICE..!!!
What's it worth where he lives..????
I know I couldn't get full price even with all my mods..
Sorry Paul...Not tryin' to jinx ya..!!!!! I've been waiting for
the start up video for a long time..!!!!!
Cheers bro..!!!!!
KEEP DA BIKE..!!!!!

Mike

Post 243 by Linga,

#243
Paul,

If you decide to part it out I would be interested in the headers.

Post 244 by ktmguy,

#244
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Post 245 by Linga,

#245
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Post 246 by loony888,

#246
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Post 247 by Linga,

#247
Technically the stickers have all been out of date on helmets for a few years now!
Different helmets are legal in different states and the red ticks are now a registered trademark so all companies have to do is pay to put it on... does not mean it meets Aussie standards.
Oh I'll be keeping an eye out for a wrecked superduke to "borrow" stickers from...

Post 248 by One67,

#248
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Post 249 by loony888,

#249
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Post 250 by MADDOG53,

#250
Me too, especially the helmet sticker rip off! Like they make special model helmets for the Aussie market?!?!!?
You will not be possible to put that bike on the road neither. If it is not a personal import or it hasn't got the compliance sticker you look at a few grand to get this sorted.
Try a shorai battery, here in Aus 280 bucks, in the states 169 usd WTF!!![/quote]


We've been getting ripped by the stealers for so long here in Oz . I bought my last helmet from the states and it came with a British standards label and saved $200.

It was understandable when we were only getting 60c for a $US


I know if the cops want to do me, they will. But till then

Post 251 by Bert,

#251
well, i insured the SD today, it gets dyno'ed this saturday and it will get a roadworthy and registration next pay. then i'll ride it, and probably remove the for sale ad and keep it.
i haven't had any interest in it even dropping 5k without it turning a wheel and frankly, i'm proud of my work and i want to enjoy it.

paul.

Post 252 by nampus,

#252
I knew you couldn't do it

Post 253 by omky756,

#253
good decision Paul!

Post 254 by loony888,

#254
You are a wise man!

Post 255 by Bert,

#255

Post 256 by ktmguy,

#256
Glad to hear it Paul..!!!
Now get out and enjoy ...

Post 257 by AGRO!,

#257
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Post 258 by ktmguy,

#258
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Post 259 by loony888,

#259
Paul, I am not sure if you have ridden a SD yet. I bought my pile and put my bike together with out riding one, and I have no regrets. You will be plesently supprised with its upright seat with dirt bike bars. I know you have plenty of time building it but no seat time yet I know you know you have a rocket, but it is a different beast. Take care with the first ride with new tyres and all. I put new tyres on last night and rode to work this am. A few degrees below freezing. Back end stepped out leaving my drive way. Another guy was not so lucky as he hit a patch of ice in the parking lot and smacked a tree. Low speed stuff but still had the cops come to see a bent bike. But down under it should be toasty warm . Take care bro.

Post 260 by loony888,

#260
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Post 261 by loony888,

#261
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Post 262 by AGRO!,

#262
so, it's still not done
the ONLY thing i skimped on on the whole bike? the battery, what has let me down? YEP the bloody battery, i have now got a yuasa and it's all good.
BUT, it went on the dyno for the run in procedure and it leaked oil.......everywhere! one of the elbows that connects the front cam cover to the oil tank was cracked, brand new, thanks KTM! replaced this afternoon and i'm sooooo happy i have the motohooligan air box no way it would have been a 10 min job with the std one.
oh well, teething issues i guess, hopefully it will get done tomorrow.

paul

Post 263 by loony888,

#263

Post 264 by AGRO!,

#264
128.95 rwhp with heat soak from being tuned.
If it was just a straight power run the operator is confident it would pass 130!
Can't wait to ride it now!!!

Post 265 by loony888,

#265
Sounds good!! Did you have it tuned using power commander?
Don't forget the high heals

Post 266 by loony888,

#266
Yeah mate PCIII

Post 267 by Aussieduke,

#267
Touch Down! Yea Paul, watch out when you pull over on the side of the road. A bud fell off his KTM 990 Adventure the first week he had it. Less than 100 miles on the clock. He pulled out of my driveway, slight up hill, and put a foot down into nothing but air. He did a tuck and roll thru the front yard grass all the way to my door step. Too bad I was not there to laugh about it. He is 6'-3".

Post 268 by loony888,

#268
thanks to jehadjoe and his how to for guiding me through what needs to be done for my first oil change.
run in, tuned, roadworthied, just need ctp and rego. could really use some overtime

Post 269 by loony888,

#269
Stop buying toys, or get a second job!

Post 270 by loony888,

#270
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