jmann
I made a tool to replace the oil pressure switch on my 2004 KTM 950 Adventure which uses the same basic LC8 motor and motor mounts as the SuperDuke.
The switch lives on the back side of the front cylinder. The book way to replace the switch will have you remove the air box.
The wrench you need is a 21mm. Das big! You have little room to move and you have to flip the wrench each time you make a stroke thru the frame/motor mount to remove the switch. The threads are straight, not tapered so at install, once you get the treads started you can pull the string and screw the switch all the way home to the crush washer. Materials used: coat hanger, aluminium tube, gasket sealer, bottle cap, string. Bend the coat hanger around the tube and use the gasket sealer to hold the tube to coat hanger. Melt a slot in the bottle cap to slide tightly over the switch contact tab. This hold it all together so you don't loose it at install. I used wheel bearing grease to hold the crush washer in place.
The switch lives on the back side of the front cylinder. The book way to replace the switch will have you remove the air box.
The wrench you need is a 21mm. Das big! You have little room to move and you have to flip the wrench each time you make a stroke thru the frame/motor mount to remove the switch. The threads are straight, not tapered so at install, once you get the treads started you can pull the string and screw the switch all the way home to the crush washer. Materials used: coat hanger, aluminium tube, gasket sealer, bottle cap, string. Bend the coat hanger around the tube and use the gasket sealer to hold the tube to coat hanger. Melt a slot in the bottle cap to slide tightly over the switch contact tab. This hold it all together so you don't loose it at install. I used wheel bearing grease to hold the crush washer in place.