bikes – what else matters!
Its been quite a lot of work, but have finally got my rally style minimalist dash completed.
Removes stock dash surround and rev counter, adds a ram style mount and usb port.
I’ll add a link to the 3D printer files once I’ve published them on maker world.
To install remove upper fairing, dash and headlight, install new parts, headlight and fairing. Probably takes about an hour.
Dash is made from 3 printed parts with a 4th part to cover the wiring loom.
As the bike was in bits I’d saved many jobs, so several posts coming.
To finish the cooling side of things, as I’d previously fitted a Z Adventure low temp thermostat, I also fitted one of their secondary cooling fans. Again if you’re tanks are off a really easy job, otherwise you have to go through that joy first!
Undo the bolts from the radiator expansion tank and the fan then sits behind it can connects to the original fan’s wiring using a ‘Y’ splitter cable.
I did have to tweak the bracket a bit to get everything to line up but nothing to worry about.
In the quest to lose more weight from the bike I fitted a Muller Motorsport air filter conversion. For me it was easy to fit, as the bike already had both fuel tanks removed, once they’re out of the way its basically remove airbox and fit kit following their instructions.
You have to transfer the air temp sensor across from the original airbox and fit a small filter to the breather hose.
Instructions provide link to suitable starting point map as well.
At the same time I fitted new Venhill throttle cables and did some general cleaning.
Recovered the KTM seat, as it had a couple of stains on it. Couldn’t find a cover anywhere so bought some fabric from eBay.
To cover the seat you need approx 900mm x 600m
the steps to recover are –
most important step is take your time and take lots of photos so you have an idea of how the original was fitted and stapled. I also put a pencil mark on the material to show the centre line.
There will be lots of content coming just haven’t had chance to upload. My dad died a few days after my last post, so needed a break and had to deal with all the issues nobody wants to be dealing with.
However there will be something familiar, but new, appearing –
In the words of Britney – ‘Oops I did it again.’
KTM has had lots of updates which I’ll upload as soon as I can, but will then be sold as my shoulders can’t cope with its size due to the mobility and strength I’ve lost.
Finally some good news PJME have sorted the machining process for removing the fixed crank pin and boring a hole to accept the same pin as the right side, happy days!
This is now available to all RG owners with written off cranks
My crank is on its way back ready for the rebuild of the rest of the bike.
Updates have been a bit slow, as been swamped with catching up on house renovation work since my frozen shoulder was fixed. Lots of updates to come on the KTM and sadly I sold the Fantic, as I’d run out of garage space.
There may be light at the end of the tunnel after some discussions with PJME they’ve found some engineers to machine off the crank and and bore a hole to take the pin the fits the other side of the crank and fix the issue once and for all.
Jig has been made to sort the pin machining just waiting for an update on the hole boring then the service should be available to all RG owners, no idea about the price though but I guess its pay it or your bikes scrap, sigh.
Was doing some work of the front fairing and noticed the headlight connectors were damaged. I removed the fairing and could see that the connectors were hanging down underneath the nav tower and look like they’ve been crushed.
More time doing research and I’ve identified the connectors as Yazaki –
I bought both from Auto-click.co.uk, part numbers linked above, the only issue I discovered is the new ones don’t come with the seals, so de-pin carefully!
De-pinning tool goes in from the front of the connector.
Whilst doing these jobs I also thought I’d design my own nav tower and have nearly finished the 3D printer models. The whole thing will be printable plus a few bolts. Once I’ve printed the prototype and am happy with it I’ll make the files available.
I also want to do a second version based the the Fantic Issimo frame, as I think that would A – be cool and B – work really well
To go with the high mudguard I’ve designed some brake hose guides to fit on the fork legs with a cable tie.
3D printer files here.
