2022 will focus on the IDBDR ride we have planned for late summer early fall. I have some needed changes and maintenance to perform as well as logging some practice hours out on the dry lakes.
- The list of stuff to do:
- Replace Lower Airbox – Done 04/30/2022Adjust TPS voltage – Done
- Zero Throttle bodies – Done
- Balance throttle bodies – Done
- Change out fuel pump and filters for new, pack old pump as spare. – Done 04/30/2022
- Adjust suspension on dry lake to determine of the rear spring should be changed out.
- Change out spring at Suspension 101 – Done
- Adjust suspension on dry lake to determine of the rear spring should be changed out.
- Check Valve clearances and adjustBalance TB’s and check and adjust TPS, if required – Done
- Change engine oil and filters, ordered kit 07/05/2022 – Done
- Change coolant – Done
- Modify ignition wiring with waterproof connector and marine grade wire with overbraid. – Done
- Remove alarm wiring and connector. – Pushed off to 2023 because I’m a slacker.
The first task this year has moved forward a good deal and that is the seat rebuild by Renazco Racing. I got an email on 01/19/2022 asking for confirmation of shipment to them of my seat. When I had to postpone my scheduled appointment back in November of 2021, we moved it to April, to be certain I’d have clear sailing. That email was quite unexpected. But, it was a great surprise. I’ve had it packed and ship it today.
Once we get our car, I’ll pull the rear shock and look more seriously into swapping out the spring. I’m still thinking I may end up going back to the OEM fork springs as well, but I want to feel the bike with the new rear spring first.
The rear shock was taken to Suspension 101 on Tuesday 02/08. Initially I thought just swap the spring. After talking to George, I may end up with a progressively wound spring and his shim stack. Time will tell. We are going to try the softer/shorter spring first.
The rear shock is being shipped back from Suspension 101 and should be here tomorrow. George had to make one of the spacers as KTM didn’t have it available. Here’s hoping this works out well, or I’ve wasted a bit of money. I’ll install it once it is here as well as take photos. Once the bike rolls again I’ll pull the tanks and replace that lower airbox, set up the TPS and flash a different map to the ECU. All that stuff. Once the seat gets back, I can go test riding. Big fun.
I also advanced my wiring removal project a bit more by getting the wiring schematic to sort out removing the alarm system wiring.
With the shock installed, my seat showed up on Saturday 04/02/2022 from Renazco Racing. I got a test ride in on Sunday for a couple of hours. I increased the rear preload, but will drop the forks a bit then remove some rear preload. I should have had the seat done ten years ago when I first bought the bike. Great seat. Looks great and rides beautifully.
Replaced the fuel pump, filters and seals. Fitted new UHMWPE tape at frame and crashbar clamp. Replaced the lower airbox with new.
Next will be the electrical modifications I want to make to the ignition to repair the broken wire there with a stronger solution. I made up the first half of the connector and replacement wiring. I want to get some overbraid to protect the wire.
Ordered tires with only the rear being shipped so far. It’s only been a month and a half and I won’t likely need them, but I’ll have them when I do.
I finished up the ignition rewire and connector upgrade.
The new wiring is a larger gage, tinned copper multi strand marine grade wire. The connectors are waterproof. I also improved the solder connection inside the ignition so the wire is laid on the PC board rather than poking straight up with no strain relief. Tiptoes inside to limit the pull on the joint and on the outside to limit the push in. The heat shrink sleeve provides more abrasion protection. I don’t use the plastic panels since I don’t ride in that much dust or water. I’ll get to the alarm wiring delete come winter here.
08/06/2022, 85,346 miles
Changed the engine oil, filter and coolant.
I’d noticed the throttle being sticky since back when I changed out the heated grips. So, I checked today.
The adhesive used to secure the grip to the throttle tube drained out the end then between the bar and the tube. The inside of the grip is a harder plastic material and the tube is aluminum.
All fixed after a little clean up.
Having returned from the Colorado trip, I ordered a Samsung Galaxy A8 tablet to use for TuneECU. Once that arrived I got the TuneECU app installed and registered and paid for along with registering the bike.
Then I reprogrammed the ECU to a new map. I used the Zuber 9 map.
The old cable I’d used on my Windows computers worked perfectly well. I have an adapter for the USB from my Mac that also worked to perfection. I ran all the tests with no issues. A fifteen minute idle then the next day an hour and a half on the bike confirmed the new map was perfect. This is the Zuber 9A map. Next up I need to check the valve clearances and correct them if required. Then set the TPS voltage as it is about 10% over right now. Once all that is done, I’ll address the suspension set up. Then the last of the winter projects will be cleaning and greasing all the bearings, then finally removing that alarm wiring.
After another fifteen minute reset, I took a test ride. I found the Zuber 9A not as much to my liking as the Zuber 9. Once back home, I swapped back to the Zuber 9 map. Once the bike cools off, I can do the fifteen minute reset and retest ride. TPS voltage is quite high at warm so I’ll deal with that next.
More Tune ECU work and checking the valve clearances. All the valve clearances were within spec. Next up after the valve check was drilling an access hole in the airbox to adjust the TPS voltage. The TPS voltage had been running about 15% proud of nominal. Once I got the hole drilled to my liking, I remapped the ECU to the Zuber 9A map. I zero’d the throttles and reset the ECU for a 15 minute idle. Once that was complete, I set the TPS voltage.
The Tune ECU tablet app works wonderfully. I finished assembly the next morning then filled the tanks and did a 100 mile test ride. Very happy with the Zuber 9A map. Once I get to the end of this tank I’ll refill and check economy.
On my last trip to Colorado the last remaining original turn signal stalk snapped while we rode gravel roads. I wired it to the rack as a roadside repair and continued with the trip. Today I replaced the stalk.
Turnsignals come in right and left sides and front and rear. The front right is the same as a rear left and same for the opposite side. Now the only difference in the right and left hand models is the weep hole on the bottom of the turn signal body.
To get a weep hole on the bottom I re-use the same body or a new opposite side body that I didn’t need the last time.
The rear is a bit more work than the front due to the racks and the tight space in the rear.
I was sitting next to the front wheel this afternoon and decided to deal with the disc rotors being out of sync with one another.
A few minutes work then fresh locking compound and torque to finish.
All better. Though the spokes are looking pretty ragged. I’ll give them a once over with some Scotchbrite when I change tires.
Test ride to run the tank to the fuel light. 175 miles. That works to about 36 mpg. This after balancing the throttle bodies. Probably need to re-check the TPS voltage.
Recheck of the TPS verified it was still where I’d set it. Replaced the Fork springs with 4,8N/mm OEM springs from 5,0N/mm. I’ve not had the chance to set the sag yet. The right fork cap gave up the limit detents for some reason after fiddling. That cap was always harder to turn the rebound damping adjustment. I ordered a replacement after rechecking the thing. When I replace the cap after the replacement arrives, I’ll pull the disc rotors and freshen up the shine on the spokes and clean the rim. After that I need to schedule a weekend at the dry lake to practice my dirt drills and maybe get some skill and comfort back.
That ends the year. I’m left with a few tasks for 2023.
First though the odometer reading today,
A total of 2,917 miles for the year. All that the result of a few errands, test rides and one short trip.
We’ll see what we can do about topping that in the next year.
Plans for 2023
First off the outstanding maintenance and repair issues will be addressed
- Clean up the front wheel spokes
- Renew front wheel bearings
- Service front forks and replace the right side fork top
- Clean up the rear wheel spokes
- Renew the rear wheel bearings
- Remove the alarm wiring
- Renew swinger bearings
I’ve got all the spares to finish the work, just need to set aside the time and get at it.
Travel Plans 2023
The plan for 2023 is for one big trip that is based at 3 Step Hideaway with a few folks and ride loops each day. Maybe even include one or more overnight camping loops in the mix.
Anyway, that is how 2022 worked out and what I can see for 2023 from this vantage point.
Cheers, and safe travels all.