Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Husqvarna => Topic started by: voorvel on December 21, 2020, 11:36:14 pm

Title: 501 Rally/Adv build
Post by: voorvel on December 21, 2020, 11:36:14 pm
Sooo I've now been in the Netherlands for a couple of years and did a nice 3500km trip to Sweden on my 990S.

I never gelled really well with the 990. Guess I spent too many years on 450's and my ass is a bit light for it.
Its a beast of a bike and handles amazingly well for its size but its no 500 (of course)

I decided to go back to something familiar again, but this time, I wanted to spoil myself.

My now ex-990S
(https://i.ibb.co/C6Wr3J7/IMG-20201024-142930.jpg)

So 1st order of business, finding a bike.

Got a 2017 501 with a fresh topend on marktplaats.
(https://uploads.tapatalk-cdn.com/20201217/0151cc75984d0b1e82ad2581a27fb378.jpg)

Still in good looking condition
(https://uploads.tapatalk-cdn.com/20201217/90469bec385dcdaa2d468aa1d62bc5ac.jpg)
(https://uploads.tapatalk-cdn.com/20201217/2199f1f5f3a943dda7891f879ad631d5.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 21, 2020, 11:40:44 pm
Although I'd prefer to support local, the Nomad Adv tower seems to carry its weight a bit farther forward than the Radegarage alternative.

And at almost the same price, the carbon fiber rade part looks pro! (and weighs a lot less)

First couple packages started to arrive and I immediately started with assembly   O0
(https://uploads.tapatalk-cdn.com/20201217/cdc501adcd2f83d4fa909e09d1355ce4.jpg)

The tower:
(https://uploads.tapatalk-cdn.com/20201217/43b13c25c7f0410ab99556f920bc3834.jpg)

2x35Watt LED spots.
The low beam is road legal  :thumleft:
(https://uploads.tapatalk-cdn.com/20201217/5c633da7e7373167eeee5749731be11e.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 21, 2020, 11:54:26 pm
The mounting brackets for the tower are nicely labelled with bolts etc stapled to the associated package.

This kit wont fit the earlier model KTM/FE.
From 2017+ KTM reduced the weight of these bikes even more + the frame mounts a bit lower to the steering stem, allowing the tower's top bracket enough space between frame and top triple clamp.

For this reason, I especially looked for a 2017+ model bike.

This package also includes bar risers/steering damper base mount
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:01:21 am
First fitment of the tower:
(https://uploads.tapatalk-cdn.com/20201217/36ff9c518d8eea836fc3d519489a889f.jpg)

Of course, I found the 1st stripped thread  >:(
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:15:51 am
Rade is kind enough to also supply a dash tidy kit.

It consists of a new mounting bracket + carbon cover behind which all wires are to be tucked in.
Really nice looking unit  8)

Although this is an FE, it has no indicators/switch gear/ matching wiring harness, so I had to add this of course.
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:28:31 am
I also found that the stock harness was a bit short so i had to split it in two and run it up both sides of the frame.

Some pics of the rear indicators + half of wiring harness running up the other side of the frame:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:33:45 am
And now to tidy up the mess below the dash..
Gotto love cable ties!

Important to verify that nothing gets stretched or scuffed when turning the bars.

Im very happy with the results though  O0
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:39:05 am
moar  ;D
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:46:24 am
Moving on to the lights and screen.

Really bling looking lights.
The new Radegarage screen has a separate section for the lights, which reduces reflection.
Also, as can be seen, the surrounding bits are screened off with black vinyl.
Title: Re: 501 Rally/Adv build
Post by: Noneking on December 22, 2020, 04:39:02 am
Nice!
Sub
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on December 22, 2020, 06:56:07 am
Very Naaise  8).

Good choice with Rade Garage (although I love the RebelX stuff at the moment). I have the R/G tower on my 701 and excellent design and value for money. Also great guys to deal with - I have fed back inputs to them that they have applied in later models like mounting the front indicators inboard behind the screen, airbox adjustment etc).  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: sidetrack on December 22, 2020, 09:19:04 am
I like that the whole tower is carbon fiber. I watch this 450L guys videos from time to time and he just got a alu tower from an Italian firm but man that thing looks heavy (6:10) ! Sub.

Title: Re: 501 Rally/Adv build
Post by: m0lt3n on December 22, 2020, 09:59:12 am
epic stuff.
sub, thanks for sharing
Title: Re: 501 Rally/Adv build
Post by: AfricaOffroad on December 22, 2020, 10:06:22 am
Subscribing  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on December 22, 2020, 10:08:03 am
Very Naaise  8).

Good choice with Rade Garage (although I love the RebelX stuff at the moment). I have the R/G tower on my 701 and excellent design and value for money. Also great guys to deal with - I have fed back inputs to them that they have applied in later models like mounting the front indicators inboard behind the screen, airbox adjustment etc).  :thumleft:

Oh and the lights are superb and Euro spec  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 10:19:39 am
Very Naaise  8).

Good choice with Rade Garage (although I love the RebelX stuff at the moment). I have the R/G tower on my 701 and excellent design and value for money. Also great guys to deal with - I have fed back inputs to them that they have applied in later models like mounting the front indicators inboard behind the screen, airbox adjustment etc).  :thumleft:
I wanted to support Manuel with his Dakar missions.
Building his 1st Dakar bike in his grannies kitchen almost warrants the higher price, but RebelX is almost twice the price of R/G and to be honest I don't see that extra value?
The only part thats better IMO is the patented mounting bracket. The rest is 4mm alu plate vs carbon fiber.

Awesome of you to share design ideas with R/G and for them to take it seriously :thumleft:

Sent from my FIG-LX1 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 10:50:16 am
I like that the whole tower is carbon fiber. I watch this 450L guys videos from time to time and he just got a alu tower from an Italian firm but man that thing looks heavy (6:10) ! Sub.



Yes my youtube also directed me to that guy's build.
(6:50) - its got a bit of heft to it
In contrast the R/G weighs 300g  :thumleft:

Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 10:54:59 am
The indicator part of the switchgear finally arrived.
I also ordered some random LED blinker off Amazon, which i could fit in the space under the seat.

Seems to me the stock battery was exchanged for something even smaller  ::)
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:12:09 am
Also included in the R/G kit, is a GPS mounting baseplate.

It's more suitable to the Montana/Zumo etc type deals but I still love the gpsMap variant, so I had to make some adjustments.
I test fitted a couple of different RAM mounting "balls" (not sure what you call them) until i found one that works with my gps.
 
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:16:16 am
Wrapping the crossbar with the same fabric tape that I used for the wiring harness, turned out to be a good idea.

Dont have to crank down that hard on the mounting hardware + it sure protects the parts from being damaged/scratched
I will be rigging the power connection from the light's supply, once the 12v to 5v usb adaptor arrives from Amazon.
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:20:47 am
This is the power hub to driving all your hardware.

As stated, it's connected to the headlight supply, so nicely fused and it will ensure that your battery does not get drained when switching off the bike.
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:22:38 am
aaanyway, back to fitting the lights..
The end result:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:32:44 am
That did not go without some.. baboon tuning.

The bottom spot wont fit as the curvature of the bottom corners of the carbon tower did not allow enough clearance.
I could FORCE it in there but the heat sync of the light will only expand more and might not end well.

I had to remove the bottom corners from the heat sync.
As can be seen in the below pics, the first test mount shows that there is still some tension.

I worked away a lot more material and got it to fit much better (will update this post with a pic of current status)
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 11:46:59 am
Meanwhile, some more roadworthy shizzle arrived.

Too bad I bought 2 left side mirrors  :bueller:
At least they are well priced.

Quite happy with their small size and how they can fold away.
Also took a moment to add some protection bits, purchased in a black Friday moment of weakness
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:01:35 pm
Fitting the screen and side covers also had their, lets say "challenges"

All seems fine here
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:03:29 pm
Until I tried to fit the side covers.
Granted I know that the kit is meant for the 15L tank (which I will be ordering soon) so for now, lets just have a teaser
 >:D
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 12:05:11 pm
Erm, that does not bode well

Neither does the fender, hitting the side cover when turning the bars
 :imaposer:
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on December 22, 2020, 03:57:06 pm
Get hold of Rade - they should sort you out without issue. Sent me a whole new tank once.
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 07:07:30 pm
Since 2017, Radegarage went to a new screen design. One which reflects less light and looks better in my opinion.

So they sent me the new screen and old side panels.
It might be possible to fit the 2020 side panels to my bike, but who knows.

Spot the difference between 2017 and 2020

Now that I uploaded both years pictures, the 2017 actually looks better to me.
(https://uploads.tapatalk-cdn.com/20201219/c426e77d5bf2b23b438dae9d18a86620.jpg)

2020:
(https://uploads.tapatalk-cdn.com/20201219/4c25639c022148ab2a89788fd8ba8259.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 07:13:27 pm
I've been battling with the electrics.   :(

After connecting everything up, the head + tail lights would not work.. at all.
At first, I did not notice that the back also did not work, so initially I investigated the bunch of wires below the dash, as thats where I made the most recent changes.

The lights only switch on when the bike starts.. so each time, I had to:
1 fit tank onto frame
2 reconnect the tank
3 start the bike
4 Check if lights work

At some point, I noticed the tail lights are also not working so I checked fuse #2, but that was still fine.
After going through the wiring harness (as I also made some change there), I still found no obvious issue.

This then directed my attention to the relays in the airbox.
I removed all of them, tested each one.
Each relay also functioning as expected  ???

At least by this time I realised that I could bridge the relay output to avoid having to start the bike each time and by doing so, I managed to get the lights to function. -so it's either a faulty relay or the input to the relay

<- not sure if you can view these pics?
(https://i.ibb.co/ngXmxwp/IMG-20201220-160101.jpg)

I did notice minor damage to the one wire which is supposed to activate the relay for the lights, but thats only to the insulation.
(https://i.ibb.co/G93Zpm4/IMG-20201220-160138.jpg)

At this point I was out of ideas and the only thing still left to do was to open up the entire wiring harness, but before doing so, I decided to just swap the relays around and ta-da! it works.

Buttoned it all back up:
(https://i.ibb.co/9twyN8X/IMG-20201220-180311.jpg)

(https://i.ibb.co/0tn4VbM/IMG-20201220-180629.jpg)

(https://i.ibb.co/mBMvHfB/IMG-20201220-190051.jpg)

(https://i.ibb.co/LQYrTWY/IMG-20201220-190104.jpg)

I'm still confused as to why/how it stopped working.
 :question:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 07:16:54 pm
Get hold of Rade - they should sort you out without issue. Sent me a whole new tank once.

Herewith our correspondence:

RG: " truth is that some customers have contacted us recently with similar difficulties during the installation.

The main reason is, that the shape of side panels has ben designed for bikes with 15lt. tank. Nevertheless, the side panel should be slightly trimmed where it obstructs the front fender in full lock (see the picture),  and same with the boreholes dislocation. Please, set the basic alignment with one or two holes and the rest needs to drilled.

Surely, we are prepare to compensate your inconvenience with the installation. Please let me know, what amount we should sent you as the partial refund."

Me: "...I am wondering if it won't be easier for me to make the 2020 side cover fit the 2017 tank, than reshaping the 2017 side covers with 2020 screen?
How about rather than a partial refund, you send me the 2020 side covers (of course, once you have stock)?"

RG: "Yes, we can try it this way. 2020 side covers are in stock, we will send them to your address. For sure, they will nicely fit to the windshield, however not so nicely to the tank. But letís have a try.

My colleague Monika will send you side panels for FE 2020."

And items in the mail.  >:D
Previous shipment took 3 days, door-to-door  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 07:31:35 pm
Took the scoot for a 1st 10km ride.

Of course i'm not able to ride it back-to-back with a 990 but at 110km/h the wind protection from the screen does not feel much different to the 990
That is awesome for a 450 class bike!

Although I have to adjust the angles of the lights a bit, they sure are powerful  :ricky:

At this point (I know its early days), I feel like I should have done this long ago already, instead of throwing money at the 990  :patch:
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on December 22, 2020, 07:34:26 pm
Looking schweet and R/G true to form will sort you out with any problems  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: sidetrack on December 22, 2020, 08:58:27 pm
The bigger tank will round things off nicely, tried the heated grips yet ?
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 22, 2020, 09:05:54 pm
The bigger tank will round things off nicely, tried the heated grips yet ?
Think so too, except, I dislike that nut cracker design of the 15L

Has not been cold enough for those heated grips yet.

Sent from my FIG-LX1 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: sidetrack on December 23, 2020, 10:24:03 am
The bigger tank will round things off nicely, tried the heated grips yet ?
Think so too, except, I dislike that nut cracker design of the 15L

Has not been cold enough for those heated grips yet.

Sent from my FIG-LX1 using Tapatalk
What tank is this ? Looks good to me
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 23, 2020, 10:40:41 am
That's a 2016 tank.
The 2017+ use the stock tank shrouds, which is a great idea.
No need to have matching decals printed, which have a limited lifetime anyway.

This is what I meant:
(https://www.zabikers.co.za/wp-content/uploads/2019/10/Mark-Husky501-15-696x464.jpg)

Images from that Cape Town bike:
(https://www.zabikers.co.za/wp-content/uploads/2019/10/Mark-Husky501-47-696x464.jpg)

Sent from my FIG-LX1 using Tapatalk
Title: Re: 501 Rally/Adv build
Post by: teebag on December 23, 2020, 04:28:01 pm
@SparkMark 's bike
Title: Re: 501 Rally/Adv build
Post by: DavidMorrisXp on December 23, 2020, 04:36:50 pm
That bike is really looking good, done with taste

Title: Re: 501 Rally/Adv build
Post by: sidetrack on December 23, 2020, 04:42:18 pm
Yip really looking good, are smaller plates allowed ?  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 23, 2020, 05:07:34 pm
Yip really looking good, are smaller plates allowed ?  :biggrin:

Have seen smaller (see attached) but in real life, its not as big as on the pics  ??? maybe the reflective attributes accentuates it, I dont know.
Does not phase me enough to break the law TBH
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 24, 2020, 07:10:54 pm
Received the 2020 side covers today  :thumleft:

They definitely fit better.
Will keep them in storage until I have a bigger tank but will most likely need to reshape them a bit.
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 24, 2020, 07:12:44 pm
Also received an uber cheap Aliexpress spring kit for the dysfunctional side stand.
Seems to work for now..
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 29, 2020, 01:45:17 pm
True to EU form, December brings fireplaces and snow, not exactly biking weather.
But then I got me some sun for Christmas!  :thumleft:

Photo taken outside my village, on my way to the East of NL, to ride a small part of the TET:
Title: Re: 501 Rally/Adv build
Post by: voorvel on December 29, 2020, 01:56:37 pm
I installed a set of heated grips the day before..
I know that sounds wrong on a 450 class bike, but they worked great and it doesn't look too bad.

The map switch had to be removed as I ran out of space on the bars- not an issue really as I don't ever see myself engaging traction control  :ricky:

The day varied a lot; from tar sections to open dirt, thick sand, single track and some mud sections.

Title: Re: 501 Rally/Adv build
Post by: voorvel on December 29, 2020, 02:06:11 pm
Was a great day!
Its been a while since I've ridden a smaller bike as I sold my 350SXF a while ago already (attached)

The 500 has so much grunt off the bottom, it made me giggle in my helmet as it pulled a power wheelie, coming out of a turn in 5th gear  :lol8: (14/48 gearing)
Perhaps I should have done this ride before mounting the rally tower but I honestly did not notice any weight difference/imbalance, compared to what I'm used to.

The wind protection is very nice to have and I agree with Sidetrack that a bigger tank will round things off nicely.
Title: Re: 501 Rally/Adv build
Post by: sidetrack on December 29, 2020, 06:51:26 pm
Lekker, a light bike with poeier is always fun to ride.
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:03:50 pm
Been waiting since Christmas for my 15L tank  :-\
Still, I had a couple other things that needed fixing.

Bike has been reluctant to start when cold, so of course, I suspected valve clearances.
I've forgotten how easy it is on enduro bikes  :3some: ,especially after doing this job recently on my 990 (pain in the ass is an understatement)

Turns out the valves are in spec so I decided to replace the battery with a " bigger" one. Kinda funny how the bigger version weighs less  :patch:

Granted its kak cold in NL at the moment but it does start easier than before. It needs about a minute to warm the battery up, before it manages to unleash all its potential.

Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:10:32 pm
The speedo decided 2020 was its last year of operation.
It errors out with some unexplained code??

It still works at times, when rotating the front wheel, but I need the thing for other specs, like distance travelled, hours FI error LED, Reserve LED, Dim/Bright  :-[
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:14:17 pm
As can be seen, the speedo also had a non-standard connector..

There are cheaper and probably better options but I really wanted to keep this part stock so I burned through some more cash on this damn thing.
While I was at it, I also decided to keep the connectors stock, so that meant JSR connectors needed to be used.

They are freeking tiny  :o 
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:17:57 pm
After attempt one, I felt proud of my soldering work!
..Only to realize that they wont fit into their housing  :dousing:

You need to crimp these little bastards, else they wont fit.
Attempt 2 looks rather nasty but did the trick at least
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:27:20 pm
Next mission;
Getting the suspension setup for my weight.

I used the Racetech tool to calculate what I would need for my weight, bigger tank and riding style.

The forks feel great so I suspect that they might still have the stock springs but I will have to investigate that once I have the tools to open the Xplor forks.
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:35:57 pm
I was way too eager to ride and did not even set the sag but it didn't take long to realize that the shock spring is way too soft

The shock has an obvious oil leak too and when I removed it today, I found the spring is a 42N/mm unit.
With bigger tank, I'm gonna need a 50n/mm. That's a huge change  :deal:

Finding a 50 was a bit hard so I settled for a 51N/mm, seeing as I have to cater for my luggage.
Unfortunately I have to send the shock in for a service as I dont have the needed tools for that either.  >:(
Title: Re: 501 Rally/Adv build
Post by: BuRP on January 10, 2021, 07:46:11 pm
Dirtwarp,

soldering wires onto crimpterminals is not a good idea as almost always some solder flows into the cable itself.... which then becomes rigid and is prone to break at that spot.
Of course this is not the case when the connection is crimped, hence the better reliability - if only because also the insulation is crimped, it becomes a decent termination.
Best to get the correct (there's 3 types out there I think) crimper, they're not too costly - but buy the ratchet type, the el-cheapo's do a nasty job...... and don't ask how I know that  :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:56:12 pm
Oh and another thing that needs attention is the clutch.
When warm, it works like a charm but again, when cold, its doing some funky shit: it wont disengage

I let it idle for like 5minutes, pull the clutch lever many times, revving the bike a bit too and then it still slams into gear, instantly killing the bike. WTF?

I took out the plates, thinking that they might be installed incorrectly. Not.
The metal plates did show discoloration and all where pretty much on the service limit, but seeing as the weather had only a couple days available for riding, I put all plates back, reverse bled the hydraulic clutch and went riding.

It might have been a bit better, but I decided to order a clutch kit + the 6 dampening rubbers as they were clearly ready to be replaced
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 10, 2021, 07:58:03 pm
Dirtwarp,

soldering wires onto crimpterminals is not a good idea as almost always some solder flows into the cable itself.... which then becomes rigid and is prone to break at that spot.
Of course this is not the case when the connection is crimped, hence the better reliability - if only because also the insulation is crimped, it becomes a decent termination.
Best to get the correct (there's 3 types out there I think) crimper, they're not too costly - but buy the ratchet type, the el-cheapo's do a nasty job...... and don't ask how I know that  :P

Ye, Runner suggested that I borrow his crimping tool  >:(
Title: Re: 501 Rally/Adv build
Post by: BuRP on January 11, 2021, 09:33:37 am
Ye, Runner suggested that I borrow his crimping tool

Ah, he again proves he's a great friend!
Mind, I also have one, feel free to come use it here, I'll throw in a braai whilst you're busy! :thumleft:




 :lol8:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 11, 2021, 10:36:22 am
Ye, Runner suggested that I borrow his crimping tool

Ah, he again proves he's a great friend!
Mind, I also have one, feel free to come use it here, I'll throw in a braai whilst you're busy! :thumleft:




 8:
He was rubbing salt in my wounds as my ass is in the Netherlands
:imaposer:

Sent from my FIG-LX1 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: sidetrack on January 13, 2021, 12:05:28 pm
 :sip:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 03:43:44 pm
Local dude (ex WP test rider) tuned me Eur200 for the shock rebuild so I told him to GFY

Allballs seal kit arrived today
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 03:45:12 pm
Dankie oom youtube
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 03:47:24 pm
following his instructions, its pretty easy.

Of course I 1st removed the screw on the reservoir in order to release the nitrogen.
Shock in soft jaws:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 03:49:36 pm
After cleaning this up a bit, i could easily press the seal down to reveal the locking circlip
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 03:55:09 pm
The shaft with shim stack and seal could be pulled from the housing once I removed the circlip.

The oil looked OK-ish
Title: Re: 501 Rally/Adv build
Post by: Kamanya on January 14, 2021, 04:27:11 pm
Out of interest, how do you get the nitrogen back in again?
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 14, 2021, 04:41:55 pm
That Ä200 bloke charges Ä7.50 to refill it.
I must just make sure that the piston in the reservoir is properly positioned

Sent from my FIG-LX1 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 06:50:27 pm
Started bleeding this bad boy.
What a mission!

Best way, according to what I now know/think is to bleed it through the top of the reservoir bolt (pointed out by the red arrow below)
I did not have the required fitting for this, so I bled it by:
1) removing the compression valve housing
2) carefully squeeze any air bubbles from the system
3) top-up with oil
4) place cap back
5) cycle shock trough a couple strokes and feel for air gaps in the stroke (pretty evident in most cases)
6) pull shock plunger all the way back
7) repeat

I did this at least 5 times and also topped up the reservoir after adjusting the piston position
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 06:53:46 pm
Bad camera work here but i measured and adjusted the piston position to 10mm here by:
1) pressing the piston all the way down through the bleed hole
2) push it back to top -10mm
3) spew oil all over your garage floor through said bleed hole
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 06:57:41 pm
Went to Van Laar Suspension yesterday to have the shock filled with nitrogen.
He tested it and reckoned I bled it well enough.

"well enough" in his books, means awesome in mine!  O0

All is now ready to be fitted with my new 51NM spring
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 06:59:48 pm
meanwhile, seeing as this 40mm sock was lying around the workplace I thought to try and protect the seals from future dust:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 07:02:36 pm
turns out it was kak idea as the spring will intervene with any fasteners
The sock might also behave unexpectedly with the flow of air, in and out of the void.

Regardless, it will still suck dust into the mix so off you go  :dousing:

Title: Re: 501 Rally/Adv build
Post by: voorvel on January 19, 2021, 07:13:43 pm
If the camera is out of focus, its because I'm breathing heavily  :biggrin:
Removed the 18" mousse. Want to replace it with a normal tube.

Man I must say this working bench/clamp thing is awesome.

I simply clamped the wheel axel into it and there you go, a much easier way to work on your wheels
(https://bcdn.hbm-machines.com/images/cache/hbm-205-48.jpg-1920x1080-c674d37c8d.jpg)

This bad boy can clamp 1000kg and carry a weight of 380kg or thereabouts
(https://bcdn.hbm-machines.com/images/cache/hbm-206-46.jpg-1920x1080-6a4ed37c8d.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 09:13:52 pm
Got to fit a new clutch and cush rubbers today.
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 09:16:25 pm
Isn't this basket a thing of beauty?!

According to dirtbike magazine, its super strong and contains what seems to be the least possible amount of material
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 09:18:24 pm
Some polishing on the sides of its teeth but I cant feel any indentations at all  :thumleft:

Dont know where those spots came from. Some rubbing of my thumb did not seem to remove them so I guess its fine.
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 09:21:49 pm
cush rubbers were totally warn and I'm glad I replaced them while I was "in" there
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 09:23:31 pm
I torqued the inner basket nut to 80nm, fitted the new plates and now I ready to ride again 
Finally! :ricky:
Title: Re: 501 Rally/Adv build
Post by: BuRP on January 24, 2021, 10:31:24 pm
Dont know where those spots came from.

Water?  ???
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 24, 2021, 11:07:11 pm
Dont know where those spots came from.

Water?  ???
Geen idee, ou.
Dis ook wat ek gedink het maar die basket het tog n laag olie altyd op?

Alles anders daar binne is prima,so dis seker maar fine

Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: BuRP on January 25, 2021, 08:19:05 am
Alles anders daar binne is prima,so dis seker maar fine

 :lol8: :lol8: :lol8:
Het iemand al vir jou gese jy begin stadigaan klink soos n Kaaskop?
Maar prima hoor!  :thumleft:

Ek's seker jy juk om te gaan ry ..... maar sien daar's nou n kans op sneeu en ys daarso  :-\
Vat maar n koffie pleks van om erens n plaas te gaan koop, so n ding beter geploeg word  :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 10:04:26 am
 ;D

Ja brand om te gaan ry! Maar teen -2 werk ek eerder in die garage nog.  >:D
Hoop my tank kom vandag, dan kan ek dit darm ook aan klussen
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 03:06:09 pm
 >:D
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 03:08:56 pm
Been waiting for almost a Month for my Acerbis tank and by chance saw a second hand one for sale.

So i cancelled my order, and got this unit for 109Eur less  :thumleft:
Great that it still has the instructions and mounting screws + O-rings available.

Too bad that I've got meetings lined up until 17:00  :(
Title: Re: 501 Rally/Adv build
Post by: BuRP on January 25, 2021, 03:40:12 pm
OK, gaan gerus aan, importeer nog maar klomp droolgoods.... wat aankom in blitstyd, minimale (indien al enige) kak met belastings of papierwerk, en boonop sal jy dit kry, niks raak weg nie!
Toe, gaan aan asseblief?



Nee, ek is niks jaloer nie, dis mos kinderachtig....
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 08:09:23 pm
The new tank uses the existing pump and fittings.
I decided to replace the filter too:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 08:12:21 pm
Pump fitted, and tank mounted. All went without much hassles.

The Acerbis is well made and fits perfectly
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 08:16:13 pm
Final part was to fit the tank shrouds and side covers.
The shrouds fitted like a glove, the side covers are a bit more of a stretch but I managed eventually.

I must say, I like its beefier look  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 25, 2021, 08:21:40 pm
Seems the 2017 tower side covers are the best option but I will definitely have to reshape them a bit to allow for the fender to move freely.

I like the look with or without them, but will see where this goes
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 26, 2021, 07:34:12 pm
.
(https://i.imgur.com/cReZAt0.jpg)

(https://i.imgur.com/rtnk8ZY.jpg)

(https://i.imgur.com/iuJMGh4.jpg)
Title: Re: 501 Rally/Adv build
Post by: Noneking on January 26, 2021, 07:43:15 pm
Netjies!
Title: Re: 501 Rally/Adv build
Post by: Sheepman on January 26, 2021, 07:54:58 pm
Just got onto this and its a great build  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 26, 2021, 07:55:28 pm
Netjies!
Thanks
Kort nog stickers.

Man! ek mis my sticker connections wat ek in SA gehad het.

Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: voorvel on January 27, 2021, 10:36:22 pm
Got me some stickers on black Friday sale  ;)

I now use the 2020 screen and 2017 fairing.
Although not all fitment holes line up, between the two, it's a minor issue for me.
I will drill two more holes in the fairing side panel and add some grommets.

On the positive side, I can now upgrade to a 2021 model and this tower, screen and the extra side panels will fit perfectly.
:thumleft:

(https://i.imgur.com/D3pHGqZ.jpg)

(https://i.imgur.com/nYTCxtO.jpg)
(https://i.imgur.com/BD0xrcC.jpg)

(https://i.imgur.com/PqWZfhV.jpg)
(https://i.imgur.com/ywKmuLW.jpg)


I had to reposition the indicator, fitted to the most convenient location.
(https://i.imgur.com/Nn5XtXK.jpg)

Now i need to find something for that empty side cover..
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 27, 2021, 10:46:52 pm
I've been in two mids about the seat.

I kinda prefer the stock navy blue colour. So the question is:

Seat concepts Tall in blue
(https://cdn.shopify.com/s/files/1/1275/4325/products/husky_blue_501-01_med_008e7537-bdc0-4ade-9e20-653b0b060287_1024x1024.jpg?v=1537501043)

..or not:
(https://cdn.shopify.com/s/files/1/1275/4325/products/Husqvarna_tall_comfort_toprear_1024x1024.jpg?v=1537501043)
???

What I do know is that my ass will need either of the two
Title: Re: 501 Rally/Adv build
Post by: BuRP on January 28, 2021, 12:32:34 am
Blue!
.... but do get a SC seat, yer arse will love you for it!  :P


Awesome build btw  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on January 30, 2021, 11:41:50 am
Finished the other side's decals last night and took it for its 1st ride, since fitting the recently added parts.

I now notice the slightly wider tank and also the increased wind protection, provided by the extra side covers + tank.
On tarmac, it's definitely more DS worthy now, but of course that means sacrifices offroad. -to be determined

The new clutch feels.. like new  :thumleft:

(https://i.imgur.com/eXmgrS3.jpg)

(https://i.imgur.com/xI6xPcF.jpg)
Title: Re: 501 Rally/Adv build
Post by: DavidMorrisXp on February 02, 2021, 08:52:34 am
Maybe none of my business, but why the clear fairing?
Title: Re: 501 Rally/Adv build
Post by: Motties on February 02, 2021, 08:58:56 am
Sjoe, dit is 'n ordentlike build. Sou graag so outjie bou as die $$$ toegelaat het. Baie nice  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 02, 2021, 09:14:40 am
Maybe none of my business, but why the clear fairing?

All the latest rally fairings are like that. I guess better vision and can see wiring etc ... and show off the tech  8)  Fairings used to be fibreglass or composite but now with new polymer lexans etc they are lighter, stronger, safer as well - aesthetically also makes the bike look lighter.
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 02, 2021, 09:26:05 am
Maybe none of my business, but why the clear fairing?
Nee jy's welkom.

It's as BigDom says.

This setup has completed many Dakar's before, and it was probably copied from the ktm factory part.

On that note, the alternatives to my kit (MotoMinded, NomadAdv) use the actual Ktm rally screen, available as powerpart.
I prefer the RadeGarage kit over those 2 for its carbon fiber tower construction.

Sent from my IN2013 using Tapatalk
(https://uploads.tapatalk-cdn.com/20210202/8da5fab91bb53e67b81caf990592fcb8.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on February 02, 2021, 12:58:54 pm
Looking good, should the rear view mirror not be on the right side of the bike ?
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 02, 2021, 02:10:39 pm
Looking good, should the rear view mirror not be on the right side of the bike ?

We drive on the right side of the road and i find the left side mirror easier to use

Im supposed to use two mirrors but for now, 1 will have to suffice
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 03, 2021, 11:48:17 am
On to the issue of combining a 2020+ screen with 2017-2019 rally side covers.

The good:
As you might recall, I received this combination from RadeGarage and as compensation, they also provided the 2020 side covers for free.
That means that I have the possibility of eventually upgrading to a 2020+ model 500/501 and this kit will still fit  :thumleft:

The bad:
Front fender hits the 2017 side covers when turning the bars.
(https://i.imgur.com/hBw8R4y.jpg)

This little 'flap' had to be removed:
(https://i.imgur.com/RDftqGN.jpg)
(https://i.imgur.com/DOohlH1.jpg)

Not sure what kind of perspex they used for this kit, but man! its extremely flexible:
(https://i.imgur.com/SekbrZp.jpg)
(https://i.imgur.com/yFOCITy.jpg)
(https://i.imgur.com/4NDLvXJ.jpg)

The ugly:
misaligned holes + mismatched bolt:
(https://i.imgur.com/ljEXbCT.jpg)

I needed to use a longer bolt, in order to mount both plastic pieces to the tower. Finding a longer both that matches is no problem.
The holes, well, nothing that I can do about those, except some sticker kit solution perhaps.

But honestly if you don't know about that minor issue, you will not know that it's there.

It's a price I'm willing to pay for having a future proof rally kit which is a lot lighter than anything else on the market
Title: Re: 501 Rally/Adv build
Post by: BuRP on February 03, 2021, 05:37:54 pm
Not sure what kind of perspex they used for this kit, but man! its extremely flexible

You're sure it's Perspex?
Polycarbonate's more likely, for it bends & does not shatter, hence safer.
Here's how you find out:
- put that little piece outside (for Saffers: in your fridge lol) for a while, then next whack it with a hammer whilst on a solid surface, say an anvil or vice
- if it shatters it's Perspex, if not it's Polycarbonate.
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 03, 2021, 06:12:36 pm
Not sure what kind of perspex they used for this kit, but man! its extremely flexible

You're sure it's Perspex?
Polycarbonate's more likely, for it bends & does not shatter, hence safer.
Here's how you find out:
- put that little piece outside (for Saffers: in your fridge lol) for a while, then next whack it with a hammer whilst on a solid surface, say an anvil or vice
- if it shatters it's Perspex, if not it's Polycarbonate.

its definitely Polycarbonate then  ;D
Title: Re: 501 Rally/Adv build
Post by: Noneking on February 03, 2021, 07:32:09 pm
On to the issue of combining a 2020+ screen with 2017-2019 rally side covers.

The good:
As you might recall, I received this combination from RadeGarage and as compensation, they also provided the 2020 side covers for free.
That means that I have the possibility of eventually upgrading to a 2020+ model 500/501 and this kit will still fit  :thumleft:

The bad:
Front fender hits the 2017 side covers when turning the bars.
(https://i.imgur.com/hBw8R4y.jpg)

This little 'flap' had to be removed:
(https://i.imgur.com/RDftqGN.jpg)
(https://i.imgur.com/DOohlH1.jpg)

Not sure what kind of perspex they used for this kit, but man! its extremely flexible:
(https://i.imgur.com/SekbrZp.jpg)
(https://i.imgur.com/yFOCITy.jpg)
(https://i.imgur.com/4NDLvXJ.jpg)

The ugly:
misaligned holes + mismatched bolt:
(https://i.imgur.com/ljEXbCT.jpg)

I needed to use a longer bolt, in order to mount both plastic pieces to the tower. Finding a longer both that matches is no problem.
The holes, well, nothing that I can do about those, except some sticker kit solution perhaps.

But honestly if you don't know about that minor issue, you will not know that it's there.

It's a price I'm willing to pay for having a future proof rally kit which is a lot lighter than anything else on the market
Good heavens!
Flexible perspex?? Look at that thumb bending!! You double jointed?
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 03, 2021, 07:34:38 pm
Not sure what kind of perspex they used for this kit, but man! its extremely flexible

You're sure it's Perspex?
Polycarbonate's more likely, for it bends & does not shatter, hence safer.
Here's how you find out:
- put that little piece outside (for Saffers: in your fridge lol) for a while, then next whack it with a hammer whilst on a solid surface, say an anvil or vice
- if it shatters it's Perspex, if not it's Polycarbonate.

It is Lexan - a UHI an 'Ultra High Impact' acrylic as used for some helmet visors.
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 03, 2021, 07:55:34 pm


Good heavens!
Flexible perspex?? Look at that thumb bending!! You double jointed?

Haha, was wondering if someone would comment on that.

Lest just say I crash well
:imaposer:


Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: BuRP on February 04, 2021, 09:44:29 am
It is Lexan - a UHI an 'Ultra High Impact' acrylic as used for some helmet visors.

Uh no Dom, sorry.
Lexan is a trade name (brand) of a certain polycarbonate manufacturer, but polycarbonate is the proper material name.
And Acrylic is something else again, properties sitting somewhere between perspex & polycarb  ;)

Look, it can be Lexan... but if it would be I'm sure Rade would (ab)use this as a major selling point and boast it on their marketing blurb, for reason it costs more than normal Polycarbonate (for it may have - not 'has' - a few improved characteristics) and it is a very well known name (proof: you mention it here  :P ).
Some glasses have 'plastic' lenses, which is polycarbonate of course: safest! One gets these in two kinds, which differ (amoungst others) in their refraction index, a higher and a lower one. The higher one costs a LOT more than the lower one, and is sometimes marketed (to 'justify' the high cost lol) as Lexan - but it isn't, they're other brands (origin Israel or Malaysia or thereabouts). The higher index results in thinner, therefore lighter!, lenses, and those who wear glasses will know that's very important  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 04, 2021, 10:04:24 am
It is Lexan - a UHI an 'Ultra High Impact' acrylic as used for some helmet visors.

Uh no Dom, sorry.
Lexan is a trade name (brand) of a certain polycarbonate manufacturer, but polycarbonate is the proper material name.
And Acrylic is something else again, properties sitting somewhere between perspex & polycarb  ;)

Look, it can be Lexan... but if it would be I'm sure Rade would (ab)use this as a major selling point and boast it on their marketing blurb, for reason it costs more than normal Polycarbonate (for it may have - not 'has' - a few improved characteristics) and it is a very well known name (proof: you mention it here  :P ).
Some glasses have 'plastic' lenses, which is polycarbonate of course: safest! One gets these in two kinds, which differ (amoungst others) in their refraction index, a higher and a lower one. The higher one costs a LOT more than the lower one, and is sometimes marketed (to 'justify' the high cost lol) as Lexan - but it isn't, they're other brands (origin Israel or Malaysia or thereabouts). The higher index results in thinner, therefore lighter!, lenses, and those who wear glasses will know that's very important  :thumleft:

I do know about these materials and use them in my profession ie. I know the differences between the registered trade names like Perspex, Plexiglas, Acrylite, Lucite, Lexan etc and their properties, and also the generic equivalents. You are preaching to the choir (I used the term 'acrylic' in a generic sense). Rade himself told me the new screens like the F4 and cowlings are made of Lexan and as their screens are made by MRA I am not double guessing him.

EDIT From the horses mouth:
Our experiences riding around the world and customer feedback were combined with new technologies and used to develop the new F4 fairing kit for Husqvarna 701. The new windshield is injected with integrated spoiler and shader, 3D shaped headlights cover. The flexible side panels are from durable Lexan. New clamping system integrates an adapter mount for the Scotts steering damper. (applicable only for Husqvarna 701 production year 2020+ due to a different mounting points.) The build is very compact and  narrow to match the size and shape of the Husqvarna 701 and keeps the original handling of the bike."
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 04, 2021, 10:34:10 am
Weet nie wat julle oor praat nie, maar beteken dit ek kan harder val?

Hierdie litte van my bietjie flex ;D
Title: Re: 501 Rally/Adv build
Post by: BuRP on February 04, 2021, 12:14:02 pm
As jy met die pragtige ding gaan val gaan jy heel beslis pragtige kommentaar kry ook!  :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 09, 2021, 12:22:09 am
Ek wik en weeg of ek hierdie moet aanskaf

(https://pierce-images.imgix.net/images/7/6/e/5/76e59989e3bd82f60896926fee14ed1ed06d5667_2_PIA_102617_0_20.png?h=630&auto=format&q=50&fit=crop&bg=F0F1F2&fm=jpg&auto=compress&w=630)

Eks net bang stof etc gaan sit tussen swingarm en cover met die gevolg dat dit eventueel meer skade doen as goed?
Title: Re: 501 Rally/Adv build
Post by: chopperpilot on February 09, 2021, 08:39:41 am
Ek wik en weeg of ek hierdie moet aanskaf

(https://pierce-images.imgix.net/images/7/6/e/5/76e59989e3bd82f60896926fee14ed1ed06d5667_2_PIA_102617_0_20.png?h=630&auto=format&q=50&fit=crop&bg=F0F1F2&fm=jpg&auto=compress&w=630)

Eks net bang stof etc gaan sit tussen swingarm en cover met die gevolg dat dit eventueel meer skade doen as goed?
Lyk netjies, en maklik om af te haal en skoon te maak wanneer jy die fiets was. 2 Cable ties aan ń kant.

Het dit op die 500 gehad.

Sent from my FIG-LX1 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: sidetrack on February 09, 2021, 08:50:45 am
Ek wik en weeg of ek hierdie moet aanskaf

(https://pierce-images.imgix.net/images/7/6/e/5/76e59989e3bd82f60896926fee14ed1ed06d5667_2_PIA_102617_0_20.png?h=630&auto=format&q=50&fit=crop&bg=F0F1F2&fm=jpg&auto=compress&w=630)

Eks net bang stof etc gaan sit tussen swingarm en cover met die gevolg dat dit eventueel meer skade doen as goed?
Nee, ek like nie daai goed nie. Net plek vir modder om weg te kryp.
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 09, 2021, 09:29:22 am
If you fit them place Duct Tape or vinyl laminate underneath as any sand or mud will abrade the swingarm finish, even if you remove and wash reasonably regularly the risk is there as it only takes a little vibration. But they do protect the swingarm from knocks and graunches - certainly in enduro and tech situations.
Title: Re: 501 Rally/Adv build
Post by: sidetrack on February 10, 2021, 10:34:14 am
Ek volg nog hier  :sip:
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 10, 2021, 11:19:04 am
Is goed want ek het nog stof bestel  >:D

(https://1d9wic1xtzvs27liaa2o9xbb-wpengine.netdna-ssl.com/wp-content/uploads/Dome-Washers-New.jpg)

(https://1d9wic1xtzvs27liaa2o9xbb-wpengine.netdna-ssl.com/wp-content/uploads/2019/11/Golan-Compact-Filter-Silver.png)

(https://cdn.shopify.com/s/files/1/1275/4325/products/husky_blue_501-01_med_008e7537-bdc0-4ade-9e20-653b0b060287_1024x1024.jpg?v=1537501043)

Sommige items is wel op back order en kom ook van die States af, so gaan wel 'n tydjie duur
Title: Re: 501 Rally/Adv build
Post by: sidetrack on February 10, 2021, 11:22:43 am
Is goed want ek het nog stof bestel  >:D

(https://1d9wic1xtzvs27liaa2o9xbb-wpengine.netdna-ssl.com/wp-content/uploads/Dome-Washers-New.jpg)

(https://1d9wic1xtzvs27liaa2o9xbb-wpengine.netdna-ssl.com/wp-content/uploads/2019/11/Golan-Compact-Filter-Silver.png)

(https://cdn.shopify.com/s/files/1/1275/4325/products/husky_blue_501-01_med_008e7537-bdc0-4ade-9e20-653b0b060287_1024x1024.jpg?v=1537501043)

Sommige items is wel op back order en kom ook van die States af, so gaan wel 'n tydjie duur
Frisbees ?
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 10, 2021, 11:35:46 am
Reusable dome washers vir CS sprocket

Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: BuRP on February 10, 2021, 04:38:57 pm
Frisbees ?

Ek het ook gewonder, en was oppad om vir die dirty warp te vra hoe groot die gat is...... maar nou lees ek dit betref wel n bikepart.





 :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 10, 2021, 05:19:42 pm
Die stock washers is kakka.
Ek het hom volgens spec ge-torque maar ek sien hy roteer steeds.

En, as ek bv n 15T CS sprocket wil probeer, kan ek nie want die stock washer kan net 1 maal gebruik word.

Hierdie dirt tricks knapie is herbruikbaar en het meer flex + sterker(https://uploads.tapatalk-cdn.com/20210210/fa9e9946fddcb0d5810ecf25055b6036.jpg)

Sent from my IN2013 using Tapatalk
Title: Re: 501 Rally/Adv build
Post by: sidetrack on February 11, 2021, 12:22:12 pm
Die stock washers is kakka.
Ek het hom volgens spec ge-torque maar ek sien hy roteer steeds.

En, as ek bv n 15T CS sprocket wil probeer, kan ek nie want die stock washer kan net 1 maal gebruik word.

Hierdie dirt tricks knapie is herbruikbaar en het meer flex + sterker(https://uploads.tapatalk-cdn.com/20210210/fa9e9946fddcb0d5810ecf25055b6036.jpg)

Sent from my IN2013 using Tapatalk
Daai patent kom ook nou al jare, nes KLR met hulle doohicky  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 17, 2021, 07:22:54 pm
OK so these mirrors are cheap, in cost and quality

aka shit

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=254286.0;attach=706981;image)

Been searching for alternatives to the doubletake mirrors as I'm no fan of its size, specifically the girth of the Ram mount as mirror stem:

(https://cdn.webshopapp.com/shops/10612/files/268015949/890x820x2/doubletake-mirror-adventure-met-ram-montageset.jpg)

'Round the world Paul' used Highway Dirtbikes' handguards + integrated mirrors on his missions, so I was looking for something similar.
Enter Powermadd:
(https://i.imgur.com/7oZVb11.jpg)

Easy to fit:
(https://i.imgur.com/A1yRWKi.jpg)

(https://i.imgur.com/Nm2Hbxk.jpg)

They are spring-loaded, which means you can either flip them out of hams-way or they will rotate inwards when dropping the bike
(https://i.imgur.com/QBSaMLS.jpg)

Folder inwards:
(https://i.imgur.com/T6ihZtf.jpg)
Camera angle is not best but they are well out of my way when folded in.

I like how its base has the same shape as the insides of the hardguard. This means that it satisfyingly 'clicks' into place
(https://i.imgur.com/t8PhN4p.jpg)

The mirror itself is concave and you adjust its angle like so:
(https://i.imgur.com/S44KKeg.jpg)

(https://i.imgur.com/O0UeADT.jpg)
Seems like great quality and they got some pretty good reviews too. Hoping i will be happy with them.
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 17, 2021, 07:32:14 pm
Luggage..
I've been using only Giant Loop all these years.
Currently have the Mojavi and Great Basin.

Unfortunately I sold the Coyote many years ago and although I really felt like getting a Coyote (or the cheap Polish knockoff), I decided to try something new for a change.

Decided to give the Enduristan Blizzard L a try. I'm aware of their issues with the horizontal straps across the seat, but I will make a plan.

(https://cdn.webshopapp.com/shops/215573/files/279336658/enduristan-blizzard-zadeltassen.jpg)
I really like how it attaches to the rear fender:
(https://cdn.webshopapp.com/shops/264365/files/210844895/enduristan-enduristan-blizzard-zadeltassen-ideaal.jpg)
Title: Re: 501 Rally/Adv build
Post by: BuRP on February 17, 2021, 07:59:22 pm
Look all lekker  :thumleft:
So, when's the first trip, and whereto?
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 17, 2021, 08:08:57 pm
Look all lekker  :thumleft:
So, when's the first trip, and whereto?

Pireneen mountains. As soon as France/Spain allows my visit.

Sent from my IN2013 using Tapatalk
Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 17, 2021, 08:15:53 pm
What are the issues with the horizontal straps across the seat?  I know Wolfman has a harness system that looks good and the Mosko Moto while expensive is also next level. I also use a GL Coyote and Mojave with a Wolfman rolltop duffel on top if I need extra space for tent etc.
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 17, 2021, 08:31:21 pm
Oak on Adv rider complained about how these straps would lose tension over time.

My biggest issue is that the buckles prevent me from sitting on that part of the seat.

I'm gonna use velcro instead of the dual buckle design(https://uploads.tapatalk-cdn.com/20210217/2c1f9ffbd0c026264155bed537aafe04.jpg)

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Title: Re: 501 Rally/Adv build
Post by: BiG DoM on February 17, 2021, 08:35:17 pm
Could you run the straps and buckles under the seat?
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 17, 2021, 08:53:25 pm
Also thought of that.
On the FE it's a bit harder to do as the side cover follows the seat, when assembling the lot.
It will make it a chore to remove the bags if I need to. (When checking into a lodge or having to replace the air filter )

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Title: Re: 501 Rally/Adv build
Post by: BuRP on February 17, 2021, 11:14:10 pm
Pireneen mountains. As soon as France/Spain allows my visit.

Awesome area, if you go soon it may even be possible to ski a little there now!
Should have been there last year, riding up from Malaga over TET routes, and visiting a friend who lives there.... but covid paid put to that  :-\
This year though..... just maybe!
Enjoy, and show us some pics here please  :thumleft:
Oh, that area (Baskenland) has sometimes rabbit on the restaurant menus: try it, fggn lekker!
Title: Re: 501 Rally/Adv build
Post by: voorvel on February 28, 2021, 07:14:41 pm
Enduristan was a kak idea.

Waiting for a Coyote..  :sleepy1:
Title: Re: 501 Rally/Adv build
Post by: voorvel on March 27, 2021, 02:21:40 pm
As discussed in the KTM thread, I've been having issues of the chain chafing the frame with 14-48 sprockets, at 60km/h in 6th.

Turns out I just have to stop short shifting into 6th too early.

That being said, I wanted to see if its possible to protect the frame a bit

I thought I'd do a 3d print of a test part
(https://i.imgur.com/9v7riUQ.jpg)

I only gave it a 50% infill for now, if it seems to do the trick, it will be printed in solid plastic
(https://i.imgur.com/xDZUnHb.jpg)

Some slots where cable ties will fit through
(https://i.imgur.com/1qeGdEs.jpg)

Fitted:
(https://i.imgur.com/wKPtsNf.jpg)
Looking at this, in retrospect, I might print the next verion to extend a bit higher up the side of the frame

(https://i.imgur.com/nrYZCe4.jpg)

Remains to be seen if it does the trick
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 01, 2021, 08:54:49 am
I've not particular liked the looks of the cable-tied wires, around the GPS:

(https://i.imgur.com/Fo1GUFL.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 01, 2021, 09:02:07 am
..and seeing as I got me a 3D printer..

(https://i.imgur.com/WTXlQSM.png)

(https://i.imgur.com/iNUet7z.jpg)

(https://i.imgur.com/VLgfSl0.jpg)

(https://i.imgur.com/LN8NkfH.jpg)

The clip rings fit into place with a satisfying snap:
(https://i.imgur.com/mZVeDRv.jpg)
(https://i.imgur.com/uGrqwwl.jpg)
(https://i.imgur.com/z5ead86.jpg)

Title: Re: 501 Rally/Adv build
Post by: BuRP on April 01, 2021, 10:45:03 am
..and seeing as I got me a 3D printer..

I saw that - nice!
You bought it purely for playing around (z-e-r-o offense asb) or for work?
Can't be too cheap hence me asking - and my bro did same, indeed for playing around, fuggit, he wanted a special lampshade!  :lol8:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 01, 2021, 10:47:19 am
It's to keep me sane in corona times.
So to fark around with

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Title: Re: 501 Rally/Adv build
Post by: BuRP on April 01, 2021, 10:52:41 am
(https://i.imgur.com/nrYZCe4.jpg)

Remains to be seen if it does the trick

How does this setup holds up?
Perhaps better if you'd rounded the edge a bit, as there's always 1 chainpin a micron higher than the others and may hook into it.... but maybe it's soft-enough plactic, dunno  ::)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 01, 2021, 06:30:59 pm
It's seen some fair amount of chafing.

I have to properly adjust the chain (needs to be a bit tighter) and then print a solid version of that part.

I might have to change from printing PLA to a harder nylon.
Nylon is a bitch to print as NL is too humid and nylon warps when absorbing moisture and cooling unevenly.
Carbon infused plastic might be better


Many options

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Title: Re: 501 Rally/Adv build
Post by: BuRP on April 02, 2021, 12:01:32 am
Many options

Here's one of them - how about taking that chain off and check how much it will 'bend', like in a curved line when flat?
Perhaps a new/better chain will solve that chafing, not normal I reckon.
Sorry, a new chain's more than 2 cents  :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 02, 2021, 08:20:48 am
Thats a new RK chain and sprockets.
Except for perhaps a too loose chain, i have no other idea why it might chafe

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Title: Re: 501 Rally/Adv build
Post by: BuRP on April 02, 2021, 12:49:37 pm
Thats a new RK chain and sprockets.
Except for perhaps a too loose chain, i have no other idea why it might chafe

Aww come on now, take it off and measure?
Will only cost you a new masterlink ..... and then you know, better than think!
Better still, take it to the shop and put it next to a new DID, and see what bends more, a rather convincing exercise if ever there is one!

Every brand makes a dud from time to time, and a cheaper chain (hey, no idea what you paid, and I'm not pointing fingers to you or a brand here please...) like Tsubaki (they used to be quite popular in NL) performed noticeably less than a DID - which is a costly chain I'll admit but also I have never heard of the kind of problem you seem to have!
Your pics show your frame is hammered, quite frankly that would hurt me, should not happen!
I just checked my (2014, 96hrs) orange 500 - and not a mark, nada, niks, and of course I (plus the previous owners) also ride with a slapper from time to time!
So in your case I'd be veryvery agterdogtig towards sideways bending of my chain here, and take it off to verify it.
Mind you, the CS, dunno, is it symmetrical or a lobsided one?
If the latter (if yes..) then maybe oopsie, turn it around!
Point here is, that side-slapping in NOT normal, and as it is relatively close to the CS I'd search until I'd find the reason .... hence my posts.

Kom nou man, vind die rede, daar IS erens een!  ;)
Title: Re: 501 Rally/Adv build
Post by: deapsquatter on April 04, 2021, 06:43:27 pm
Enduristan was a kak idea.

Waiting for a Coyote..  :sleepy1:
Did you try the Blizzards? I'm torn between  Blizzards and GL Mojave....

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Title: Re: 501 Rally/Adv build
Post by: voorvel on April 04, 2021, 06:55:04 pm
Enduristan was a kak idea.

Waiting for a Coyote..  :sleepy1:
Did you try the Blizzards? I'm torn between  Blizzards and GL Mojave....

Sent from my Pixel 3a using Tapatalk


Mojave is quite a bit smaller than the blizzard and just too small for anything longer than 2 days

The blizzards are:
1: a bit floppy when mounted. I reckon it will be better if the straps go underneath your seat. (Not possible on FE)
2: straps take up space over the seat.

I use my mojave for day rides only

Coyote:

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Title: Re: 501 Rally/Adv build
Post by: chopperpilot on April 04, 2021, 08:57:13 pm
How is the front sprocket designed?

Is it possible to flip and fit the sprocket incorrectly, with it being closer to the frame than it should?


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Title: Re: 501 Rally/Adv build
Post by: voorvel on April 04, 2021, 09:47:58 pm
It goes in 1 specific way.
Once I'm done balancing the wheels, i will go test things again.

The chain has not rubbed through the 3d printed part yet, but I will monitor things closely

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Title: Re: 501 Rally/Adv build
Post by: chopperpilot on April 05, 2021, 10:54:31 am
It goes in 1 specific way.
Once I'm done balancing the wheels, i will go test things again.

The chain has not rubbed through the 3d printed part yet, but I will monitor things closely

Sent from my IN2013 using Tapatalk


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Title: Re: 501 Rally/Adv build
Post by: voorvel on April 06, 2021, 10:53:32 pm
Modeling this:

(https://pbs.twimg.com/profile_images/1265008140254195714/Jmz-dhu1_400x400.jpg)

into:

Title: Re: 501 Rally/Adv build
Post by: voorvel on April 08, 2021, 09:50:27 pm
before:
(https://i.imgur.com/WR3wsgu.jpg)

after
(https://i.imgur.com/lu3OgZ0.jpg)

Still have to make some plan with that phone ram mount.. not sure yet
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 09, 2021, 06:23:51 pm
Thats a new RK chain and sprockets.
Except for perhaps a too loose chain, i have no other idea why it might chafe

Aww come on now, take it off and measure?
Will only cost you a new masterlink ..... and then you know, better than think!
Better still, take it to the shop and put it next to a new DID, and see what bends more, a rather convincing exercise if ever there is one!

Every brand makes a dud from time to time, and a cheaper chain (hey, no idea what you paid, and I'm not pointing fingers to you or a brand here please...) like Tsubaki (they used to be quite popular in NL) performed noticeably less than a DID - which is a costly chain I'll admit but also I have never heard of the kind of problem you seem to have!
Your pics show your frame is hammered, quite frankly that would hurt me, should not happen!
I just checked my (2014, 96hrs) orange 500 - and not a mark, nada, niks, and of course I (plus the previous owners) also ride with a slapper from time to time!
So in your case I'd be veryvery agterdogtig towards sideways bending of my chain here, and take it off to verify it.
Mind you, the CS, dunno, is it symmetrical or a lobsided one?
If the latter (if yes..) then maybe oopsie, turn it around!
Point here is, that side-slapping in NOT normal, and as it is relatively close to the CS I'd search until I'd find the reason .... hence my posts.

Kom nou man, vind die rede, daar IS erens een!  ;)

Man, I'm not sure what the previous owner had going on but the chafing on the frame could not have happened since I've had the bike:
1 - the marks would have been fresh, had it been me
2 - the inside of the sidestand also showed chafing marks
3 - I've ridden around now and the wear on the inside of the 3d printed part does not progress any further than in the pic attached
4 - The insulation tape on sidestand shows now sign of chain chafing

That being said, I will see how this bad boy holds up over my next 2K km trip
(https://i.imgur.com/FPIvyle.jpg)

(https://i.imgur.com/q7rE7J5.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 09, 2021, 06:27:39 pm
(https://bcdn.hbm-machines.com/images/cache/hbm-096-39.jpg-1920x1080-533c937c8d.jpg)

Balanced my wheels and fitted some grip puppies  >:D
(https://i.imgur.com/z5dKMNO.jpg)
(https://i.imgur.com/MhO8pDw.jpg)

Its a much improved ride now  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: BuRP on April 09, 2021, 06:34:44 pm
I will see how this bad boy holds up over my next 2K km trip

That looks a LOT better - and a nice trip ahead hmm?
Not jealous, just tell me if you could eat some rabbit there  ;)
Enjoy, looks like a looker  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 10, 2021, 02:14:20 pm
I will see how this bad boy holds up over my next 2K km trip

That looks a LOT better - and a nice trip ahead hmm?
Not jealous, just tell me if you could eat some rabbit there  ;)
Enjoy, looks like a looker  :thumleft:

Thanks, torn between Slovenia - Croatia loop or Pyrenees
Will probably go for the latter. Nice looking loop:
Title: Re: 501 Rally/Adv build
Post by: JacoM on April 11, 2021, 08:14:29 am
From the limited views of your bikes chainguard, it seems different than mine. Did you modify it? Maybe this is the reason for the schafing?
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 11, 2021, 10:04:45 am
From the limited views of your bikes chainguard, it seems different than mine. Did you modify it? Maybe this is the reason for the schafing?
No I didn't.
Care to share a pic of yours please?

Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: BuRP on April 11, 2021, 11:45:45 am
Will probably go for the latter.

Sounds like you're going alone?
And, obviously you'll trailer it there, no point in boringly wasting tyres going down over what, 1300 km or so?
Holler if you'll need some help, got a (Dutch) friend there almost on your route, South Eastern area.
Shit, would not mind being there now, the weather's fine, scenery stunning and the fuzz fines you if you do not pull a wheelie for them!  :P


"your bikes chainguard, it seems different than mine"
Well now, this would be good news IF that's true!
Gooi a few pics for him to suss out what's what?  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 11, 2021, 12:39:42 pm
Will probably go for the latter.

Sounds like you're going alone?
And, obviously you'll trailer it there, no point in boringly wasting tyres going down over what, 1300 km or so?
Holler if you'll need some help, got a (Dutch) friend there almost on your route, South Eastern area.
Shit, would not mind being there now, the weather's fine, scenery stunning and the fuzz fines you if you do not pull a wheelie for them! 


I'm most likely going solo as my single bike trailer wont carry my friend's 990 too
Got a very convenient little trailer that fits in the boot of my car O0
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 11, 2021, 12:45:26 pm
I bought the 990 to be able to cover distances to places that I'd like to explore

Took one proper trip to realize i'd rather chill in my cage for 1000km and then unleash the no-compromise dualsport 500

Sad part is that my friend has to either travel those brainless section alone or change to a lighter bike too.
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 11, 2021, 04:36:27 pm
From the limited views of your bikes chainguard, it seems different than mine. Did you modify it? Maybe this is the reason for the schafing?
This is what fitted on mine:

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Title: Re: 501 Rally/Adv build
Post by: BuRP on April 12, 2021, 11:29:28 am
Got a very convenient little trailer that fits in the boot of my car

I know that one, super lil gizmo indeed.
Lucky git you, would be totally unusable here - no potholes there hmm?
 :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 12, 2021, 12:27:31 pm
I've seen a pothole a couple months ago.

You make a valid point though as those 10inch wheels are tiny.. will see if it manages through Belgium and France

Sent from my IN2013 using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: sidetrack on April 12, 2021, 02:17:41 pm
Thats a new RK chain and sprockets.
Except for perhaps a too loose chain, i have no other idea why it might chafe

Aww come on now, take it off and measure?
Will only cost you a new masterlink ..... and then you know, better than think!
Better still, take it to the shop and put it next to a new DID, and see what bends more, a rather convincing exercise if ever there is one!

Every brand makes a dud from time to time, and a cheaper chain (hey, no idea what you paid, and I'm not pointing fingers to you or a brand here please...) like Tsubaki (they used to be quite popular in NL) performed noticeably less than a DID - which is a costly chain I'll admit but also I have never heard of the kind of problem you seem to have!
Your pics show your frame is hammered, quite frankly that would hurt me, should not happen!
I just checked my (2014, 96hrs) orange 500 - and not a mark, nada, niks, and of course I (plus the previous owners) also ride with a slapper from time to time!
So in your case I'd be veryvery agterdogtig towards sideways bending of my chain here, and take it off to verify it.
Mind you, the CS, dunno, is it symmetrical or a lobsided one?
If the latter (if yes..) then maybe oopsie, turn it around!
Point here is, that side-slapping in NOT normal, and as it is relatively close to the CS I'd search until I'd find the reason .... hence my posts.

Kom nou man, vind die rede, daar IS erens een!  ;)

Man, I'm not sure what the previous owner had going on but the chafing on the frame could not have happened since I've had the bike:
1 - the marks would have been fresh, had it been me
2 - the inside of the sidestand also showed chafing marks
3 - I've ridden around now and the wear on the inside of the 3d printed part does not progress any further than in the pic attached
4 - The insulation tape on sidestand shows now sign of chain chafing

That being said, I will see how this bad boy holds up over my next 2K km trip
(https://i.imgur.com/FPIvyle.jpg)

(https://i.imgur.com/q7rE7J5.jpg)
Maybe the chain adjusters were skew or he mixed up the left and right side wheel spacers ?
Title: Re: 501 Rally/Adv build
Post by: sidetrack on April 12, 2021, 02:27:29 pm
I bought the 990 to be able to cover distances to places that I'd like to explore

Took one proper trip to realize i'd rather chill in my cage for 1000km and then unleash the no-compromise dualsport 500

Sad part is that my friend has to either travel those brainless section alone or change to a lighter bike too.
Nooit, I'm a history geek would stop in every small village in France and take pictures of old churches and buildings  :thumleft: Maybe not much dirt but would make it fun to get to the ride itself. Guess you would need plenty of time though. Carcassonne well worth a visit  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 12, 2021, 05:06:53 pm
Yes that's the thing; after covering 1300km, the real 2000km ride only starts.

Not enough time

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Title: Re: 501 Rally/Adv build
Post by: voorvel on April 12, 2021, 05:40:04 pm
Or alternatively do the full TET of France (think that's 5000km) and then do Pyrenean part.

And then follow that up over December (winter time here) with Spain to Morocco and back.

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Title: Re: 501 Rally/Adv build
Post by: Pumbaa on April 12, 2021, 09:02:03 pm
I've seen a pothole a couple months ago.

You make a valid point though as those 10inch wheels are tiny.. will see if it manages through Belgium and France

Sent from my IN2013 using Tapatalk
Think you will have to take extra care on their roads.  Our roads here are just so good that the small tyres are OK. Luckily our road/ car taxes are used for the right thing here.

Sent from my SM-G975F using Tapatalk

Title: Re: 501 Rally/Adv build
Post by: voorvel on April 17, 2021, 11:23:08 am
I've been in 2 minds about the stock handguards.
On the one hand, I really like their look and the handguard-mounted mirrors also flow nicely along the same lines:

(https://i.imgur.com/Nm2Hbxk.jpg)

On the other, I hate how the clutch and brake lines forces you to compromise with either the tilt of the guards or your controls. I can never get both to be exactly how I want them.

(https://i.imgur.com/GTZH1Rx.jpg)

So that always leads me to aftermarket which is:
1) expensive
2) the Cycra's are a bit dated in look IMO
(https://i.imgur.com/78S4yZd.jpg)

In ZA, its still OK to just tilt the guards down, but in EU, you need the protection from the elements. If only I could extend the exiting guards somehow  :o
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 17, 2021, 11:27:46 am
Been experimenting with photogrammetry, better known as photo to mesh

Check, I scanned the existing handguard, by taking lots of photos and using Meshroom to create a mesh.

I will be printing the addon piece today.. holding thumbs
(https://i.imgur.com/dTC7joG.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 17, 2021, 03:29:03 pm
Unfortunately my support piece collapsed during print, so its not perfect yet:
(https://i.imgur.com/mrengsJ.jpg)

Also still printing at 150%, so not best quality but OK for prototyping
Part is designed to fit inside the slots of the handguard:
(https://i.imgur.com/vt2n29l.jpg)

Area circled in red was not fully printed due to support collapsing
(https://i.imgur.com/p0QRsjG.jpg)

Version 2 will have this part included.
It will be used to bolt everything together
(https://i.imgur.com/7GVlQPK.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 18, 2021, 07:39:18 pm
*My garage needs a cleaning, pardon the mess  ::)

Got the left side done!
I must say, I'm happy with the result:
(https://i.imgur.com/aQh2xpl.jpg)
There's a little 'H' in that Husqvarna emblem. Maybe I will also paint that yellow O0

(https://i.imgur.com/CYYKpSD.jpg)

It clearly offers better wind protection:
(https://i.imgur.com/l3AznGV.jpg)

and the foldable mirror, fits in nicely behind the wind shield:
(https://i.imgur.com/N3Rfcgb.jpg)
(https://i.imgur.com/wPsWaNO.jpg)

(https://i.imgur.com/EvNyHTl.jpg)

Mirror folded inwards
(https://i.imgur.com/pyOfZtg.jpg)

One down, 1 more to go
(https://i.imgur.com/bvChA6i.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on April 23, 2021, 12:42:36 pm
Wens ek kon kom loer soos in die ou dae  :( Die bike lyk nou seriously gesort  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 23, 2021, 03:37:45 pm
Al wat jy kort is vliegtuig kaartjies. Kamer is gereed, selfs n Yamaha wat vir jou wag
:thumleft:

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Title: Re: 501 Rally/Adv build
Post by: voorvel on April 24, 2021, 05:26:37 pm
Both handguards mounted
 ;)
(https://i.imgur.com/3X7OZMG.jpg)

Those USB cables can sometimes annoy me a bit, specifically when not plugged into something as they tend to rattle and flap around.

So I decided to solve that:
(https://i.imgur.com/81pa15C.jpg)
(https://i.imgur.com/8Ahyb5s.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 24, 2021, 05:30:38 pm
Plugging the cable into its housing, will at least also protect it from the rain

USB for the phone, which is used as a speedo mostly:
(https://i.imgur.com/r2fBxNf.jpg)

Title: Re: 501 Rally/Adv build
Post by: voorvel on April 24, 2021, 05:32:41 pm
And the mini USB for the GPS:
(https://i.imgur.com/8BLAgqT.jpg)

(https://i.imgur.com/TK5gVcc.jpg)
(https://i.imgur.com/eBqTTVW.jpg)
(https://i.imgur.com/m9iiLIm.jpg)
Title: Re: 501 Rally/Adv build
Post by: Noneking on April 24, 2021, 06:07:00 pm
Lyk baie netjies!
Title: Re: 501 Rally/Adv build
Post by: sidetrack on April 26, 2021, 08:50:44 am
Post some pics of this beast in action  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 26, 2021, 10:41:32 am
Went for a ride yesterday indeed  :ricky:

Had so much fun in the thick, whooped out sand tracks. For those sections, unfortunately I have no pictures as stopping is no option in them  ;D
Te whoops are spaced about 1.5m apart, so you can imagine how deep they are. Man they were nice to ride!

The track goes through a nature reserve with a cattle grate. The grate sits a couple feet higher than the track, so you jump the grate, and enter the whoops at some speed. I remember having to negotiate a sharp S-bend, all whooped out, so you have to change direction in those whoops, twice in midair  :thumleft:
It sounds a bit gnarly, but dude, this scoot just operates that stuff.

The night before the ride, I was YouTubing  about Xplor forks and their mid stroke issues, strongly contemplating upgrading to better stuff, which will undoubtedly be better, but honestly, I'm OK with what I have for ADV riding.

Some pics:
(https://i.imgur.com/scYnL5c.jpg)
Heading to Eindhoven. In the past I would be sitting on my 990 on the highway. Must say, the cage is comfy.
The plan was to do a loop of the TET.
Park somewhere near Einhoven and go south.

I love the fresh smell of pine in the morning  :thumleft:
(https://i.imgur.com/tKQ03sl.jpg)

Lots of foresty areas around here but you have to mind the locals on their horses though
(https://i.imgur.com/93yZS5C.jpg)

Making may way south, with as you can imagine, lots of water everywhere
(https://i.imgur.com/EnQJIE6.jpg)
(https://i.imgur.com/PA7QOa2.jpg)
(https://i.imgur.com/OE61PkN.jpg)
 :thumleft:
(https://i.imgur.com/nsoS1aP.jpg)

Nice whooped track this, too bad you cant see much of it in the photo
(https://i.imgur.com/0v7255x.jpg)

Bike parked inside one of the whoops. These things are wide and go over the crest of the hill, bit of a dragons back
(https://i.imgur.com/IUGPnYu.jpg)
(https://i.imgur.com/licScOW.jpg)

Things opened up a bit now, as I headed towards the thicker sandy sections.
(https://i.imgur.com/eeadgdP.jpg)
(https://i.imgur.com/mh03Nnq.jpg)
(https://i.imgur.com/uqtC335.jpg)
(https://i.imgur.com/GtRAlfn.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on April 26, 2021, 11:16:24 am
Had some intermittent connection issues with my USB devices yesterday.  ::)

Have not had the time to look inside the tower, but I expect that the connections between the USB cables and the 12v to 5v dc-dc converter, were acting up.

Been using this:
(https://images-na.ssl-images-amazon.com/images/I/512WRGw7HmL._AC_SL1020_.jpg)

But will be changing to the following 5A converter:
(https://images-na.ssl-images-amazon.com/images/I/51%2BlPgyMPFL._SL1001_.jpg)

With a side-mounted fuse box:
(https://images-na.ssl-images-amazon.com/images/I/61zYmhWsunL._AC_SL1000_.jpg)

..and connecting the USB connectors directly to the source:
(https://images-na.ssl-images-amazon.com/images/I/31pzC7A3D3L._AC_.jpg)
(https://images-na.ssl-images-amazon.com/images/I/71HEaDlg6TL._AC_SL1500_.jpg)

I expect this will solve it
Title: Re: 501 Rally/Adv build
Post by: sidetrack on April 26, 2021, 01:12:53 pm
Mooi, dit lyk soos n skildery
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 02, 2021, 01:51:14 pm
Solving the USB connection issues..
Been searching for a proper fitment location of the fusebox. At 1st, I thought fitting it directly behind the screen might be good, but it looked a bit silly.
(https://i.imgur.com/I5COnek.jpg)

Placing it on the side could work, but I will have to remove some excess material 
(https://i.imgur.com/nh0HLx4.jpg)

Lots of space inside the tower for all your wiring needs, you just need small hands  ::) This is where the RebelX design is better as you can remove one half of the tower, to get to all the wiring.
(https://i.imgur.com/pP7m7LA.jpg)
I use those industrial Velcro strips for attaching the parts to the tower. Nothing more irritating than parts slapping around in there.

View from behind the headlight; enough clearance it seems
(https://i.imgur.com/nTWwVJZ.jpg)

Seeing as I added an additional USB-C cable, I needed to shorten all wires and properly route them to the fusebox
(https://i.imgur.com/8Q0gIMd.jpg)

Work in progress:
(https://i.imgur.com/ZfOBsoF.jpg)
(https://i.imgur.com/aXP21nS.jpg)
(https://i.imgur.com/4T3Lo1p.jpg)
(https://i.imgur.com/mh3yexz.jpg)

Tucks away nicely  ;) 
(https://i.imgur.com/UHDPhWY.jpg)

One extra USB with a 'garage'
(https://i.imgur.com/5iNdniP.jpg)

Fortunately, my earlier 3d-printed cable housing can properly cater for the extra cable:
(https://i.imgur.com/NHruM9g.jpg)
(https://i.imgur.com/kGMLbMI.jpg)

The dash with Carpe Iter App:
(https://i.imgur.com/csgGgci.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 02, 2021, 02:01:36 pm
Time to service the forks  8)

(https://i.imgur.com/jayO7Jt.jpg)

Way overdue as the old oil looks more like hot chocolate than oil  :o
(https://i.imgur.com/e5vSPtG.jpg)

Lets fix that shall we?
(https://i.imgur.com/bs6rbF4.jpg)

Soft jaws came in very handy for this job.
(https://i.imgur.com/e7sbxqy.jpg)

I found two of these plastic shims at the bottom of the spring, in the second fork leg. And none in the 1st..
(https://i.imgur.com/886SBTP.jpg)
At first I thought hmm, this fork does not use a shim down there, but when stripping the second leg, I found the missing one.  :xxbah:

Made me go back into the 1st fork leg again, to fit the missing part.
I would imagine this to make quite an impact as the lack of the shim will cause stiction as the spring turns back and forth during compression. 

All done  :thumleft:
(https://i.imgur.com/fqw5Aes.jpg)

I replaced the oil and dust seals while i was in there.
Turns out to be a very simple job
Title: Re: 501 Rally/Adv build
Post by: sidetrack on May 04, 2021, 08:45:32 am
Nice, anything left to do ? The bike looks sorted now  :ricky:
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 04, 2021, 08:50:26 am
Nice, anything left to do ? The bike looks sorted now  :ricky:
Yes, but only bolt-on's
Waiting for parts ordered from the States in February

Should arrive the day after tomorrow


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Title: Re: 501 Rally/Adv build
Post by: BuRP on May 04, 2021, 11:57:39 pm
Uhh, maybe not finished yet, refer my pic: a heatsink, prolly the RR, and it is mounted behind the headlight i.e out of any cooling wind?
If so I'd reconsider this, get loadsa cooling where it's needed  ;)
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 05, 2021, 12:10:38 am
I rarely ride in anything above 20įC but you make a very good point.

There is very little airflow inside the tower. Could be a passive cooling setup but I will stick a temp sensor on there, now that you pointed that out.

Thx

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Title: Re: 501 Rally/Adv build
Post by: voorvel on May 05, 2021, 12:24:18 am
On 2nd thought, if those led lamps survived multiple Dakar tests (kak warm daar), then it might be ok for my usage.

Will see how they last
:thumleft:

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Title: Re: 501 Rally/Adv build
Post by: BuRP on May 05, 2021, 09:49:11 am
.... led lamps

Will see how they last

Ah, not your RR (Rectifier/Regulator) then - which needs to shed a shitload of energy in heat during riding, especially when you don't have large consumers (like heated grips etc) on - but a LED-driver.
These things are meant to sit a bit out of the airflow due to their usage/purpose, hence the large ribs perhaps ..... leave it bru, if it kaks you're only in the dark and can fix it laters  :thumleft:
One way of remedying the airflow would be to mount a hose of sorts, or, with your above-average handy 3D printing skills you could perhaps make something more elegant you suspect-elegant designer you  :lol8:
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 06, 2021, 02:31:29 pm
Finally!
Stupid Corona had me waiting for months


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Title: Re: 501 Rally/Adv build
Post by: voorvel on May 06, 2021, 07:12:39 pm
Seat fitted.
I was a bit in 2 minds about how it might look, but I like it.

Definitely way more comfortable
(https://uploads.tapatalk-cdn.com/20210506/4bec95d230042cc1c9ca5e273b79371e.jpg)(https://uploads.tapatalk-cdn.com/20210506/6d529b3b46d805910a6f5dd5ffebb1fd.jpg)

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Title: Re: 501 Rally/Adv build
Post by: voorvel on May 06, 2021, 07:15:25 pm
Also fitted the fuel filter.
Must say that I'm no fan of how KTM made the fuel line snake about.

Seems simply too long.
I might reroute this once I've emptied the tank.
*Edit* after refitting, I'm happy with the routing

(https://uploads.tapatalk-cdn.com/20210506/5ef095fda26c41f2b0b9a433fb984acb.jpg)
(https://i.imgur.com/O5tgoQ9.jpg)
(https://i.imgur.com/APPZbwy.jpg)

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Title: Re: 501 Rally/Adv build
Post by: voorvel on May 14, 2021, 12:09:18 pm
The brake line bracket has been bugging me a bit.
At full extension of the forks, this hose fitting catches the radegarage bracket:
(https://i.imgur.com/9Egj49L.jpg)

Lets fix that shall we 
(https://i.imgur.com/uv5Loyh.jpg)

Will it be able to flex enough?  :o
(https://i.imgur.com/BvLQwQQ.jpg)
(https://i.imgur.com/3t4Bbln.jpg)

(https://i.imgur.com/zOHVCKM.jpg)
Yep 

(https://i.imgur.com/vZZlQEu.jpg)
As can be seen, I still need to print a spacer, but it clamps really well (to the fork)  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 14, 2021, 07:09:16 pm
Upgrade
(https://i.imgur.com/qFnkMYh.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 14, 2021, 11:49:48 pm
Been a bit annoyed by the Seat Concepts' fitment.

Its base does not match the stock seat where the rear 'lips' of the seat slides into the subframe, causing the rear of the seat to lift away from the subframe.
If you were to press down on the back of the seat (where the SC badge is), you can feel it flex up-and-down by about 5mm

On closer investigation, the lips of the stock seat are about 2mm thicker, causing it to 'pull' the rear of the seat down:
(https://i.imgur.com/VuXwRyZ.jpg)

Made 2 brackets that, with some force, clips into place, adding 2mm more width to the new seat:
(https://i.imgur.com/bX9FEIx.jpg)
(https://i.imgur.com/vAiSPyA.jpg)

(https://i.imgur.com/Q4qWUs4.jpg)

Worked like a charm!
(https://i.imgur.com/LJvfFXJ.jpg)
(https://i.imgur.com/pyYbKIH.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on May 17, 2021, 08:05:53 am
Following and hope the borders open up soon for a ride  :ricky:
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 17, 2021, 10:34:52 pm
My parade got rained on this weekend.

Belgium, France and Spain still a no go and I learned that a Slovenia-Croatia loop won't work as Slovenia enforces a 2 week lockdown for all entering from Croatia.


World's gone mad.
I should take up knitting

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Title: Re: 501 Rally/Adv build
Post by: sidetrack on May 18, 2021, 08:04:42 am
My parade got rained on this weekend.

Belgium, France and Spain still a no go and I learned that a Slovenia-Croatia loop won't work as Slovenia enforces a 2 week lockdown for all entering from Croatia.


World's gone mad.
I should take up knitting

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Clog carving
Title: Re: 501 Rally/Adv build
Post by: BuRP on May 18, 2021, 08:19:46 am
World's gone mad.

Correct, and that earns you the "Statement of the Year" award!
Make that a dual one, for 2020 & 2021 ..... but let's fucking hope it won't become a running award!
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 23, 2021, 11:21:38 am
Used to carry a nice medic pack in the glovebox of my 990.
(https://travelsafe.nl/wp/wp-content/uploads/2019/06/TS0512-Globe-Scout-18-2-560x650.jpg)

Made a bracket for it, in order to fit my 501:
(https://i.imgur.com/7neXbbo.jpg)

The horizontal plastic 'flap' slides into the medic pack's slots
(https://i.imgur.com/nLP6nQb.jpg)
(https://travelsafe.nl/wp/wp-content/uploads/2019/06/TS0512-Globe-Scout-back-17-2-516x650.jpg)
(https://i.imgur.com/IF3uijs.jpg)

I ensured a reduced distance to the base, which forces the bag down, into place. It makes for a tight fit
 :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on May 30, 2021, 07:21:38 pm
Been preparing for my next trip.
I decided to change the GPS and phone wiring -in essence, I want less wires but also redundancy.

Ordered RAM's wireless charger. They have the X-clamp version too but I've been getting quite annoyed by the way my current X-clamp would press the buttons on the side of my phone. So decided to try another option. Will see how it handles the phone in landscape mode..
(https://cdn.webshopapp.com/shops/10612/files/316286348/image.jpg)
Its a bit heavy though.. specs state 300g but maybe that includes all wires and such. The carbon part of my tower only weighs 300g, so that puts things into perspective  :o
So although its much handier, it does weight substantially more than my current old-school X-mount.
But anyway, going this route means I wont need dedicated USB-A and C wires anymore.

Both phones will require something like this:
(https://canary.contestimg.wish.com/api/webimage/5ed8ae566d7df71685379ab3-large.jpg?cache_buster=cab9f511593b4367b7b1e6f53544f55a)

I like the cleaner look of the tower already
(https://i.imgur.com/3WvEIRd.jpg)
I've mounted a redundant USB plug on the side of the tower, visible on the bottom left, in the above picture

One 20watt and redundant 15watt USB supplies:
(https://i.imgur.com/hXAtCuH.jpg)

While I had the tower removed, I thought I'd see how much it weighs, vs the stock unit.
(https://i.imgur.com/dpfsDTV.jpg)

540g:
(https://i.imgur.com/tDY6iTo.jpg)
vs 1900g:
(https://i.imgur.com/7lT3t0h.jpg)
This includes the tower mounting brackets, screen mountings, fuse box, GPS mounts and all wiring
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 01, 2021, 07:58:54 pm
Ek moet nou ophou upgrades doen en begin bike ry

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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 01, 2021, 07:59:36 pm
Cone valve meesters

(https://uploads.tapatalk-cdn.com/20210601/97b8550ac9eee867785b3c92cbfc3181.jpg)

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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 02, 2021, 12:14:47 am
Hulle is wel 2016 model met 26mm diameter as. (My 2017 het 22m diameter as)

Lyk my ek kort net ander as en bypassende bearing spacers. Die bearings sien ek is dieselfde asook die binneste lang spacer

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Title: Re: 501 Rally/Adv build
Post by: BuRP on June 02, 2021, 10:03:03 am
Ek moet nou ophou upgrades doen en begin bike ry

Ek het van 'iemand' gehoor dit gaan daadwerkelik binnekort gebeur  ;)
Behalwe n puik test vir die bike sal dit jou farklekoors stop sit, en ons hoop n rattlekoors sal jou gespaar bly  :P
Gooi foties as dit gaan gebeur!  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 04, 2021, 06:34:37 pm
Is reg.
My verlof is geboek.


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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 05, 2021, 10:36:48 pm
Finally got me a semi-decent crimp tool

(https://i.imgur.com/CWM9IqC.jpg)

..and decided to tidy up some wires behind the 'dash'
(https://i.imgur.com/5FLFNB7.jpg)

Man, it was pleasing being able to crimp the wires so effortlessly  O0

The connector for the indicator unit:
(https://i.imgur.com/TxbfA7z.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 05, 2021, 10:45:04 pm
Turns out my current lower fork guards will also not fit these cone valve forks  :(

Picked me up a set of 2015 yellow fork guards from a local KTM shop. Naturally, I had to bling them out a bit:
(https://i.imgur.com/vVUk06w.jpg)

Will mount the wheel on Monday, once I have the new axle + spacers.

In the meantime, I'm trying to arrange for a B&B that will allow me to stash my vehicle with them for a week.

The current plan is PCR test on the 15th -> trailer to south of France on 15th/16th -> start bike trip from 17 to 22'ish -> return to NL 23rd
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 05, 2021, 10:47:24 pm
Found 1cm lower and wider pegs, while visiting KTM

I couldn't resist.
(https://i.imgur.com/NLU6Ddq.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 07, 2021, 08:49:37 am
Finally got me a semi-decent crimp tool

(https://i.imgur.com/CWM9IqC.jpg)

..and decided to tidy up some wires behind the 'dash'
(https://i.imgur.com/5FLFNB7.jpg)

Man, it was pleasing being able to crimp the wires so effortlessly  O0

The connector for the indicator unit:
(https://i.imgur.com/TxbfA7z.jpg)
Nice crimper, getting gatvol of using needle nose pliers and solder. What do you call that crimper, crimp types ?

Title: Re: 501 Rally/Adv build
Post by: BuRP on June 07, 2021, 10:37:47 am
gatvol of using needle nose pliers and solder.

Once you've used a decent crimping tool only once you'll never use anything else again.
It's like a factory crimp, even the insulation (btw, up to you to trim oaa properly) is held by a - separate - crimp!  :thumleft:
There's 3 different tools for, duh, 3 different types of terminals, and the ratchet-type crimping tools (Japanese or Taiwanese) are the best.
Looking around one can find them, but a proper tools supplier (or electrical-) can help you here.
Eh, for the cheapskates they're not cheap, but as said, use a decent tool once and you'll be hooked - oh wait, that should be crimped?  :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 07, 2021, 01:15:43 pm
I searched for a JST crimping tool that can handle wires sizes of #20 to #32

#32 is a bit too small, so a 28 might suffice.
As Blurp said, if you want to do it the right way and with the least amount of frustration required, just do yourself the favour and get one.

(https://i.imgur.com/xVf6Hut.jpg)

https://www.amazon.nl/dp/B002AVVO7K/ref=cm_sw_r_cp_apa_glt_i_28THPNFTCRYM05KQNH4R?_encoding=UTF8&psc=1 (https://www.amazon.nl/dp/B002AVVO7K/ref=cm_sw_r_cp_apa_glt_i_28THPNFTCRYM05KQNH4R?_encoding=UTF8&psc=1)
Title: Re: 501 Rally/Adv build
Post by: 2StrokeDan on June 07, 2021, 02:29:15 pm
Shrink a short length of heatshrink tubing onto the wire/fitting joint, it will break off on that joint if not supported and there is some movement.
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 07, 2021, 06:03:27 pm
Bigger axle + bearing spacers were indeed what was needed:
(https://i.imgur.com/J3ig0AU.jpg)

Rode around the village. Doesn't mean much for testing the new suspension, but at least I could verify that it tracks straight.

(https://i.imgur.com/8CfQlwx.jpg)
(https://i.imgur.com/ZHXVU6M.jpg)

Now I just need to do an oil change and then I'm ready  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 07, 2021, 07:53:16 pm
Hoeveel swaarder is jou bike nou met die groter as ?  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 07, 2021, 07:59:40 pm
Ja self nie seker waarom KTM die as moes verander nie.
Seker maar om meer flex te gee of iets.
As diameter het glo n groot verbetering op die YZ gemaak.

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Title: Re: 501 Rally/Adv build
Post by: BuRP on June 08, 2021, 10:02:53 am
Seker maar om meer flex te gee of iets.

"Hulle is wel 2016 model met 26mm diameter as. (My 2017 het 22m diameter as)"
Dikker as dink ek, dus minder flex?
4mm dikker behoor heelwat minder te flex  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 08, 2021, 10:51:26 pm
Been doing the oil change when I noticed some moisture where the coolant hose attaches to the radiator inlet.

Replacing the hose clamp did not solve it.. can it be that the hose itself is fukt?

(https://i.imgur.com/vCp2nRG.jpg)
(https://i.imgur.com/cJprbYx.jpg)
Title: Re: 501 Rally/Adv build
Post by: BuRP on June 09, 2021, 08:37:04 am
can it be that the hose itself is fukt?

Can yes, dunno...
Rubber hoses are fine but do give hickups from time to time, whilst sillicone hoses never do this!
If you've got enough time left get a set, blue would do nicely too  ;)

And when you're busy (and if not done so already) replace all crimped-type hoseclamps with normal old fashioned wormscrew types, stainless ideally, so when out & remote you will be able to help yourself instead of phoning a friend!
Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 09, 2021, 08:56:04 am
Remove the hose and check the radiator pipes maybe there is gunk on them causing a bad seal
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 09, 2021, 06:49:04 pm
Let it idle for a while, following the oil change and saw no leaks.

Anyway, ordered a set of Samco hoses just to be sure :thumleft:

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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 09, 2021, 11:23:26 pm
Wanted to adjust my new forks to the stock settings.
They are currently setup for 95kg, which should be good for my bigger tank setup.

The cone valve requires a specific tool, for setting the preload.

Nothing that n can't print though.

Worked like a charm
:)

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Title: Re: 501 Rally/Adv build
Post by: BuRP on June 10, 2021, 06:35:24 am
a specific tool, for setting the preload.

Nothing that n can't print though.

You bugger!  :P
Runner's having a few made, by waterjet I believe.
Indeed out of plastic  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 10, 2021, 11:58:49 am
Lekker watter tiepe plastiek is daai ? Kan die printer Nylon doen bv ?
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 10, 2021, 12:06:07 pm
Lekker watter tiepe plastiek is daai ? Kan die printer Nylon doen bv ?
Nylon is a bitch as it tends to warp as it cools down.
There are better alternatives though, like carbon infused materials, which are quite strong.

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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 10, 2021, 12:46:19 pm
Nylon printing tricks


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Title: Re: 501 Rally/Adv build
Post by: voorvel on June 11, 2021, 04:00:12 pm
Hoses arrived today

(https://i.imgur.com/UK3v2X7.jpg)
(https://i.imgur.com/eiivo7e.jpg)
The thermostat is however eliminated with this kit, so I will have to let the bike warm up well, when riding in colder climates.

Hoses fitted, liquids added etc, only to notice that I had this pipe fitted the wrong way around   :patch:
(https://i.imgur.com/qmhzXr8.jpg)

How it should be:
(https://i.imgur.com/izsEa0E.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 11, 2021, 04:25:43 pm
Now how about some lovely billet disc protectors  :deal:
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 11, 2021, 04:35:15 pm
Now how about some lovely billet disc protectors  :deal:
I think I like these

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Title: Re: 501 Rally/Adv build
Post by: sidetrack on June 11, 2021, 06:18:38 pm
Now how about some lovely billet disc protectors  :deal:
I think I like these

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Place that order !
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 11, 2021, 10:24:11 pm
(https://i.imgur.com/QLiTyHG.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on June 15, 2021, 10:51:53 am
Nog so 700km om te gaan.


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Title: Re: 501 Rally/Adv build
Post by: sidetrack on August 02, 2021, 08:07:20 am
Any upgrades ?  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: voorvel on August 02, 2021, 09:54:46 pm
Not much, just wanted to do something about the numberplate.
Your inception worked  ::)

(https://i.imgur.com/ArBRU55.jpg)
(https://i.imgur.com/aMKCxqs.jpg)
(https://i.imgur.com/i8xxs4K.jpg)
(https://i.imgur.com/n4Qtg94.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on August 25, 2021, 01:58:27 pm
Smaller numberplate fitted.
(https://i.imgur.com/fcl76v2.jpg)

Still not the same size as what I used to have in ZA but definitely smaller than stock plate.

Here is a 990 for reference:
(https://i.imgur.com/mB70mNl.jpg)
Title: Re: 501 Rally/Adv build
Post by: sidetrack on September 20, 2021, 09:49:27 am
Te stil nou jy kort nog n projek  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: voorvel on September 20, 2021, 08:15:52 pm
Ja.
Wik en weeg oor hierdie kleur.

En wag dat Van Laar suspensie klaar kry met my vurke se tuning.
Title: Re: 501 Rally/Adv build
Post by: voorvel on September 20, 2021, 08:19:17 pm
Eintlik wil ek daai SloveniŽ- KroasiŽ loop gaan ry, maar my vrou het ander vakansie planne in gedagte 🥴
Title: Re: 501 Rally/Adv build
Post by: BuRP on September 20, 2021, 09:08:17 pm
Eintlik wil ek daai SloveniŽ- KroasiŽ loop gaan ry, maar my vrou het ander vakansie planne in gedagte

Jy bedoel sy wil nie agterop nie?
Tsk tsk tsk .....
 :P
Title: Re: 501 Rally/Adv build
Post by: voorvel on September 20, 2021, 11:02:58 pm
Eintlik wil ek daai SloveniŽ- KroasiŽ loop gaan ry, maar my vrou het ander vakansie planne in gedagte

Jy bedoel sy wil nie agterop nie?
Tsk tsk tsk .....
 :P

Dit, en ek vind dit vreemd om met my ass in haar gesig te staan  :biggrin:
Title: Re: 501 Rally/Adv build
Post by: BuRP on September 21, 2021, 12:40:54 am
ek vind dit vreemd om met my ass in haar gesig te staan

Ja, ek's met jou daar...... maar dan laat jy haar tog bestuur?
 :lol8:
Title: Re: 501 Rally/Adv build
Post by: voorvel on September 25, 2021, 12:06:24 am
Got the forks back from Van Laar.
They sure feel plusher than before.

The springs were the correct ratios but the shims or cone valve was apparently changed to match my description of needs.
He also gave me a printout of shock and fork settings for sand and hard pack.

Gonna test them out tomorrow  :thumleft:

(https://i.imgur.com/qsYrW68.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on September 25, 2021, 11:02:23 pm
Daar het ek toe nou gaan ry vandag, en kon nie die lang, diep whoops gedeelte vind nie.  :o

Anyway, dis baie droog nou hier, en op die bietjie sinkplaat wat ek gery het, voel die vurke heerlik plush.
SovÍr is ek happy. Moes ook die vurk drop in die clamps want aanvanklik was die bike heel twitchy.
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:27:25 pm
I was never truly happy with the white colored design.

Decided to go with back plastics
(https://i.imgur.com/Gj4sO7R.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:28:25 pm
.. a sticker kit

(https://i.imgur.com/uOgcS9j.jpg)

and a pipe  >:D

(https://i.imgur.com/gYHC4nS.jpg)

Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:31:16 pm
was nice working on my bike again. Feels like I need to get another 450 project to keep me busy :biggrin:

Fitting the new plastics was a bit of a mission. The fender came out of the packaging all twisted skew  :patch:

Bling-o meister
(https://i.imgur.com/L0TkezZ.jpg)

(https://i.imgur.com/vUOgSZZ.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:36:36 pm
After fitting the quiet insert, I'm quite happy with the pipe  :thumleft:

(https://i.imgur.com/TwGVPio.jpg)

Lifting the front in 5th gear at 80km/h is no issue
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:38:26 pm
Not the best photos but I'm very happy with the result  :thumleft:

(https://i.imgur.com/siMDkTS.jpg)

(https://i.imgur.com/CDHZJVk.jpg)

(https://i.imgur.com/b6ljjeg.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 02:40:39 pm
Better lighting in my messy garage

(https://i.imgur.com/h1Njk9M.jpg)
Title: Re: 501 Rally/Adv build
Post by: Andrew_Smith on October 24, 2021, 08:49:23 pm
Damn sexy bike, love the FMF and golden forks up front combined with the lights and windshield. Looks mean and ready for an adventure!  :thumleft:
Title: Re: 501 Rally/Adv build
Post by: voorvel on October 24, 2021, 10:49:42 pm
Thanks.

If my ZA passport was worth anything, i could have planned a trip to Portugal.
(This involves a UK to Santander ferry, but a British visa is damn expensive)

Hopefully I will have my dutch passport next year and then I can at least do December trips to warmer places
 :ricky:

For now, I have to utilize the heated grips.
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 03:36:52 pm
Found some handguards on special.
 :thumleft:

I think I might still prefer the looks of the stock ones with the added 3D parts and mirrors, but I did find that my mirrors vibrated quite badly and adversely effecting its visibility.
(https://i.imgur.com/LqHQXJx.jpg)

These have the Husky blue plastic inserts which fits in nicely with the new graphics and I have some back shields on backorder to replace the white sections.

The biggest bonus is that I can now tilt the controls down, to fit my long arms better
(https://i.imgur.com/qvc1yt6.jpg)

Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 03:40:31 pm
Doubletake mirrors from amazon
(https://i.imgur.com/uNBrzpW.jpg)

They show no vibration, so thats a plus too
(https://i.imgur.com/fteXEjI.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 03:46:35 pm
Found a nice 48mm brake line 3D model on the net.
It has a cable-tie running through the middle which allows for a nice tight fit to the forks:
(https://i.imgur.com/3oKE8vi.jpg)

(https://i.imgur.com/TBfHmp1.png)
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 04:01:00 pm
Peeking inside the tank while the bike was idling, I observed some air bubbles.. apparently that is partly caused by the 52psi pressure regulator but i decided to fashion up a pressure gauge to test the FI system

(https://i.imgur.com/KOaQyw3.jpg)

Seeing as I replaced the stock quick disconnects with metal variants, I could re-use the stockers for this purpose ;)

Turns out the pump manages 3bar. Which is below the 3.5bar minimum.
Lower pump pressure will result in a lean condition and in combo with the new exhaust, I suspect it was not very happy  :patch:
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 04:08:37 pm
I was erm-ing and ah-ing about what to do with this and decided to just go for the all balls pump rebuild kit:
(https://www.allballsracing.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/4/7/47-2036.jpg)


Out with the pump

(https://i.imgur.com/xXpHKr2.jpg)
(https://i.imgur.com/VsLl8Jj.jpg)

While I'm in here, I also increased the inlet holes, at the bottom of the pump housing. The stock holes are very tiny:
(https://i.imgur.com/iEkKgfq.jpg)

This does not include the Mahle K97 pre-filter and the current filter has over 50hours on it, filtering fuel from 4 different countries. It does look quite back  :o
(https://i.imgur.com/ZE17brh.jpg)

This is now on order from the states and who knows how long I will have to wait for it, but its a life-long item and filters at 35microns (stock is 40)
(https://static.wixstatic.com/media/be4f25_93b392e76df34aff94eb6e5c22411b49~mv2.jpeg/v1/fill/w_1076,h_846,al_c,q_85/be4f25_93b392e76df34aff94eb6e5c22411b49~mv2.jpeg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 04:20:06 pm
Nice ear clamp tool:
(https://i.imgur.com/NfKxNYP.jpg)

Makes for neat fittings  O0
(https://i.imgur.com/iwiZ0Rm.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 21, 2021, 04:22:03 pm
Its been 50hrs since I last checked the valve clearances.
All still nicely in spec

How neat is this frame under the tank?  :thumleft:
(https://i.imgur.com/z9nFTqW.jpg)
Title: Re: 501 Rally/Adv build
Post by: voorvel on November 24, 2021, 11:18:44 pm
Goed soos nuut