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Author Topic: 501 Rally/Adv build  (Read 8413 times)

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Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #180 on: April 26, 2021, 01:12:53 pm »
Mooi, dit lyk soos n skildery
Little by little, one travels far
J.R.R Tolkien
 
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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #181 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.


Placing it on the side could work, but I will have to remove some excess material 


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.

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


Seeing as I added an additional USB-C cable, I needed to shorten all wires and properly route them to the fusebox


Work in progress:





Tucks away nicely  ;) 


One extra USB with a 'garage'


Fortunately, my earlier 3d-printed cable housing can properly cater for the extra cable:



The dash with Carpe Iter App:
« Last Edit: May 02, 2021, 02:02:46 pm by voorvel »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #182 on: May 02, 2021, 02:01:36 pm »
Time to service the forks  8)



Way overdue as the old oil looks more like hot chocolate than oil  :o


Lets fix that shall we?


Soft jaws came in very handy for this job.


I found two of these plastic shims at the bottom of the spring, in the second fork leg. And none in the 1st..

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:


I replaced the oil and dust seals while i was in there.
Turns out to be a very simple job
« Last Edit: May 02, 2021, 02:16:00 pm by voorvel »
 

Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #183 on: May 04, 2021, 08:45:32 am »
Nice, anything left to do ? The bike looks sorted now  :ricky:
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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #184 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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Offline BuRP

Re: 501 Rally/Adv build
« Reply #185 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  ;)
Sparta MC50, 46 other 50cc's, Garelli Tiger Cross, Jawa 250, Kreidler RS (plated), Kawasaki S1 250/3, S2 350/3, H1 500/3, H2 750/3, Suzuki GT380/3 - 10 year gap - KDX200, BMW 1150GS Adventure, Honda CBR600RR, Honda XR650R 2007 & 2003, Honda CRF230, Yamaha BWS100, BMW F800GS Adventure, Husqvarna 701 Enduro 2018, KTM 790 Adv R 2019, KTM 2020 XC-W TPI 300 Six Days, KTM 2014 500 EXC-W Six Days, KTM 790 Adv R Rally 2020, KTM 890 Adv R Rally 2021
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #186 on: May 05, 2021, 12:10:38 am »
I rarely ride in anything above 20C 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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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #187 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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Offline BuRP

Re: 501 Rally/Adv build
« Reply #188 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:
Sparta MC50, 46 other 50cc's, Garelli Tiger Cross, Jawa 250, Kreidler RS (plated), Kawasaki S1 250/3, S2 350/3, H1 500/3, H2 750/3, Suzuki GT380/3 - 10 year gap - KDX200, BMW 1150GS Adventure, Honda CBR600RR, Honda XR650R 2007 & 2003, Honda CRF230, Yamaha BWS100, BMW F800GS Adventure, Husqvarna 701 Enduro 2018, KTM 790 Adv R 2019, KTM 2020 XC-W TPI 300 Six Days, KTM 2014 500 EXC-W Six Days, KTM 790 Adv R Rally 2020, KTM 890 Adv R Rally 2021
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #189 on: May 06, 2021, 02:31:29 pm »
Finally!
Stupid Corona had me waiting for months


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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #190 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


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« Last Edit: May 06, 2021, 07:15:41 pm by voorvel »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #191 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





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« Last Edit: May 09, 2021, 09:26:04 am by voorvel »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #192 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:


Lets fix that shall we 


Will it be able to flex enough?  :o




Yep 


As can be seen, I still need to print a spacer, but it clamps really well (to the fork)  :thumleft:
« Last Edit: May 14, 2021, 02:39:19 pm by voorvel »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #193 on: May 14, 2021, 07:09:16 pm »
Upgrade
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #194 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:


Made 2 brackets that, with some force, clips into place, adding 2mm more width to the new seat:





Worked like a charm!


« Last Edit: May 15, 2021, 09:45:16 am by voorvel »
 

Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #195 on: May 17, 2021, 08:05:53 am »
Following and hope the borders open up soon for a ride  :ricky:
Little by little, one travels far
J.R.R Tolkien
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #196 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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Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #197 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
Little by little, one travels far
J.R.R Tolkien
 

Offline BuRP

Re: 501 Rally/Adv build
« Reply #198 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!
Sparta MC50, 46 other 50cc's, Garelli Tiger Cross, Jawa 250, Kreidler RS (plated), Kawasaki S1 250/3, S2 350/3, H1 500/3, H2 750/3, Suzuki GT380/3 - 10 year gap - KDX200, BMW 1150GS Adventure, Honda CBR600RR, Honda XR650R 2007 & 2003, Honda CRF230, Yamaha BWS100, BMW F800GS Adventure, Husqvarna 701 Enduro 2018, KTM 790 Adv R 2019, KTM 2020 XC-W TPI 300 Six Days, KTM 2014 500 EXC-W Six Days, KTM 790 Adv R Rally 2020, KTM 890 Adv R Rally 2021
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #199 on: May 23, 2021, 11:21:38 am »
Used to carry a nice medic pack in the glovebox of my 990.


Made a bracket for it, in order to fit my 501:


The horizontal plastic 'flap' slides into the medic pack's slots




I ensured a reduced distance to the base, which forces the bag down, into place. It makes for a tight fit
 :thumleft:
« Last Edit: May 23, 2021, 12:07:02 pm by voorvel »