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Author Topic: 501 Rally/Adv build  (Read 8300 times)

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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #40 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #41 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.
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #42 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..
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #43 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:
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #44 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.

« Last Edit: December 29, 2020, 02:10:41 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #45 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.
« Last Edit: December 29, 2020, 02:06:54 pm by dirtWarp »
 

Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #46 on: December 29, 2020, 06:51:26 pm »
Lekker, a light bike with poeier is always fun to ride.
Little by little, one travels far
J.R.R Tolkien
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #47 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.

« Last Edit: January 10, 2021, 07:04:55 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #48 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  :-[
« Last Edit: January 10, 2021, 07:18:53 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #49 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 
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #50 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
« Last Edit: January 10, 2021, 07:18:25 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #51 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.
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #52 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.  >:(
« Last Edit: January 10, 2021, 07:40:48 pm by dirtWarp »
 

Offline BuRP

Re: 501 Rally/Adv build
« Reply #53 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
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 #54 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
« Last Edit: January 10, 2021, 07:59:21 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #55 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  >:(
 

Offline BuRP

Re: 501 Rally/Adv build
« Reply #56 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:
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 #57 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

 

Offline sidetrack

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Re: 501 Rally/Adv build
« Reply #58 on: January 13, 2021, 12:05:28 pm »
 :sip:
Little by little, one travels far
J.R.R Tolkien
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #59 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