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Author Topic: 501 Rally/Adv build  (Read 8319 times)

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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #60 on: January 14, 2021, 03:45:12 pm »
Dankie oom youtube
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #61 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:
« Last Edit: January 14, 2021, 03:57:49 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #62 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #63 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
 

Offline Kamanya

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Re: 501 Rally/Adv build
« Reply #64 on: January 14, 2021, 04:27:11 pm »
Out of interest, how do you get the nitrogen back in again?
Somedays, life's like a middlemannetjie.
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #65 on: January 14, 2021, 04:41:55 pm »
That 200 bloke charges 7.50 to refill it.
I must just make sure that the piston in the reservoir is properly positioned

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Offline voorvel

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Re: 501 Rally/Adv build
« Reply #66 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #67 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #68 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
« Last Edit: January 19, 2021, 06:58:12 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #69 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:
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #70 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:

« Last Edit: January 19, 2021, 07:03:51 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #71 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


This bad boy can clamp 1000kg and carry a weight of 380kg or thereabouts
« Last Edit: January 19, 2021, 07:23:00 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #72 on: January 24, 2021, 09:13:52 pm »
Got to fit a new clutch and cush rubbers today.
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #73 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #74 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.
« Last Edit: January 24, 2021, 09:20:18 pm by dirtWarp »
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #75 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
 

Offline voorvel

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Re: 501 Rally/Adv build
« Reply #76 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:
 

Offline BuRP

Re: 501 Rally/Adv build
« Reply #77 on: January 24, 2021, 10:31:24 pm »
Dont know where those spots came from.

Water?  ???
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 #78 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

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Offline BuRP

Re: 501 Rally/Adv build
« Reply #79 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
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