KTM EXC520 tidy up

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

The bike formally belonging to MattSpratt is now in my garage, As described it definitely needs a tidy up and a bit of work. I thought I would keep track of mods and changes here.

The plans in rough order of when they will be done.

Fit the following parts,
Kickstart,
Rear Tyre,
Side Stand

Sort out the wiring
A good service
Sort the Speedo out

Then once it is running well I plan a supermoto conversion, fresh panels and graphics.

I had a quick blast round the streets it is horrid on tarmac, the engine however feels really good, no nasty noises and really grunty.

Right first things first, getting it started, no kickstart and a dodgy electric start means that Matt and used a couple of wires you could use to bridge the Solenoid. The wires Matt had used where far too thin and had melted, rather than risk it I rewired it myself and put some block connections on either end (Stinkwheel please don't hate me), it works but I don't like it. I will get the electric starter going ASAP.

Pics not great I'm afraid but here they are

You can see the modified starter by the seat.
https://img.photobucket.com/albums/v295/chris-red/IMG_0380.jpg

https://img.photobucket.com/albums/v295/chris-red/IMG_0381.jpg

Cut wires and I'll not sure why.
https://img.photobucket.com/albums/v295/chris-red/IMG_0383.jpg

I like the slogan Laughing

https://img.photobucket.com/albums/v295/chris-red/IMG_0382.jpg
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

Raf · Spanner Monkey Joined: 18 Feb 2009 Karma :

Funny how matt always complains about my bikes being bodged..
So he finally sold it? Thought he was keeping it.
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CBR1100xx - BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125

reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

ditch the gay monster stickers for a start
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when the shit hits the fan make sure its facing the other way.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I thought that went without saying Laughing

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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

this thread makes me sad
make it out to me in your will

clue with the electric start. by the headstock you can see where the insulation has split on the switchgear, and sometimes the button works by moving the bars hard to the left. I assume that's where the broken wire is.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

ive got a standard endcan ? ive got loads of exc 400/450/525 bits tbh
____________________
when the shit hits the fan make sure its facing the other way.

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

it's got a stock system, i just also gave him a leovince system with it.
Yeah, fuck knows why that was cut off. I got it off a ktm guy i know.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I sneezed and this happened

https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/189945_10150111086678476_512803475_6308183_7732250_n.jpg

Trying to tackle a lot of the odd jobs that need doing.

The wiring is shite, countless wires just hacked off for no good reason, I found the starter circuit runs through the indicators for some reason. It was easy enough to find fix and problem with the starter. I also sorted out the horn which had had the wires removed form it and cut off. I really want to go through the loom and tidy it up hopefully I'll get round to that tomorrow.

The front brake calliper has the retaining pin sized, I tried everything apart from heat to try to get it out, it wouldn't budge, I'm keeping an eye out for a cheap second hand one an while considering my options I'm going to let a mate and my dad have a look first.

There is a brand new calliper on ebay, I was thinking of getting if I can get it for the right price, it comes with pads which would be a be bonus, and wouldn't need a rebuild which I would otherwise be doing on the current one and wouldn't need a new retaining pin.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

reggie · Spanner Monkey Joined: 22 Dec 2009 Karma :

Dzus fastener for the airbox, wut ? Question

Tank pad bung thing (plugs into the frame and the tanks sits on top of it.)

im gessing the little things just above the rocker cover ?
____________________
when the shit hits the fan make sure its facing the other way.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

quarter turn fasteners is what some people call them. make sure you get the right length though.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I got brand new caliper on ebay for about £80, expensive yes, but considering it comes with new pads and will not need new seals or a new retaining pin, plus I don't have to faf about getting the pin out. I think it is a good buy.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Right got a fair bit done today, fitted new kickstart, I have the bruises to show my ham fisted attempts of kicking it, it's easy when you work out the knack. Also fitted a new tyre it handles so much better. It's mostly back together now, I need a rear bulb I also need to find some screws I have miss placed there is a load of them I have put some where safe. Laughing

Only thing it needs now is a good service on the brakes. According to the KTM dealer the only way to buy the seals from KTM is if you buy a whole new calliper at a cost of £200, Fuck That.

After a bit of investigation and help from the KTM forum, I found that the 2003 calliper is the same part number and they list the seals on the fiche for it.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

what was wrong with the calliper? iirc, the pads had a fair bit of life left, and it stopped pretty well. Other than the horriffic squeal.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

The front has no life on the pads and the retaining pin is seized in. I managed to get a brand new one on ebay for cheap ish considering I needed new pads and a new pin and I would have replaced the seals so figured might as well. The rear is fine, but if I am going to bleed it through and I can get the seals cheap I might as well do a rebuild on them so the whole lot is totally refreshed.

I still don't think I have ridden it at full throttle yet, I got the back end doing a U turn, that put a massive smile on my face.

I bought a new airbox lid as it was in slightly better condition than mine but more importantly it has the 2 Dsuz fasteners with it, it got it for less than the cost of one fastener.

I am waiting on a friend of a friend who is welding the baffle tube to the end cap for the Leo Vince exhaust.

Hopefully with be getting muddy on saturday All the bike needs is a few nuts and bolts and a bulb.

I'm considering getting one of these.

https://www.trailtechproducts.co.uk/acatalog/Vapor_Stealth.html

Still waiting on...

Trail Tech Side Stand.
Misc nuts and bolts.
Fork seals
Spark plug
Stainless brake pin for the rear calliper.

A quick question about the clutch, It seems to 'kangaroo' sometimes when I'm trying to do slow speed stuff. I put this down to one of 3 things.

1. Problem with my technique, not sure though because clutch control and slow speed work is something I am really good at.
2. Clutch needs, Bleeding/Adjusting.
3. That's just the way it is, being the type of bike it is.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

Why did you order a stainless brake pin for the rear? It's got a quick release lever on it which (iirc) is an aftermarket replacement.

The plug was replaced about 2000 miles ago, so there's pretty much no need for that.

Other than that, the bike's fucking easy to step out on. I was getting about 3/4 of a small roundabout by the time I got around to selling it.

I never had any issues with the clutch though, it's probably the technique.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!! Mr. Green

Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Right latest update.

I went laning Saturday and Sunday, Saturday was great loads of fun, Sunday not so much.

I got stuck after about 10 minutes and had to push the bike out of this which wrecked me.

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/189512_10150118066868476_512803475_6368637_368534_n.jpg

More or less all the bits have arrived now,

[img]https://img.photobucket.com/albums/v295/chris-red/P1010242.jpg

Including,

Brand new calliper from Oz
https://img.photobucket.com/albums/v295/chris-red/P1010243.jpg
https://img.photobucket.com/albums/v295/chris-red/P1010245.jpg

The front is seized to shit this came up for a steal so rather than bugger about trying to drill the old one, I bought this.

Also received my Trail Tech stand.
https://img.photobucket.com/albums/v295/chris-red/P1010247.jpg

It was slightly more expensive than the KTM one but the guy at KTM said the factory ones were not that good. It fits well, and looks very well made but is a bit pricey at £90.

The bike has also now been de-monstered

https://img.photobucket.com/albums/v295/chris-red/P1010246.jpg

Anyone know what this is?
https://img.photobucket.com/albums/v295/chris-red/P1010248.jpg

It seems to be some kind of sensor (temp?) it was tucked behind the engine on top of the oil filters.

There was a bung missing from the Leo Vince exhaust I got with it, in response to a thread I made a very kind BCFer made me some at work(in a very cool job may I add), made me some using a weird and wonderful machine. I believe they wish to remain anon so I will honour that.

This is the process they used...
https://www.bbc.co.uk/blogs/daveharvey/2011/03/new_from_airbus_a_bike_to_tran.html

and here is the finished result.

https://img.photobucket.com/albums/v295/chris-red/P1010252.jpg

The rougher looking ones are the ones made for me they are rougher to the touch and slightly softer but for all intents and purposes the same. Now I am just waiting for the end cap to come back from a friend of a friend who is welding it to the baffle tube I bought.

The clutch 'Problem' does appear to be my technique the more I use it the less it happens.

Part of me really wanted to strip it to the frame and get it all powder coated but my head tells me this would be pointless as it will be getting battered. The only thing I am doing to 'tidy' it is replace rusty bolts as I go.

It is going in for a service this weekend, then after that the next updates will be attempting to fit Cagiva Mito wheels for it and sticky Road tyres.

Almost forgot, this should be coming in the next few days.

https://www.trailtechproducts.co.uk/acatalog/7500-R2250.jpg

I broke the front speedo sensor when I was stripping it down, a cost of a replacement is £30+ Evil or Very Mad

.

On the KTM forum they said this is essentially the same part for £4.

https://uk.farnell.com/hamlin/59070-2-t-02-a/sensor-plastic-barrel-m8-no-hv/dp/5540860.

Great I thought, oh shit, Minimum order £20, I contacted them and asked if they would let me just buy that sensor maybe with a surcharge, they said no but suggested I buy things like batteries from them to make up the £20.

I ordered some tape, some heat shrink and 3 sensors. I figured I could sell them on ebay and make a profit. Order goes through, then today I get 2 emails one saying the tape and heatshrink had been dispatched, the other saying the sensors would arrive in 3 months. Evil or Very Mad

I wrung them up to cancel so I have over priced tape and heat shrink I didn't really want in the first place.

I went to order them Sensor from KTM, but decided I would rather spend £85 and get a decent unit with tacho rather than spend £30+ on just making the shitty speedo work.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I don't think so it looks more like a temperature sensor

You can't see in the photo, but the end looks like this.

https://www.reuk.co.uk/shopImages/lm335z-temperature-sensor.jpg
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

CHR15 · Turbo nutter bastard Joined: 14 Jun 2008 Karma :

thats a transistor...

maybe its a diode?

they can have 3 legs.

does it have a clutch starter switch or side stand switch?

i'd be really interested if you could find out from your mysterious bcf'er what the machine was that made those things.

looks like spark erosion.. but on plastic Thinking

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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

From one of the PMs

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Best picture I could get.

https://img.photobucket.com/albums/v295/chris-red/P1010256.jpg
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.