Unusual Tools for the KTM

[Fizzer Thou]

Anybody who has ever owned a bike may well have lifted a spanner at some time so as to maintain their machine.At some time I knew that I would have to do more than the usual to the KTM,being a race bike as it is and the need for them to be fettled a little more than just another bike so as to keep it at its best

But the bike has its oddities,like the location of the rear shock absorber and the difficulty in adjusting the spring preload,without having to remove it

https://i360.photobucket.com/albums/oo49/akathewall/2007%20KTM%20200XC/IMG_1637.jpg~original

There is a spanner available from the USA,but I have always been of the opinion that,if someone else can make one,then so could I.

I have lost the pics of when I made the spanner,but it works perfectly.One day I will get around to having it black anodised

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150831_133753_zpsy2lwgqyu.jpg~original

But there are other components on the bike which are not a standard size,like the hex cap for the rear brake master cylinder.It measures about 21mm across the flats and in the past I have used what I had available at the time,namely an adjustable spanner.But with the softness of the cap material it was quite easily damaged.
When I looked around for a suitable spanner,there are some good quality tools around for lots of drinking vouchers.But for something that is only going to get occasional use I did not see the need to spend upwards of £20 just for one reasonable price tool.

So,having made the rear shock spanner,I decided to make a 21mm spanner.How hard could it be ???

So I started off with a 27mm nut and drew around the circumferance of that so as to get the right shape for a six point spanner,then cut the shape out for the template

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_160940_zpsylyv0t8i.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_160958_zps6sgftanv.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_161121_zpsfrcltnnf.jpg~original

As the hex cap does not need too much leverage to tighten it onto the master cylinder body,the handle does not need to be too long.
There is not much space between the cap and the master cylinder,so the outer circumferance of the ring spanner means that the 27mm A/F should be sufficient

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_162111_zps9fxwumfa.jpg~original

Next,the material.I have some ally plate of the right thickness.equal to the depth of the hex on the cap

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_162500_zpsvohgduso.jpg~original

I do not have any 'engineers blue' but a blue felt tip pen was sufficient before using the template to mark the outline of the tool

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_162629_zpsps45n8vv.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_164112_zps4uyi8rug.jpg~original

Having found an approximate centre I then drilled out the middle of the area to be machined out

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_164411_zpsqmjh6skd.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_164628_zpsotu24295.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_164803_zps7fkeh4p9.jpg~original

Then the tedious task of filing out the middle of the drilled area

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_165433_zpsbbsewehr.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_171721_zpsvhfuykmy.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150830_173937_zps2ko9qx45.jpg~original

Nearly there

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150831_133854_zpsvtizx82u.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150831_133914_zpsi6dba0ub.jpg~original
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[Fizzer Thou]

Had some time to finish off the tool.

Used a band saw to rough it out

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150901_140523_zpsd7ne8exu.jpg~original

Then filed it to shape before polishing it up

https://i1073.photobucket.com/albums/w384/Rhencullen5/KTM%20Tools/20150901_150636_zpsm9lbkflz.jpg~original

Fits and works perfectly
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'

[DrDonnyBrago]

Why did you have to make a 21 mm spanner?

[Matt B]

[Kickstart]

Hi

Irony is I picked up a 21mm Facom spanner cheaply when Halfords were having a clearance. A lot less than £20.

All the best

K
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[DrDonnyBrago]

Yes Matt, about 21 mm across the flats.

So....

Wouldn't a 21 mm, 13/16 (20.6 mm) imperial, Whitworth 7/16 (20.8 mm) fit?

Filing/grinding out a heated up pov spec spanner wouldn't have been overly arduous either.


OP - Please don't take my question as criticism.

[Matt B]

I get your point.

I've ground down cheap spanners to make them thinner for access and adapted stuff to fit. But sometimes it's nice to make something specific to do the job.
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[Suntan Sid]

A job well done and you get the added satisfaction of knowing you made it yourself!

I do have one question though, was there a particular reason you cut the spanner out from the very middle of the sheet?
Being a bit of a tight wad myself, I reckon I could have got 3 spanners out of that piece of alloy.
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[DrDonnyBrago]

[pompousporcup...]

[Fizzer Thou]

Thank you the comments everyone.The problem with the reservoir cap is that it is more like 20.6mm a/f and the 21mm 12 point spanner that I found in B&Q was not only a very loose fit but also a bit of a waste of money.Making my own spanner meant that it could be made specifically for that job and,being made to measure,will not take up more space than was necessary in the spanner drawer.

As for the amount of sheet material used,I have an abundance of ally sheet.That and it was easier to file out the inner part of the spanner by holding the sheet in the bench vice.

The usefulness of the spanner became all the more worthwhile when my fellow KTM enduro owning friends asked if they could borrow it.Maybe I should go into production during the many rainy Sundays
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'