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 project 990

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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/15/2010, 9:02 pm

so far i have put on a 2 into 1 exhaust, to make room for the neduro 2.2 gal aux fuel tank, and lighten the bike by 17lbs. a real skid plate by black dog cycle works, and some 1 1/2 longer footpeg extensions, with a hole lot more mods to do before my next trip to prudoe bay in july. i think these pegs are gonna be a great addition for me, because i wear a size 14 boot most stock pegs fit my big toe an that's about it. the ktm pegs are harder than the hubs of hell, so if any body ever tries to drill these babies, take your time turn bit slow, an use lots of cutting oil.
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griz901

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Posts : 931
Join date : 2009-02-20
Age : 52
Bike : Honda XR650R

PostSubject: Re: project 990   2/15/2010, 9:26 pm

Is it just me or is adv rider a launching pad for new products or what!? I seem to remember seeing that auxiliary tank on someone's ride a couple years ago and now they are selling them en masse.

Have to admit, going orange sure has it's perks when it comes to top shelf farkles!

Keep the project posts coming! I've still got some winter left to get rid of
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/17/2010, 6:41 pm

the next farkle was to be a side stand brace for the 990, for some stupid ass reason ktm bolts the kickstand directly to the engine case. they are known to break the bosses out of the case, so i called kirt at black dog cycle works an he sent me a kit that braces the case, it catches 2 more bolts that are actually frame bolts so it has 5 points of hold instead of 3. put it on last night, while snugging the last bolt i noticed a spacer was to short allowing the brace to rub on an oil line. [this is not good] so called kirt today for some info an he said this had never been an issue. [of course i'm the only one in history to have this problem] i purchased it around christmas , and he now has a new and improved version that moves the stand so it is completely attached to the frame and not at all to the engine case, like it should be. kirt offered to send me the new one and take back the old one, which i thought was mighty white of him. [ nice guy ] so when the new an improved model gets here i will have some pics. maybe have my new evolution clutch slave cylinder mounted and bleed later tonight. well maybe.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/19/2010, 8:12 pm

so the side stand saga continues, was supposed to have the side stand fix of all side stand fixes today buuut , kirt called me last night to tell me that after waiting 2 months for the part he tryed to put one on his 950 and it doesn't fit!! so i decided to make what i had work until he gets the other part figured out. while at work today i machined out a new spacer the correct length so it won't touch the oil line. reinstalled brace and new spacer and now there is ample clearence for oil line. then i noticed the top of bracket was touching the bottom of the crank case, bearly, but touching just the same sooo take it back off and do a bit of grinding for some clearence and put back on it fits at last. so now it's
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/25/2010, 9:18 pm

well finally after damn near 3 hours i'm finally down to the motor. i have said it before, an i'll say it again, the 990 is an absolute blast to ride, however working on it is a no good dirty rotton . well any way here she is buckass naked
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/25/2010, 9:32 pm

the parts to be installed: new fuel filter, ignition curve switch which allows me to switch the ignition curve for low octane fuel with out removing the seat and unplugging the wires. i always run the good stuff when i can get it. alot of places on the way to prudoe only have 2 choices of fuel, the lowest of low octane regular or diesel. clutch slave cylinder, sas block off kit which goes with the special plugs and resistors. this is all to fool the ecu. so that it still thinks i have the catelatic converters, smog pumps and various other emmision things i have taken off, and would like to shuv up al gores ass!!! an take a look at that fuel filter kit in the clear plastic bag, that better be the filter of all filters for a $120.00.
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big jer

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Bike : XR650L , 990KTM

PostSubject: project 990   2/25/2010, 9:37 pm

the parts pile that is required to be removed before any work is to be done
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TheFlying"W"

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Join date : 2009-05-19
Bike : '03 WR450F, 2009 Vmax

PostSubject: Re: project 990   2/26/2010, 7:23 am

I firmly believe it is half the reason we buy our toys, so we can take them apart and "work" on them. I have a couple projects scheduled for my WR in the coming week myself. Keep up the good work Jer. Looks good!
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griz901

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Join date : 2009-02-20
Age : 52
Bike : Honda XR650R

PostSubject: Re: project 990   2/27/2010, 8:45 pm

TheFlying"W" wrote:
I firmly believe it is half the reason we buy our toys, so we can take them apart and "work" on them. I have a couple projects scheduled for my WR in the coming week myself. Keep up the good work Jer. Looks good!

+1

Aint that the truth!

Do you have a pre-planned route to AK, Jer?
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/27/2010, 11:39 pm

WORK!!!! when you work on a 990 ktm that is exactley what it is!! WORK, which is just one of the many 4 lettered words i have used tonight. i got the smog pumps removed and the sas [ sorry ass sonsabithes] plates on. now all i have to do is solder in some 22k ohm resisters in to the factory plugs, well and put the throttle bodies, the air box, 2 fuel tanks, faring,seat, an a hole bunch of other stuff. shit!! i got alot of WORK to do tomorrow. maybe i'll take the brp. out for a spin tomorrow afternoon an lower my blood pressure a bit. an after i get the 990 back together, i sure hope it starts. well griz, we know where we want to go but how were gonna get there we aren't for sure yet. when my mechanically declined cousin an i get together for a trip the planning is usually done on the way. it's way more of an adventure that way.
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griz901

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Join date : 2009-02-20
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Bike : Honda XR650R

PostSubject: Re: project 990   2/28/2010, 7:33 am

big jer wrote:
well griz, we know where we want to go but how were gonna get there we aren't for sure yet. when my mechanically declined cousin an i get together for a trip the planning is usually done on the way. it's way more of an adventure that way.

Nice - hope you get out for a little bit today on the , sounds like you need a little to offset the orange koolaid work

griz
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TheFlying"W"

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Join date : 2009-05-19
Bike : '03 WR450F, 2009 Vmax

PostSubject: Re: project 990   2/28/2010, 4:10 pm

Speaking of your mechanically declined cousin, how is he doing after his get-off? Hope he is healing well.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/28/2010, 4:21 pm

mechanically declined cousin got all 21 stitches removed, he is healing up pretty good, he says it's still a bit tender but he's a woose an i think he is trying to milk the wound for all it's worth.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/28/2010, 4:31 pm

here is most of the stuff removed from the 990, it doesn't look like much but it sure made for alot more room around the engine
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   2/28/2010, 4:47 pm

this little sas block off plate was a real pain in the . the lower bolt that holds it on was just long enough that it ran in to an oil line just before it was fully unthreaded. once i got it out i instantly dropped the bolt in to the deep dark bowels of the 990. with the help of a magnet an some praying i found it an retrived it from the bowels of the beast. after repeated attempts to get the bolt back in, and failing miserably every time , i was not going to let it beat me so i got a screw driver in by the oil line an pried it out just a bit an finally got it started. that is one of my fat fingres pointing to the dreaded plate. the one on the rear cylinder is very easy to do
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   3/7/2010, 5:50 pm

finally, project 990 is finished. well almost, need to do an oil change and new chain an sprockets, but i think i'll put 4 or 500 miles on it before i tear it back down for a service, an inspect my work. the beast fired right up, and then promply died i thought maybe air in fuel system after changing filter, so i turned key on an off a couple times, which cycles the fuel pump, and hit the go button again an it took off an never missed a beat. i was a bit concerned with all the wiring i had to deal with for the fuel ingection, as i am color blind so tracing the proper wires is sometimes a tough deal for me. after all the cussing, swearing , bloody nuckles, late nights oh an lets not forget the $$$$ it took, after going for a short ride it all came back to me why i have this bike, DAMN is it fun to ride!!!
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griz901

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Join date : 2009-02-20
Age : 52
Bike : Honda XR650R

PostSubject: Re: project 990   3/7/2010, 6:28 pm

Nice

Amazing what a quick spin around the block can do for a person's mental stability
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: project 990   4/8/2010, 7:42 pm

the 2.2 gallon tanks for cuz'es an my 990 have arrived!!!! an also got the new an improved side stand brace from blackdog cycle works, now to find a little time to install all this . i will post pics of the install.
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griz901

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Bike : Honda XR650R

PostSubject: Re: project 990   4/10/2010, 8:46 am

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big jer

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Join date : 2009-08-13
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Bike : XR650L , 990KTM

PostSubject: Re: project 990   4/11/2010, 7:28 pm

got the tank mounted , the fit could have been a bit better. had to do some grinding on some things so everything fit fairly free and was not under alot of tension.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: Re: project 990   4/11/2010, 7:32 pm

the fill spot is a bit un-handy, but it works.
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griz901

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Bike : Honda XR650R

PostSubject: Re: project 990   4/11/2010, 8:16 pm

So what kind of range does that give you?
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big jer

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Age : 49
Bike : XR650L , 990KTM

PostSubject: Re: project 990   4/12/2010, 8:55 pm

well, if i can be gentle on the throttle i should get about 280 miles. my mpg has a wide range. worst i ever got was 36, best was 49, so i usually get some where between 42 an 44. total amount is 7.3 gallons, but don't know how much i can suck out of the tanks. have heard if you point it down hill an lean to the left an let right tank drain to the left tank, an then shut the right tank off there is quite a bit of fuel that can be gotten. just a soon not have to test that trick. here is a teaser pic of the rack i'm working on for the mighty 990.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: Re: project 990   4/12/2010, 9:05 pm

this is what i'm gonna mount, the 2 soft bags on the side i use on the the top flat case is off of my snowmobile, the rack is going on the top of the trunk to hold everything. [ i hope ] should give me a lot of storage.
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big jer

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Posts : 539
Join date : 2009-08-13
Age : 49
Bike : XR650L , 990KTM

PostSubject: Re: project 990   4/12/2010, 9:10 pm

one more teaser pic for griz.
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