Busy with cleaning and polishing all (my) things automotive today. Still had a little spare time to give this a shot of Ozempic. No idea how it will sound, but shouldn't be crazy loud. Hoping that now gutted, this will speed the flow a little.
Due to the "sparse" service history of the bike - a couple of MOT's and an oil change or two- I checked the KTM recommended servicing schedule. It appears that the bike requires the valve clearances and relevant adjustments every 9300 miles. Current mileage is 10,500. Looks to be a tricky job for an amateur hammer man, especially as the area to work in is fairly compact. I reflected on my spannering skill levels and achievements for a few moments... I quickly stopped dreaming & called my trusty bike mechanic to explain my predicament. He sighed and pointed out that all men, women, together with their dogs are clamoring on the blower -and frequently inside/outside his workshop- in order to get their bikes on the road for summer. I had nothing particularly persuasive to say in response, so chose to leave an awkward silence in our conversation which someone other than me would therefore have to fill. This is a good tactic which has worked for me previously with girlfriends, family, colleagues, bosses and assorted people buying bikes or cars from me. We then agreed that he would collect the bike today and complete the valve check during the next two weeks by fitting it in around other work. He also said he would MOT it too! A man in a van appeared an hour later and took it away. So a shame that it will be gone for a while which means all the other jobs will have to wait. But on balance it was the ideal result. The bike will be useless without an MOT & engine anyway. Besides, my AWOL KTM clutch parts won't arrive until Wednesday.
Yay the parts finally arrived! Getting OEM from KTM via Austria was a complete cluster fcuk. First attempt the order went west into the ether. Then the parts arrived -or at least some them- after a second mandatory 2 weeks wait, as thats how long OEM bits takes to arrive from KTM Europe. However KTM have no steel clutch plates available, they are on back order, there is no confirmed date blah blah… So I call around, and around, and around eventually finding some. After a few days the delivery arrives and theres no steel plates, just a set of friction plates and they’re the wrong ones. There appears to be a UK wide shortage of KTM steel plates for a 390. Still I’m happy ‘cause I speak with the guy at EBC direct who sells me a full kit for £138. Three days later I get an email saying that there has been a computer error, there are no kits actually available, they are on backorder, no confirmed date, blah blah - again! I request a refund. Then I find another crowd in Frome who are offering steel plate sets by a company called Newfren Italy. I buy them immediately as I have no other choice. Renewing the clutch When I bought the bike the clutch came separate -in a plastic bag. Unfortunately, I discover a bolt has been over-tightened in the inner clutch hub resulting in the bolt shearing. Happily I was able to drill it out with a modicum of swearing and no helicoil. I’ve never installed a clutch before, but my manual was pretty good and after looking at the diagrams, I pile in. Now KTM 390’s have two types of steel plates in their clutch (perhaps most bikes do?). The Newfren set only contains one type. At last my luck with parts is less bad as the totally fubared -blue and bowed- ones are the type they have sent, and I can reuse the originals of the other kind. It all goes back together with a bit of loctite and the special clutch tool - I've never seen one of them before! Quick insert of Motul, plus 3 sieves, rubber washers etc and all is well. I refill the coolant, wondering if this is the moment when I find out about a busted rad that needs replacing but its all fine. At this point I’m both excited and nervous. As the clutch was out when I bought this Meccano set, I’ve never heard it run. Will it run? What if I’ve bought a dud? First press of the button, the bike fires straight up. I have an exclamation symbol on the dash, but no EML. Phew! It sounds pretty good too. Now its very late so I resist the urge to rev it long & loud. But a big grin spreads across my face from ear to ear. Suddenly all the frustration of waiting for parts for the last few weeks is gone and I’m back in the game.
The bike had an aftermarket tail tidy -a tatty & crooked thing which had seen better days. A total barstardo to remove, as three of the four allen bolts had semi seized in place. Unrepeatable muttering and cursing for some time turned the air blue in my little wooden "workshop", but eventually it came off and straight onto the bin. I replaced it with the OEM weird/ ugly one that came in a box with the bike. Lets face it, this is a quirky looking machine and a zen origami miniature tail piece is somewhat incongruous. The original long stalk thing looks far more in keeping with the overall look methinks. Plus it positions the reg plate to dramatically reduce the amount of wet road dirt I’d otherwise be wearing all over my back! Once the reg plate was drilled and in place, remounting the tail section and rear light followed. The light has somehow lost one of its locator tabs but a little strip of aluminium, a couple of blobs of epoxy putty, together with some black silicone (to stop vibration) sorted that out nicely. I then switched out the front brake master & lever as it was all scuffed up from someone else's misfortune. Bled the brake, added a small top up to the rear reservoir and as the pads are fine, thats the braking all serviced. Next I mixed up a little of the black plastic filler and used it to repair some scrapes on the righthand switch surround and the edge of the speedo. Once the repair was done, a little finishing with 2000 wet & dry, plus a small amount of polish and damage is almost invisible. Result!
A tail tidy is all well and good but if you ride in marginal conditions and not just heatwaves it’s an essential. Nice that you’re tidying up the 390, but can we have some pictures.
Yes here it is. Works really well. If you can’t find any around your neck of the woods let me know and I’ll send you a can.
Got up this morning and decided it was time to take it on a test ride. A quick buzz around the neighborhood to see how the little thing actually performs. Time to see if my efforts are actually making the bike ride better as well as look better! I must say I'm really pleased. Its every bit as agile as I hoped. Turns on a proverbial dime and as its so light making direction changes just happen. The engine is fast revving and not lacking when riding around at all. Now I was just doing legal speeds on a shakedown fun relaxed ride, but tbh thats all I intend to use the bike for. Gears were all fine, you do have to run up and down them a fair bit, but thats to be expected really with a low cc bike. No false neutrals either. Though the clutch definitely needs a bit of adjustment -just can't get good mechanics these days! It has a very comfortable riding position, relaxed and simple. The suspension seems fairly stiff which was a surprise and its not adjustable. If I still think its hard after a few more rides, I might switch the rear shock. The bike came with an "KTM Ergo comfort seat". I can't imagine how hard the standard one must be if this plush option LOL! I also have the OEM so I will switch it over and see. I think I've discovered what the odd cable and connector that I have left over is for. The bike won't start unless its in neutral even with the clutch in, so I will have to find out where that fits into the wiring loom. I haven't been able to remount the front tank fairing pieces as there' none of the rubber fittings and very few of the crews & u nuts. KTM want £93.80 plus VAT and you guessed it, back ordered until at least July. eBay have a full fairing fixing kit for £21 via China - its ordered! The short ride out turned into a run up the Cat & Fiddle, into Buxton and back via Leek. A quick eighty miles and all is well. Time to go and t.cut the petrol tank and meddle with a few other bits...
Next up is the Rapid Bike Evo piggy back. Its a little gizmo which smooths out the fueling. The ECU on these bikes allegedly cannot be remapped. Maybe thats something to do with the A2 rules? The bikes leave the factory already tuned with a lean fuel set up and the Euro emissions rules prevent the ECU adding extra fuel to meet Euro emission regs. If you then add a lot more air, you may run in engine problems. This box sits in between the sensors & the ECU and re-calibrates the readings to trick the ECU. Meaning that most fueling/airbox mods can be done without the risk of running the engine too lean. I had to remove the tank to access the wiring but the Indian manufacturer has done a great job of making the install itself easy. The connectors are all compliant with the stock KTM wiring, so it's literally a plug and play and took maybe 20-30 mins in total. It sits nicely in the tail piece under the pillion seat. There's no EML lights on the TFT so I haven't cocked it up. There's no change in how the bike runs -which there shouldn't be- so another good sign! Ideally I will never notice any differences now when I make (minor) changes to the air intake & exhaust.
Thanks Chris. There's still a lot more to do to the little bugger though. None of it really makes any sense but the changes are relatively cheap to make and I'm having fun fettling it. Riding it is a blast. I'm definitely in my Chapman period; "simplify, then add lightness".
Riding today in the sunshine was more important than meddling. Though I did cut the tank some more and added the air box mod! I thought the filter expensive at £52, but since I won't ever need to buy another its OK.
Pulled off most of the manky exhaust and gave it a good clean up. The brown heat discoloration I don’t mind. Its the burnt on road crap and slight surface corrosion -thats got to go! The finish on these exhausts is similar to a sand cast, so with the brass wire wheel on the buffer/ grinder it was quick & easy. That buffer is one of the best (and cheapest, most used, time saving) tools I’ve ever bought! I didn’t want the faff of removing the header/down pipe as it requires the rad removing to access the studs and they are likely to be rusted solid. That can be a job to look forward to this autumn. I cleaned this part in situ using emery tape wrapped around once and pulling on alternate ends. Simple and quick. I also put on the £30 "replica Akra". The OEM has road scars and a few mashed rivet heads where someone has attempted to mod it? I will sort out now its off. My faux end can isn't super loud, its the same as the standard one, I measured the db using the Apple communicator. None of the deep thrumming, rumbling of a Ducati though -thats for sure! More of a brap sound like a dirt bike. It’ll do. Barstardo springs were a right pain. Is there a special pair of pliers or something similar that stretches the springs easily? There's no way everyone buggers about with a small screwdriver levering the things then looking for them again on the floor -like I did!
I just use me fingers or a screwdriver if it's a stubborn spring. But yes you do try and struggle on with a screwdriver or try a hook pick tool you have in the only to see it succumb to the strength of the spring.
Managed to steal a little time out of my busy schedule to empty another box from the hallway. I've added a screen. Not too sure about this. TBH, I only got one because I was mindlessly scrolling through Ali Express just after I bought the bike and had a momentary loss of reasoning. I can remember wondering back in the day why all the ol’ boys had them on their Honda 90’s -my mates and I thought maybe they used them as a sail to go faster. But times change. I’ve seen so many of you guys fitting them to Adventure bikes so its time to give it a try... It doesn’t look too bad. So we’ll see how it is out & about. I could get used it? Though I’m still not totally OK with having grandad (Saga) insurance, so the screen will have to earn its keep or it’ll be on eBay. LOL.
