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union 03-31-2014 12:29 AM

Supermoto Rebuild
 
Bare with me for a bit. This is a compilation of what Ive done this winter. It might take a few tries and posts to get it working here.

KTM Breakdown - YouTube



union 03-31-2014 12:30 AM

I apologize for some of the poor quality but I only have a cellphone to take shots with and Ive been banned from buying anything before Christmas.

Today was shock and swingarm day.

Quick overview of a shock service

So here it is. WP Shock out of my SMR

http://i28.photobucket.com/albums/c2...ps427a9c32.jpg

Before any work is done to the shock all its current settings are documented.

http://i28.photobucket.com/albums/c2...ps12e3adc0.jpg

http://i28.photobucket.com/albums/c2...psda3a11fe.jpg

I did the compression as well but its a bit of a pain to take photos and work on the shock at the same time.

The spring is the first thing to come off

http://i28.photobucket.com/albums/c2...ps56c22676.jpg

http://i28.photobucket.com/albums/c2...psf940ab28.jpg

Next before any actual shock disassembly happens the nitrogen pressure is released.

http://i28.photobucket.com/albums/c2...ps793ce361.jpg

Now the shock is ready to get opened up

http://i28.photobucket.com/albums/c2...ps1ac6cca0.jpg

http://i28.photobucket.com/albums/c2...ps8f3d6375.jpg

http://i28.photobucket.com/albums/c2...psa3017064.jpg

Shock shaft comes out

http://i28.photobucket.com/albums/c2...psfd885ad0.jpg

http://i28.photobucket.com/albums/c2...ps160b1ead.jpg

Now the oil in the shock body can be dumped.

Loosen the nitrogen chamber but dont take it off unless youre over a oil sink or youll get oil on the floor.

http://i28.photobucket.com/albums/c2...ps348b1c26.jpg

Tip the shock so the open end of the shock body is facing down and then remove the nitrogen chamber.

Youll end up with something like this

Shock body

http://i28.photobucket.com/albums/c2...psff6bea27.jpg

Nitrogen chamber with the dividing piston

http://i28.photobucket.com/albums/c2...ps9c99734a.jpg

Wash cycle time

http://i28.photobucket.com/albums/c2...ps670ad8f5.jpg

Rinse and drying cycle

http://i28.photobucket.com/albums/c2...ps44444f25.jpg

Now its time to reassemble

Lay out the parts to make sure you have everything and inspect the pieces to make sure nothing is broken or needs replacement.

http://i28.photobucket.com/albums/c2...ps32fb360b.jpg

A little grease on the oring of the diving piston to help it move inside the nitrogen chamber

http://i28.photobucket.com/albums/c2...ps2a1af3df.jpg

http://i28.photobucket.com/albums/c2...ps6ccbefc1.jpg

Push the piston to the other end of the chamber and fill with oil

http://i28.photobucket.com/albums/c2...psfb0207ce.jpg

A little grease on the threads of the shock body where the nitrogen chamber goes.

http://i28.photobucket.com/albums/c2...psc4f9a183.jpg

Tip the shock so the nitrogen body can be threaded on without spilling oil out of it

http://i28.photobucket.com/albums/c2...ps1f7627ca.jpg

WP shocks require a special tool to pressurize them.

http://i28.photobucket.com/albums/c2...ps57bc2e3e.jpg

Pressurize the shock to force the oil out of the nitrogen chamber and into the shock body.

http://i28.photobucket.com/albums/c2...ps05110539.jpg

Bleed out the valving. A note about WP. Thread on the spring perch before inserting the shock shaft or youll have to bleed it over. The perch doesnt fit over the the mount at the clevis. Dont ask me how I know:)

http://i28.photobucket.com/albums/c2...ps8ccc3128.jpg

Slowly release the pressure while pushing the seal down and into the shock body. Insert the snap ring that holds the seal in place and re-pressurize. Make sure the shock is functioning properly and then put the cap on.

http://i28.photobucket.com/albums/c2...ps398e4cf6.jpg

A little never seize where the perch will end up when the spring is set to the right preload.

http://i28.photobucket.com/albums/c2...psa5853229.jpg

Return the shock spring and clickers to their settings and youre all done :)

http://i28.photobucket.com/albums/c2...ps3a0f1763.jpg

http://i28.photobucket.com/albums/c2...ps20007b80.jpg

union 03-31-2014 12:33 AM

Swingarm time

This is pretty straight forward. Pretty much just pulling everything off the swingarm, cleaning it, greasing the bearings and putting it back together.

Here it is in all its glory

http://i28.photobucket.com/albums/c2...ps296c6b93.jpg

Everything off with the link

http://i28.photobucket.com/albums/c2...ps65084623.jpg

It didnt show well but luckily KTM used captured need bearings in most spots. The smaller of the three was not a captured bearing so it required special attention so the needles were not lost in the cleaning process.

http://i28.photobucket.com/albums/c2...ps283ccbc4.jpg

In the sink and ready to get cleaned

http://i28.photobucket.com/albums/c2...psa58901ee.jpg

Getting greased

http://i28.photobucket.com/albums/c2...ps8ae30d6b.jpg

http://i28.photobucket.com/albums/c2...psbd64955e.jpg

http://i28.photobucket.com/albums/c2...psa25fdaa1.jpg

A little never seize on the chain adjustment bolts

http://i28.photobucket.com/albums/c2...ps0dd18bba.jpg

Reinstalling the link and plastic parts

http://i28.photobucket.com/albums/c2...psa96747c4.jpg

Swingarm complete

http://i28.photobucket.com/albums/c2...psc8b58676.jpg

union 03-31-2014 12:34 AM

Did the front end this weekend. Took as many photos as I could but its a bit of a pain considering some of the steps come close to requiring three hands.

Here we go

Front end off the bike from the previous break down

http://i28.photobucket.com/albums/c2...ps4f5a221c.jpg

http://i28.photobucket.com/albums/c2...ps3674cb94.jpg

You should have taken a ride height measurement before this point but if you didnt this is your last chance to get the reference measurement so you can return the bike back to the geometry it had.

http://i28.photobucket.com/albums/c2...ps15cc0d59.jpg

http://i28.photobucket.com/albums/c2...ps3fbbf5e9.jpg

Forks on the bench and ready for a service

http://i28.photobucket.com/albums/c2...ps12c4ac0c.jpg

Document the settings

http://i28.photobucket.com/albums/c2...ps138a78f8.jpg

http://i28.photobucket.com/albums/c2...ps87d2c3b6.jpg

These forks have a pressurized bladder similar to a shock

http://i28.photobucket.com/albums/c2...ps78648d76.jpg

These are twin chamber forks so loosen the inner chamber but dont completely back it out before taking the cartridge out

http://i28.photobucket.com/albums/c2...ps7098f6d7.jpg

Now for the outer chamber.

http://i28.photobucket.com/albums/c2...psc5c9eeec.jpg

You should now be able to slide the outer tube down
http://i28.photobucket.com/albums/c2...psc9e2a05a.jpg

Now back out the the lower bolt

http://i28.photobucket.com/albums/c2...ps6fedb508.jpg

Now youll have to compress the spring so the metering rod sticks through the lower end of the fork and use the cartridge holding tool to hold it in place.

http://i28.photobucket.com/albums/c2...ps1d68ad89.jpg

http://i28.photobucket.com/albums/c2...ps37d2a0ca.jpg

Now compress the spring and pull out the tool. Be careful here because if you slip it could fire the cartridge out of the top of the fork.

One free cartridge

http://i28.photobucket.com/albums/c2...ps0381ac33.jpg

Now remove the dust seal and snap ring for the oil seal.

http://i28.photobucket.com/albums/c2...psbb38db21.jpg

You should now be able to slide hammer the forks apart

http://i28.photobucket.com/albums/c2...ps85dc0a63.jpg

On to the cartridge.

If you loosened the inner chamber before removing the cartridge from the fork then this come apart easy.

Remove the compression valving

http://i28.photobucket.com/albums/c2...ps7b800847.jpg

Time to go to the wash tank

http://i28.photobucket.com/albums/c2...ps573c9ed8.jpg

Clean and ready for inspection

http://i28.photobucket.com/albums/c2...ps3b30f7e7.jpg

Reassembly time

Lay everything out to be sure you have it all. Forks generally have pairs of everything

http://i28.photobucket.com/albums/c2...psdf263b47.jpg

Cartridge assembly.

Put the rebound valving back into the chamber

http://i28.photobucket.com/albums/c2...ps9405b3b0.jpg
http://i28.photobucket.com/albums/c2...ps172b7455.jpg

Fill with oil and bleed

http://i28.photobucket.com/albums/c2...psecc39910.jpg

Install the compression valving and pressurize

http://i28.photobucket.com/albums/c2...ps6872bbe0.jpg

http://i28.photobucket.com/albums/c2...ps25c674c8.jpg

When done your cartridge should look like this

http://i28.photobucket.com/albums/c2...psaaa9c535.jpg

On to the outer tubes

http://i28.photobucket.com/albums/c2...psec58434d.jpg

Some seal grease

http://i28.photobucket.com/albums/c2...ps86c16547.jpg

Inner tube ready for new seals

http://i28.photobucket.com/albums/c2...ps118c091b.jpg

O-ring for a travel indicator

http://i28.photobucket.com/albums/c2...ps8d4480c5.jpg

Time for seals and bushings

http://i28.photobucket.com/albums/c2...ps0abe5211.jpg

http://i28.photobucket.com/albums/c2...ps1fd1a3c7.jpg

A little grease in the outer tube to help the bushings and seals slide into place

http://i28.photobucket.com/albums/c2...ps50c95ec2.jpg

Drive the seals in using a seal driver and a soft faced hammer

http://i28.photobucket.com/albums/c2...pscccf90c5.jpg

Ready to go

http://i28.photobucket.com/albums/c2...ps87e0f183.jpg

Assembly is pretty much the opposite what was done to disassemble

http://i28.photobucket.com/albums/c2...ps647ee73c.jpg

http://i28.photobucket.com/albums/c2...ps292704e6.jpg

http://i28.photobucket.com/albums/c2...ps552a537d.jpg

http://i28.photobucket.com/albums/c2...ps057672c9.jpg

Now put a specified amount of oil in the outer chamber

http://i28.photobucket.com/albums/c2...ps488d5149.jpg

Close the tube and set the clickers

http://i28.photobucket.com/albums/c2...psa833c7c7.jpg

union 03-31-2014 12:35 AM

Today was one of my least favorite things to work on.

Brakes.

The caliper didnt need a rebuild but I wanted to change over the fluid.

Sounds easy enough but look closely at the caliper

http://i28.photobucket.com/albums/c2...psb4ddeb3f.jpg

There is no bleeder. I cant do a banjo bleeder either because of clearance issues.

So the hose comes off.

http://i28.photobucket.com/albums/c2...ps7253c7a8.jpg

Time to push the pucks back in to get as much fluid out as you can.

http://i28.photobucket.com/albums/c2...psd937a667.jpg

Cycle it through a few times and then let any left over drain out

http://i28.photobucket.com/albums/c2...pse6a31957.jpg

Time to clean up the caliper

http://i28.photobucket.com/albums/c2...psc6cbe4a7.jpg

No photo but you can also blow all the remaining fluid out of the master and brake line.

Now for the bitch of the system. Refilling the caliper.

With the brake pads installed blow air into the caliper to extend the pucks.

http://i28.photobucket.com/albums/c2...ps54e2a02d.jpg

I dont have a vacuum bleeder or any other fancy brake tools so this takes a bit of time a patients. I do have an idea for next time that should make it easier

http://i28.photobucket.com/albums/c2...psd49c0c23.jpg

Now with the caliper full or close to full of new fluid reattach the brake hose and master.

http://i28.photobucket.com/albums/c2...ps7e44fbaa.jpg

Push the pucks in to force the fluid back up through the line and into the master cylinder.

http://i28.photobucket.com/albums/c2...psfd74ab11.jpg

If all has gone right then all that should be needed is a final bleed when the system is back on the bike. For me this will happen some time in March.

union 03-31-2014 12:39 AM

Not a lot to show but the motor has been dropped off to the builder today.

http://i28.photobucket.com/albums/c2...ps78f6cae3.jpg

The plan is a high compression piston and a lightened and balanced crank. The head was in the plan as well but I dont have the money for it this year so its going to have to wait until next time. Ive asked my guy to take photos of the progress so hopefully Ill have some good stuff to share.

My engine builder sent me some photos of the progress.

http://i28.photobucket.com/albums/c2...ps0deae89f.jpg

http://i28.photobucket.com/albums/c2...ps90cecdf4.jpg

http://i28.photobucket.com/albums/c2...ps8ff3a9be.jpg

http://i28.photobucket.com/albums/c2...ps8b9de043.jpg

Anyway here is the redone crank.

http://i28.photobucket.com/albums/c2...pseab62aa0.jpg

http://i28.photobucket.com/albums/c2...ps4c12832c.jpg

A couple more engine shots were sent to me today. Should be picking it up this weekend.

http://i28.photobucket.com/albums/c2...psdc759906.jpg

http://i28.photobucket.com/albums/c2...ps8181ac7e.jpg

More engine. Im putting these up as I get them.

Nice slipper shot

http://i28.photobucket.com/albums/c2...pse03d1b48.jpg

Cylinder

http://i28.photobucket.com/albums/c2...ps85fc6554.jpg

New high compression piston

http://i28.photobucket.com/albums/c2...psf9d6c413.jpg

Engine is finished. Here is the final round of photos.

http://i28.photobucket.com/albums/c2...ps871ce002.jpg

http://i28.photobucket.com/albums/c2...ps9f068297.jpg

http://i28.photobucket.com/albums/c2...ps7e412691.jpg

http://i28.photobucket.com/albums/c2...pse599402d.jpg

union 03-31-2014 12:41 AM

So here I am. Busted up ankle and the beginning of the season in jeopardy depending on what the Dr says between today and tomorrow. I figure theres something I can do. When I ordered my brake pads they sent along a sanding block to scuff up the rotors. Its not something Ive done in the past and didnt consider it until they sent the block with the pads. So today I go at it.

With the help of Brady this time

http://i28.photobucket.com/albums/c2...ps5a85b38c.jpg

http://i28.photobucket.com/albums/c2...psadeffcc7.jpg


Its a bit unsettling when you realize what really stops these bikes. Most people think its the giant rotor but that is just a heat sink. its the six little 6mm bolts with a dab of loctite that are the stopping power.

Picked up my secret weapon yesterday :D

Its amazing well probably not but how difficult it is to launch a bike at my staggering height of 5'6. Its only made more difficult in motocross style boots since they restrict freedom of movement a lot more then standard road race boots. Currently I have to find the lowest point on the seat just to get a toe to scrape the ground. Im sure its pretty pathetic looking, even mroe so that a lot of the guys I race against can flatfoot at the grid.

New lower seat:) Its about 1/2 inch lower then the stock seat. Hopefully it makes launching the bike a bit easier

http://i28.photobucket.com/albums/c2...ps66595340.jpg

Comparison of both.

http://i28.photobucket.com/albums/c2...pse837c989.jpg

My next options if this doesnt do the trick is to ride on the seat pan or as suggested by my friend take the seat off and wrap a blanket around the subframe :)

union 03-31-2014 12:42 AM

Picked up the motor this morning and got to work when I got back to the shop.

http://i28.photobucket.com/albums/c2...ps4093605d.jpg]

http://i28.photobucket.com/albums/c2...ps9332498a.jpg

DIdnt finish it because I didnt have my bar risers. They were with my machinist. Luckily he sent them to me and they were waiting for me when I got home. Bars on tomorrow and hopefully Ill have some fuel for it by the end of the week and Ill be able to fire it up.

union 03-31-2014 12:44 AM

Fired it up today

Heat cycle smr - YouTube

union 03-31-2014 12:47 AM


TLRSKUNK 03-31-2014 03:06 PM

Hot damn SMR porn.

Buddy just built a sick 2013 SMR. Had the suspension lowered an inch when he had it built as well.


Now what offset are you running on the triples and what are they costing you to get cut?

I had 12mm triples on my 560 and the swingarm notched to shorten it an inch Thing turned on a dime.

union 03-31-2014 05:15 PM

Quote:

Originally Posted by TLRSKUNK (Post 909994)
Hot damn SMR porn.

Buddy just built a sick 2013 SMR. Had the suspension lowered an inch when he had it built as well.


Now what offset are you running on the triples and what are they costing you to get cut?

I had 12mm triples on my 560 and the swingarm notched to shorten it an inch Thing turned on a dime.

Factory SMRs come with the suspension already lowered a bit. Not interested in lowering it anymore. It affects the geometry too much and with an already flat swingarm angle getting flatter the rear grip would only get worse.

The clamps this year will be adjustable between 4 and 6mm. I also have a set from last year that are 5-7mm and the stock clamps are 14-16mm. I'll have options depending on where I go.

Last year in the original build we put the swingarm in the bridgeport and slotted out the axle guide by about 10mm.

http://i28.photobucket.com/albums/c2...psa977764f.jpg

http://i28.photobucket.com/albums/c2...ps041f12f7.jpg

http://i28.photobucket.com/albums/c2...ps4f587954.jpg

TLRSKUNK 03-31-2014 09:56 PM

That's what was done to mine. Only thing I hated about it was the fact that it really made the chain a PITA to adjust.

and I know the SMR is already lower. Dave Behrand at FBI did his suspension build(as well as my 560SMR)

what did a set of triples cost you?

union 04-01-2014 05:13 AM

I get a break because he sponsors me but a custom one off upper and lower to your specs with no stem would run around 700.

TLRSKUNK 04-01-2014 02:44 PM

That really isn't a bad price for a set of triples cut to your spec.

union 04-01-2014 05:01 PM

Quote:

Originally Posted by TLRSKUNK (Post 910282)
That really isn't a bad price for a set of triples cut to your spec.

Its a really good price. A lot of people don't realize the work put into the clamp before it gets cut. We used to have our own line of clamps and the price break would be around 5 sets and then again at 10 sets. 1 set at a time isn't really worth it for the machinist.

I found out about 1/2hour ago that they were delivered to the shop. I'll get a few photos and toss it up when I get home tonight.

TLRSKUNK 04-01-2014 05:40 PM

Awesome.
and I agree one off machine work is more hassle then it's worth and that's why most guys won't even mess with it. every one wants cheap stuff and doesn't want to pay for time.

AKDMA 04-01-2014 06:09 PM

Nice! I finally just got another one myself (WR426). I'm tempted to just leave it alone, but seeing this makes me wonder what it could be.

union 04-02-2014 04:55 AM

Final part got delivered today. The photos don't do these justice. The detail work is awesome. I can't thank Mike at Diamondback Designs enough.

http://i28.photobucket.com/albums/c2...psd503a165.jpg

http://i28.photobucket.com/albums/c2...pse3ff82f7.jpg

http://i28.photobucket.com/albums/c2...psed4edceb.jpg

http://i28.photobucket.com/albums/c2...ps89c1dde8.jpg

G2G 04-02-2014 07:17 PM

I saw the pics of the triples on his FB page and knew they had to be yours. Looking good dude.;)


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