Commuters Motorcycle Club

Your bike, your style! - Tell us about you and your bike in here! => Blog it! => Topic started by: CoxyLaad on 08:58 - 28 September, 2018

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:58 - 28 September, 2018
Split from here: http://dashack.co.uk/go/index.php/topic,10116.msg207080.html#msg207080

As of 12pm today I am heading off for a 3 day tour of Scotland on the mighty TDM.

At some point in the proceedings it will tick over 100,000 miles on the clock.  I am hoping the left most digit on the led screen is a knackered and it effectively resets itself to zero miles  :D
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 13:09 - 28 September, 2018
Good bike init.
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 13:11 - 28 September, 2018
Nope, it reads 100000.
Hold on.

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Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 13:15 - 28 September, 2018
Here you go

(https://uploads.tapatalk-cdn.com/20180928/01fc3a32c1ed8c24a8c8604e84ae4a10.jpg)(https://uploads.tapatalk-cdn.com/20180928/0f62cc94903a3635fcbb48a132718d8a.jpg)(https://uploads.tapatalk-cdn.com/20180928/8d6c45de080653a3b911614c8c3981c6.jpg)

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Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 14:50 - 28 September, 2018
Mmmmm, cake.....

Got about 18k to go on Kylie before hit the 100,000.

Admittedly Gaz put about 99.9% of the miles on it so far though, so I've got some catching up to do, but she's in a bit of a retirement home now by comparison so not sure how long this will take.
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 18:37 - 28 September, 2018
Mmmmm, cake.....

Got about 18k to go on Kylie before hit the 100,000.

Admittedly Gaz put about 99.9% of the miles on it so far though, so I've got some catching up to do, but she's in a bit of a retirement home now by comparison so not sure how long this will take.
go for two cakes... 100000km then do the miles.
Title: Re: Re: Coxylaads MT-RX
Post by: AlunL on 10:03 - 29 September, 2018
Cake? Did someone mention cake?
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 10:24 - 1 October, 2018
Back.
Made an embarrassing maths error and as the clocks were on 96,000 miles and i only planned to do around 900 miles im not sure how I planned to hit 100k on the trip
Not sure what I was thinking there haha

The trip was brilliant. Since getting the bike off cb and doing a bit work on it I have hardly used it, less than 600 miles put on it in a year. I can honestly say that bike was built for blasting round scotland, the suspension is so compliant when the roads got rough it was massively confidence inspiring, and really comfortable. I think I need to sort out another power commander as the engine feels a touch rougher on small throttle openings, plus it will help with my forthcoming plans for the winter.

So impressed with the balance of the bike, I didn't realise it was possible to have a bike handle that well and still feel soft and compliant. 

We got utterly drenched on the Saturday which is standard for Scotland this time of the year but it didn't spoil my enjoyment. The bike was just as good in the wet.

So I have a few ideas to improve the bike.
1. Power commander, or ignijet ecu for full adjustability.
2. Headlights. They are dogshit compared to a modern bike.
With this in mind I may consider building myself a new front end altogether today more adventure spec - fibre gassing new panels etc. We will see.
3. Not sure about this one as I dont want to muck up a very nice handling bike - I have a set of r6 5 spoke wheels, I might fit the 17" front - has one on here done that? What was the results?
180 rear to go in, and maybe even an r6 rear swing arm.  All this is for looks as the bike handles well, but i have the wheels and an itch...
4. Oversized throttle bodies. I have some 42mm tbs from an f800 bmw. They might make the engine breath a bit better, combined with the big bore 2 into 2 trx exhaust that I am going to make fit. Again its not strictly required as at no point on the trip was I thinking I need more power, but I like the technology and I already have the parts in my garage to work with.   

I have to be careful here as the bike handles really well right now, but everything can be improved on... I think.
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 11:02 - 1 October, 2018
:eatspopcorn
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 13:32 - 1 October, 2018
Made an embarrassing maths error and as the clocks were on 96,000 miles and i only planned to do around 900 miles im not sure how I planned to hit 100k on the trip
Not sure what I was thinking there haha

FAIL! (http://emoticons.datahamster.com/lol.gif)
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 17:00 - 1 October, 2018
I might fit the 17" front - has one on here done that? What was the results?

Yep, I have an R6 front wheel on Kylie.  The effect is very good IMO.

Firstly, with a slightly stumpy inside leg measurement of 30" the smaller wheel brings the TDM to the perfect height for me - may not affect you, just a consideration.  Also the tyre choices improve massively.

In terms of handling, it does seem to improve things and slightly quicker turn in.  Personally I like the change, but didn't really have a problem with the 18" to be honest.

The power commander doesn't make too much of a difference IMO but does help.  Kylie runs pod filters and Fuel silencers, and a downloaded map for a K&N and race cans works really well with an AFR in safe regions and fuel economy is pretty much the same as before.
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 19:51 - 1 October, 2018
The power commander was only there to correct the fuelling for the high lift cams and gas flowed head.
Wouldn't be surprised if it's running a little lean without it.
Do you have an afr to check it?

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Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 20:54 - 1 October, 2018
Yep, I have an R6 front wheel on Kylie.  The effect is very good IMO.

Firstly, with a slightly stumpy inside leg measurement of 30" the smaller wheel brings the TDM to the perfect height for me - may not affect you, just a consideration.  Also the tyre choices improve massively.

In terms of handling, it does seem to improve things and slightly quicker turn in.  Personally I like the change, but didn't really have a problem with the 18" to be honest.


hmm. I have no problems with the handling of the bike. An improvement would be nice, but lets be honest I would be doing for cosmetic reasons. I loved the compliance of the bike over the rougher roads, I am wonder if that is partly because of the large rolling radius of the front wheel?

We shall see, If I decided to do it I will go all in and fit the r6 rear and an R6 swing arm.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 20:58 - 1 October, 2018
The power commander was only there to correct the fuelling for the high lift cams and gas flowed head.
Wouldn't be surprised if it's running a little lean without it.

its certainly not running optimal anymore, I managed to get a copy of the original map from Alan, and at the top end at WOT is actually takes a bit of fuel out. its not the first time I have seen that though my fireblade was the same.

it runs a lot leaner on light throttle openings, which makes the bike feel a little rougher off the throttle.  I will sort it over the winter. If a cheap power commander doesnt come up I may just stump up for an ignijet and go full customizable with the maps both ignition and fueling.

Quote
Do you have an afro to check it?


I am thinning on top and very sensitive about my hairline why would you say that
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 22:20 - 1 October, 2018
Because he wants you to take a look next time you comb over to his
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 12:56 - 2 October, 2018
CB - can you remember if the TDM has stock length dog dones on it or are they slightly shorter?
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 13:50 - 2 October, 2018
I'm pretty sure they are stock and I had the shock built to suit with ride height adjustment and lifted the rear by 15mm with that.

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Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 14:23 - 3 October, 2018
4. Oversized throttle bodies. I have some 42mm tbs from an f800 bmw. They might make the engine breath a bit better, combined with the big bore 2 into 2 trx exhaust that I am going to make fit. Again its not strictly required as at no point on the trip was I thinking I need more power, but I like the technology and I already have the parts in my garage to work with.   

Just a thought and I could (probably am) wrong, but would oversized TB's risk reducing your low down torque.  With carbs, when going wider it usually had the effect of improving the airflow for higher power at high revs, but at the detriment of low range torque, since the wider throat slows the air flow down resulting in poorer cylinder filling at lower engine revs.

Just thinking the TDM engine runs out of puff pretty early so I wouldn't want to reduce the low-mid torque as that's pretty much the main character of the engine.

That said, if it's just for shits and giggles, maybe give it a go and see what the result is - easy to go back I guess if no better/worse or maybe it would open up that top end where it's lacking a little at the moment?
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 15:17 - 3 October, 2018
that was indeed the case, but it was much worse with carbs, the lower gas speed in the throttle body reduces the venturi effect which draws the fuel out of the jets.

With injection that is not an issue as the injectors pulse the fuel in regardless of the gas speeds.

The the lower gas speed can lead to slightly less cylinder fill but the effect is much reduced. Look at the likes of the aprilia rsv1000 and virtually every ducati, they are running 46mm up to 52mm throttle bodies, so I dont there will be much of an problem, and look at the effect a set of 41mm FCRs has on a stock trx motor - a big jump in hp and mid range torque.

Think of the 42mm TB's as FCR's without the shitty fueling  :D

just got a quote back from the guys at ignijet - 848 euro for the unit plug and play. its a lot of money when I didnt even pay that for the bike, but it will give me so much more flexibility, such as removing the ignition limiters in the first 3 gears, deceleration fuel cut etc etc that you cant get rid off on the stock ecu.

I am talking myself into it
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 15:41 - 3 October, 2018
Hmmmm good point, I'm forgetting the FI will probably be less problematic. Will be interesting either way  :)

I did think about the possibility of adding FI to the ZRX just for a bit of a project.  While it's possible, I think the costs involved with all the modifications needed isn't really worth it when there's nothing really wrong with the carbs.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 16:23 - 3 October, 2018
I think the hardest part of the job will be making the adaptors to attach the throttle bodies to the head.
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 16:52 - 3 October, 2018
Is e-throttle common on bikes yet?
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 17:14 - 3 October, 2018
Mine is
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 20:05 - 3 October, 2018
I think anything high end made in the last 3 or 4 years is.
But as always it's started to filter down to mid-range models now.
I've just fitted new heated grips and it reminded me of a story about heated grips interfering with the electronics in the throttle grip on early examples.

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Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 21:01 - 3 October, 2018
Even if not fully "fly by wire", most decent bikes for quite a while now have ECU controlled secondary butterflies, so even if the rider thinks they are wanging the throttle open the bike is still intervening to control air flow.

I took the secondaries out of the FZ1 and the throttle response was a lot sharper, but I also noticed it bogged easier if too quick to open it. Soon realised the ECU control made for a nice smoother operation abd also maintained correct AFR, so put them back in.
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 21:55 - 3 October, 2018

I took the secondaries out of the FZ1 and the throttle response was a lot sharper, but I also noticed it bogged easier if too quick to open it. Soon realised the ECU control made for a nice smoother operation abd also maintained correct AFR, so put them back in.

That sounds like it would have been better fully e-throttle?
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 07:20 - 4 October, 2018
Im sure mr yamaha knew what he was doing ;)

I think it allows for 'best' of both worlds.  You have the quick response of a direct cable driven throttle, with the smoothness of the ECU controlled secondaries.  Also the secondaries act as a sort of dynamic port sizing thingy to control the air flow, so at slow rpm the ports can be effectively narrowed by the secondaries to create faster air flow, while being independent of the throttle control, and at WOT open fully to allow full air flow.

As mentioned though, these days it's all fly by wire (at least in high end machine, budget stuff will probably still be cable).
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 08:23 - 4 October, 2018
Ahem... My trx is now fully ride by wire. I have spent a bit time mucking about with the throttle maps.  Initially I had feck all engine braking and it was really disturbing. In fact it was a major contributing factor to my off at cadwell. Got it spot on now though.

Although I will add to this, its the stupidest setup I have ever seen, as it has a standard cable throttle, and the cables run all the way to the throttle bodies just like a traditional cable, but instead of actuating the throttle butterflies directly it actuates a potentiometer which is then feeds into the ecu, and the ecu decides what its going to give you in terms of throttle openings.

You would think they would just have the potentiometer in the throttle grip and save all the cabling crap. I can only assume it was a cost thing.
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 20:43 - 5 October, 2018
Probably. Buyers wouldn't buy the bike when word got out the potentometer was in the handle-bar assembly so each time you crashed/dropped it would pay much more than just some plastic parts?
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 20:24 - 7 October, 2018
I played my first game of rugby in 10 years last friday. My good god how did I do that week in week out.
I'm fairly certain I would be in less pain if simply stepped into a motorway and got hit by a speeding juggernaut

Loved the game though, I flashes of the old brilliance came straight back, for about 15 yards until I pulled my hamstring hahaha what an old ba :censored rd !
Title: Re: Re: Coxylaads MT-RX
Post by: AlunL on 09:20 - 8 October, 2018
Lol. Well done for trying Coxy!

My son plays rugby for a local U13s team. It’s a lot harder (they’re fitter and tougher) than I remember. I’m happy to be a spectator and to help the coaches to carry the tackle bags and cones during training.
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 09:26 - 8 October, 2018
Haven't played since I was at school and I was crap even then.

I think the teacher had it in for me as I wasn't particular big as a kid but I wasn't a very quick runner, so he chose me as a prop!

Quite enjoyed the physical aspect of being in the scrum, but I'd generally go home with the shit knocked out of me most times :D
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 16:01 - 8 October, 2018
starting to walk normally again now. my ribs are proper bust. what I great idea that was!

I only did it because Nathan has started playing u8's rugby and I thought it would be good to 'refresh' myself on what its all about.

Pain, is what its all about  :D
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 16:21 - 8 October, 2018
I wished I'd heal like I did back then.  What would have made you limp for a couple of days max, now seems to take 3 months and then still gives you jip in the cold weather for 5 years  :(
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 21:31 - 8 October, 2018
You're preaching to the choir mate.
Spammers Horn Tabs is all good and well but they should cut it with ibuprofen and codine for the aching body in the morning.
It's like going on a long ride. I haven't forgotten how to do it but I did forget how much hard work it can be.

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Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 10:36 - 9 October, 2018
. I haven't forgotten how to do it but I did forget how much hard work it can be.

That's pretty key to doing something again tbh  ;)
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 11:27 - 9 October, 2018
When I fall out of my kayak,  I find the water is not as hard as tarmac.   :P
Title: Re: Re: Coxylaads MT-RX
Post by: AlunL on 15:35 - 9 October, 2018
When I fall out of my kayak,  I find the water is not as hard as tarmac.   :P
We live in a soft-water area too.
Title: Re: Re: Coxylaads MT-RX
Post by: celticbiker on 16:53 - 9 October, 2018
When I fall out of my kayak,  I find the water is not as hard as tarmac.   
We live in a soft-wa :censored ker area too.

Fixed that for you.

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Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 14:50 - 15 October, 2018
Well. garage has been fully cleaned out, new shelving and work benches installed, and the TDM is now on the operating table...

i will be keeping a log as I go.
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 18:39 - 15 October, 2018
Well. garage has been fully cleaned out, new shelving and work benches installed,

Well jel!
Title: Re: Re: Coxylaads MT-RX
Post by: BashplateAlAssad on 20:11 - 15 October, 2018
I'd love a garage... even a dirty one!
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 23:48 - 15 October, 2018
Me and the missus broke the rule by drinking on a Monday night. She’s asleep beside me and silently farting and I guarantee her dirty garage needs clearing out
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 08:34 - 16 October, 2018
I'd love a garage... even a dirty one!
me too
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 10:40 - 16 October, 2018
I should stop moaning. I am complaining that I don't have enough space to do want I want to do.

anyways I made a start last night. First job was to remove the old exhaust headers. failed at the first hurdle. the inside nut on the left header just crumbled away to roundish shaped nub.

I have a removal tool which I used on exactly the same problem when I build the TRX900 6 or 7 years ago. Works great, havent used it since then, couldnt find it.

(https://farm2.staticflickr.com/1937/44634785774_7790b78a7b.jpg)

(https://farm2.staticflickr.com/1956/43542633780_41d0a8d3f8.jpg)

It will be interesting to see what everything is like after 97,000 miles on the road.
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 11:16 - 16 October, 2018
Yeah the header nuts on Kylie are the same. I'm dreading having to take them off, but hopefully as long as the studs are solid then replacing them shouldn't be too bad.

I'm in two minds whether to sort them out now before they crumble any more, or simply leave it in a 'aint broke, don't fix it' way.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 11:25 - 16 October, 2018
I have ordered a new tool to get it off, if that fails it will be getting the angle grinder treatment.

Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 12:23 - 16 October, 2018
Yeah the header nuts on Kylie are the same. I'm dreading having to take them off, but hopefully as long as the studs are solid then replacing them shouldn't be too bad.

I'm in two minds whether to sort them out now before they crumble any more, or simply leave it in a 'aint broke, don't fix it' way.

if you dont need to remove it and you are ok with looking at it, don't touch it. I can pretty much gaurantee they wont fail. I am hanging off mine with a massive set of mole grips and its not budging. once the rusted bits are flaked off the metal underneath is solid (and round)
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 12:42 - 16 October, 2018
Yeah that was my thinking too.

When they get like that you really need acetylene torches to free the rust.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 14:08 - 16 October, 2018
I have one two of these.

https://www.ebay.co.uk/itm/3-8-DRIVE-IMPACT-STUD-EXTRACTOR-REMOVAL-for-6mm-to-13mm-BOLTS-STUDS-NEW/232780637210?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

The one time I used it to remove the stud on the engine from the trx900 it was a complete none event. it just came straight out like it was finger tight.

I'll let you know how I get on when my replacement one arrives on Thursday....
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 14:26 - 16 October, 2018
Yeah I have one of those too.  Same experience too, had a seized stud on the Faz, and that and an impact wrench spun it out instantly :)
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 14:41 - 16 October, 2018
I've had to weld a nut on the end of a stud before because so little was left. Welded on nut  + impact wrench tests your welding skillz!

The heat from the welding would have also helped.
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 19:05 - 16 October, 2018
My studs usually shear flush with the head!
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 19:16 - 16 October, 2018
I am a stud
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 19:40 - 16 October, 2018
I am a dud

Corrected for you 🐒
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 21:33 - 16 October, 2018
My studs usually shear flush with the head!

That's why I had to get the welder out! Welded a washer on first, then nut onto the washer. Few ugga duggas of the rattle gun, and out they came.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 11:33 - 17 October, 2018
well stud extractor number 2 has arrived so I will be attempting the job tonight.
Title: Re: Re: Coxylaads MT-RX
Post by: Vu Ja Dave on 23:33 - 17 October, 2018
I successfully attempted a job this morning.
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 00:11 - 18 October, 2018
Was it a big jobby?
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 13:36 - 18 October, 2018
its on going.

the offending stud came no bother at all. and once i removed the exhaust I could see the state of the other studs. Its fair to say that after 97000 miles, the needed replacing.
So I took them all out. Only the last one (far left) snapped.
I am in the process of drilling it out now. what fun.

(https://farm2.staticflickr.com/1943/44479585895_8a0618651b.jpg)

(https://farm2.staticflickr.com/1974/44670063234_e8f553a32c.jpg)

I took the fairing panel off just to have a look at see what I was up against.  I will have to make a decision whether to go all in and dispose of the front fairing completely and build something more GS adventure bike looking, or attempt to make myself some new side panels to get rid of the early 2000's rounded fat look and make something sharper and more angular.

(https://farm2.staticflickr.com/1960/45393782621_63b933b350.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 13:43 - 18 October, 2018
looking for inspiration I came across this:
(https://i.ytimg.com/vi/x196xhrHg4w/mqdefault.jpg)

not totally my cup of tea but it shows what can be done.

I either do my own version of that or a go full jonny 5/cyclops:
(http://www.advpulse.com/wp-content/uploads/2018/03/BMW-F800-GS-Adventure-Motorcycle-Round-the-world-build.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 14:01 - 18 October, 2018
Those GS style side panels look ok - or something like KTM with really angular aggressive panels.

(http://cdn.shopify.com/s/files/1/1502/8810/articles/KTM-banner_1024x1024.jpg?v=1518188672)
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 14:18 - 18 October, 2018
liking this:

(https://s1.cdn.autoevolution.com/images/news-pictures-600x/another-yamaha-tdm-sketch-iwata-is-brewing-something-up-83442-7.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 19:10 - 18 October, 2018
Yup, make it 175kg and 125hp and soft compound tyres and then yes please
Title: Re: Re: Coxylaads MT-RX
Post by: AlunL on 11:27 - 19 October, 2018
liking this:

(https://s1.cdn.autoevolution.com/images/news-pictures-600x/another-yamaha-tdm-sketch-iwata-is-brewing-something-up-83442-7.jpg)
That’s how they should build the next S10
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 23:14 - 19 October, 2018
so I was 50 50 whether to modify the exisitng side panels, make some new side panels, or go the whole hog and build a full fairing.

this was interesting, and its given me some inspiration
https://www.youtube.com/watch?v=trm3LcR-53A

I might have a go and building some side panels from scratch and see how that goes.

If it works I may go made and build the whole fairing. I have a shit load of foam modelling board to play with.  bring it on
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 21:45 - 20 October, 2018
Interesting and sculptural
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 22:34 - 20 October, 2018
Ok so I had an hour today so I started the strip down of the bike.

fairings come off fairly easily
(https://farm2.staticflickr.com/1957/45455270441_36782f88df.jpg)

headlight removed
(https://farm2.staticflickr.com/1905/30514834267_769eb41411.jpg)

I wasn't sure what I am going to do for a headlight so just for the crack I fitted up the custom headlight I made for my trx when it was a road bike. Didnt look to bad.
(https://farm2.staticflickr.com/1918/31580052398_9e628b0259.jpg)

I might stack them one above the other if I have the space.  The current plan is I am going to build myself a new fairing from scratch.  Fingers crossed it wont look dog turd.


Also I was looking at fitting the larger throttle bodies.  Up from 38mm to 42mm.
(https://farm2.staticflickr.com/1903/31580045508_f8da5e7fc9.jpg)

Like fitting a set of FCR's to the bike but with benefit of digital fueling.  based on what FCR's do to a TRX I am fairly certain this will increase the performance of the engine right through the rev range, but I am starting to think maybe I should just do this later. Get everything setup with the ignijet ecu and it can be next years project.
It may well release more power, and that would be nice but to be honest I don't really need any more power out of it. I've never found the bike lacking at all.  I may change my mind but I think for now I am going to concentrate of building a new front end for the bike, and give the engine a good going over so its in tip top condition - compression test, valve clearances etc.



Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 18:14 - 22 October, 2018
I have metaphorically sat in my armchair with a cigar and a glass of whisky to watch this fairing creation unfold....
Title: Re: Re: Coxylaads MT-RX
Post by: Vu Ja Dave on 00:55 - 23 October, 2018
I always wanted to make a Dakar styled fairing for Dr Djebel. Tide 'n' time .........

(https://i.servimg.com/u/f62/19/80/81/56/110.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 16:18 - 24 October, 2018
intersting. that picture brings me onto my next opinion pole.

Looking at the 2 projector headlights I have, what are peoples thoughts on orientation.

I am thinking side by side at the moment but have the option of stacking the headlights one above the other.  I don't have a picture of them stacked one above the other so you will just have to imagine them.

Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 16:58 - 24 October, 2018
I like side by side, but only if the lights are in proportion, which is why I changed my TDM from dominator to 850 lights.

Those little projector lights do seem to look good when stacked vertically though.
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 22:22 - 24 October, 2018
999 had stacked lights and nearly killed Ducati sales despite winning the bulk of WSB titles and owning truly exquisite manufacture and design

Horizontal is safe

Ultimately perfection in innovation and creation is in the eye, hand and mind of the creator

Both are simultaneously right and wrong
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 23:29 - 24 October, 2018
Jesus that's deep. I was expecting more along the lines of vertical looks dog shite  :D
Title: Re: Re: Coxylaads MT-RX
Post by: Vu Ja Dave on 23:51 - 24 October, 2018
 ;D Indeed.

Tall and thin has never been a good look unless your a supermodel.
Title: Re: Re: Coxylaads MT-RX
Post by: E.T. on 07:35 - 25 October, 2018
Diagonal will give you both. Just sayin.

Your decision I prefor next to each other...but I'm an old fart
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 09:19 - 25 October, 2018
Vertical for larger (i.e. taller) fairings. dakar adventure esque bikes.

Horizontal for anything more street / road oriented.

Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 09:33 - 25 October, 2018
first draft of the new fairing:

(https://farm2.staticflickr.com/1960/45540949521_e4330e79b6.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 09:54 - 25 October, 2018
Nice and aerodynamic.

You should mount the lights in the Malteaser tub on the front ;)
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 10:04 - 25 October, 2018
brilliant idea.

I think I might have to cut a couple of eye holes in the fairing though for safety reasons
Title: Re: Re: Coxylaads MT-RX
Post by: Readmarx on 18:28 - 25 October, 2018
Perhaps a self-portrait iththe eye cut-outs...?

(http://rossihelmets.com/wp-content/uploads/2008/11/Rossi-mugello-2008.jpg)
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 08:33 - 26 October, 2018
is there an easy way for me to seperate this blog so I have a road bike one and a track bike one?

needs splitting off from reply #568
Title: Re: Re: Coxylaads MT-RX
Post by: Rob the Nog on 08:36 - 26 October, 2018
Maybe easier to just start a second bloggo :dunno

You can delete posts on your own blogs, so if you wanted to strip out road stuff for a different blog then you could do it with a bit of leg work.
Title: Re: Re: Coxylaads MT-RX
Post by: CoxyLaad on 08:56 - 26 October, 2018
I think gary should sort this out. we pay him enough for this forum...oh hang on.
Title: Re: Re: Coxylaads MT-RX
Post by: Zippy on 11:40 - 26 October, 2018
is there an easy way for me to seperate this blog so I have a road bike one and a track bike one?

needs splitting off from reply #568

I'll try and sort it.

Er, I'll do it at the end of the day, so you can save your work before I cock something up!  ;)

(EDIT: Done)  ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:47 - 26 October, 2018
Top man Zipster!

Love the title, thats staying.

[alan sugar] Gary, your fired. [/alan sugar]
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 17:15 - 26 October, 2018
I actually like stacked. Just a thought, why not go for both in a triangular configuration.
Two low beam on the bottom one high beam on the top or one low beam on the bottom and two high beams on the top.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 13:35 - 28 October, 2018
I actually like stacked. Just a thought, why not go for both in a triangular configuration.
Two low beam on the bottom one high beam on the top or one low beam on the bottom and two high beams on the top.

Sent from my SM-G950F using Tapatalk
Triclops. That’ll look good.

(https://uploads.tapatalk-cdn.com/20181028/d587ad762e9f9ca88cac377ac4dac54f.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:27 - 28 October, 2018
Could be done better...

(http://ll-media.tmz.com/2016/08/26/0826-3-boobs-total-recall-3.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:02 - 28 October, 2018
vito.

This afternoons progress:



had the afternoon in the garage and started mucking about fabricating the new front sub frame:



Some bits of flat bar

(https://farm2.staticflickr.com/1912/43788822190_a1437869be.jpg)



turned into this:

(https://farm2.staticflickr.com/1911/43788822040_c314962ba1.jpg)



to house these:

(https://farm2.staticflickr.com/1973/44881943234_d08b451803.jpg)



starting with the scaffolding

(https://farm2.staticflickr.com/1952/45555842312_cb95d6b916.jpg)



(https://farm2.staticflickr.com/1930/44692523575_538bf00a07.jpg)



looks like a set of specs

(https://farm2.staticflickr.com/1973/45606286361_bdb7eefd81.jpg)



(https://farm2.staticflickr.com/1902/45606293701_0107dfe49a.jpg)



(https://farm2.staticflickr.com/1935/31733971098_37968e0f38.jpg)



Next job is to build a mount for the clocks to bolt to, then extend it to make some fixing for the new screen.



once all thats on its time to get creative with the fibre glass.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:21 - 1 November, 2018
Change of plan. I don't think I can get the shape I am wanting with the headlights as they are so I am going back to one over the top of the other.

I love the look of this
(https://i.ytimg.com/vi/KmVcj6OUaPI/maxresdefault.jpg)

I have bought a clear tracer touring screen, so I am going to mount the headlights behind them, hopefully it will work.

I like the shape of the side panels on this bike too.

I actually had a bit of a wobble last night and knocked up a spreadsheet on how much more it would cost me to simply sell the tdm on and go buy a ktm adventure.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:14 - 1 November, 2018
I actually had a bit of a wobble last night and knocked up a spreadsheet on how much more it would cost me to simply sell the tdm on and go buy a ktm adventure.

Trouble is, if you just went and bought one, would you then still have an urge to try fabricating something.

If part of the fun you're after is the fabrication side of things and creating a bespoke bike (which I get the feeling it is), probably better to stick with the TDM.

Otherwise I know what will happen - it'll only a be a few months and the KTM will be stripped and having expensive bodywork altered to look like a TDM ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:29 - 1 November, 2018
That is a good point.

I will stick with the plan.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 15:20 - 1 November, 2018
I agree with Nog!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:43 - 1 November, 2018
I like that 700 Yam too

Been interesting reading about its development
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 07:37 - 2 November, 2018
It does look good.

Presume it's the MT07 engine?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:54 - 2 November, 2018
yes mt07 engine
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Sidestand on 17:18 - 2 November, 2018
It would be interesting to see that Yam in the dark with it's lights on - I think there'll be a lot of backwards reflection.

I once fitted a perspex headlamp protector to my GSA - then binned it because it reflected too much glare back at me
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:55 - 2 November, 2018
ditched the horizontal arrangement, the vertical one is more compact.


(https://farm5.staticflickr.com/4807/45637812722_65fee981df.jpg)

(https://farm2.staticflickr.com/1937/43870404150_004216f297.jpg)

(https://farm2.staticflickr.com/1906/45688375351_c2625a26fc.jpg)

(https://farm5.staticflickr.com/4828/45688377831_a07d7e614e.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:30 - 3 November, 2018
Yeah prefer vertical :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:37 - 4 November, 2018
Me too
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:15 - 5 November, 2018

finished the structural bracing, its not going anywhere now

(https://farm5.staticflickr.com/4833/43900165450_f84891e3e1.jpg)

(https://farm5.staticflickr.com/4880/43900153230_1dc3f8c085.jpg)

(https://farm2.staticflickr.com/1941/43900152690_29ae487dce.jpg)

I am waiting for my modelling foam to turn up then its time to make a start on building a fairing  :o
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 06:33 - 7 November, 2018
What speed rating is this fairing/light Assembly for?  ;D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 07:58 - 7 November, 2018
based on the steel I have used it will probably be around mach 2

fairing might have dissolved before then but the lights will still be on
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:41 - 7 November, 2018
Considering my 850 lights stay on at <cough> motorway speeds, on cheapo fork brackets, I think you'll be more than fine with those :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:19 - 7 November, 2018
My modelling foam board arrived today. commencement of the abomination that is my fairing is to start :-X
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:19 - 15 November, 2018
Not a great deal happened lately. Got some bad news about Emma, her brain tumour has returned. We are waiting to see the surgeon to see what they want to do.  Its just one of those things we have to deal with. She is super strong and I am sure she will be fine.


So I managed to do a little bit last night. I have made myself an adjustable bracket for the clocks. I got the idea from a review of a triumph tiger 800xc, it had clocks where the angle was adjustable.  I thought 'I like that idea' so copied it.

(https://i.imgur.com/Pbm9bMU.jpg)

(https://i.imgur.com/0eF2dAl.jpg)

I added some DRLs to the side of the main lights, but I am thinking its a bit too busy so might be chopping them off and putting them somewhere else.

(https://i.imgur.com/LVRoYYf.jpg)

You have to imagine it all contained within a fairing. not easy to do at the moment.

I have been thinking about the fairing options, and I might do away with a screen altogether and just make everything out of fibreglass (or carbon fibre)

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:37 - 15 November, 2018
Mmmm, carbon fibre!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:51 - 15 November, 2018
Sorry to hear that news fella, fingers crossed for you all.

I like the sound of an adjustable screen - I may have to pinch that idea for Kylie ;)

I quite like the looks of the side DRL's, but hard to think what it will look like in a fairing, so you may be right about being busy.

I have an old SV1000 top fairing you could have.  I don't think it will help you since you have gone vertical alignment of the lights whereas the SV is very wide horizontal, but you'd be welcome to have it if you wanted to chop it up and use pieces as a base for support etc (it's cracked on one side so cutting up wouldn't be an issue).
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:17 - 15 November, 2018
cheers for the offer rob but I may as well do this from scratch, given I have to make the plug mould etc
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 15:57 - 15 November, 2018
Likewise, so sorry to hear the news.

Busy lighting?...well it's nearly Christmas, I think some antlers on the front and you'll be there!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 19:57 - 15 November, 2018
So sorry to hear about Emma, but I'm sure she'll be kicking it's ar5e [filtered] again in no time.
I know we're a 1000 miles away (practically speaking) but if there is anything at all that we can do to help, don't hesitate to ask.
On another note, can't wait to see how blue turns out.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:38 - 16 November, 2018
best of luck Mrs Coxy.  :-*
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:19 - 16 November, 2018
Just having a bit crack on here with all my internet buddies is a great help.

clocks in their lowest setting:
(https://i.imgur.com/sip70Dx.jpg)

Clocks in their highest setting (well actually they could rotate round and point forward at the moment but imagine the fairing is in front of it)
(https://i.imgur.com/4cZhVuD.jpg)

Probably where it will end up for day to day use:
(https://i.imgur.com/ZnZ8ONB.jpg)

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Sidestand on 22:43 - 17 November, 2018
Sorry to hear Emma is ill again Coxy

Best wishes for a full recovery this time

Mick
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:31 - 18 November, 2018


Clocks in their highest setting (well actually they could rotate round and point forward at the moment but imagine the fairing is in front of it)


I couldn't possibly imagine that.  :-\
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 07:43 - 18 November, 2018
Best wishes for Emma.

Love the adjustable clocks, not in love with DRLs. Keep up the excellent work Coxy!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 18:53 - 18 November, 2018
All best for Emma and family
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:25 - 19 November, 2018
hmmm. not sure where I am going with this. 

(https://i.imgur.com/hdxD371.jpg)

(https://i.imgur.com/UmAtJoc.jpg)


the cutting and shaping isnt so bad, its my artistic abilities that I am not so sure about. I dont want to create something that just looks rubbish.
The biggest problem I am having is that clocks are enormous, so I have make every thing way wider than I want to.

The flat sides will be broken up when I build the side panels, but I am starting to waiver a little in my resolve.

I'll give it a go. worst case I will refit the stock gear and chalk it up to experience
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 12:43 - 19 November, 2018
Hmmmm, certainly unique......


I think the bottom light is throwing me - it looks like a sad robot with it's bottom lip out.  I think it's worth sticking with it though, bit of shaping and painted up and will probably look ok.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:46 - 19 November, 2018
Quote
bit of shaping and painted up and will probably look ok

hahaha thats pretty much the best I can hope for isnt it  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 16:02 - 19 November, 2018
Actually I'm wondering if a high level 'beak' might help give it the length you need.

Either move the existing one up or get a cheapy off ebay - I got one for around a tenner intending to do the same on Kylie but haven't got around to it.

(https://i.imgur.com/BLFfnTm.jpg)

If the main one was left on and painted black so it didn't stand out, it would give the bike a more big trailie look.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 16:07 - 19 November, 2018
good photoshop skills.

I have never been a fan of the beak.

the look I was wanting to acheive was a cross between this:

(http://bikereview.com.au/wp-content/uploads/2016/12/2016-KTM-1190-Adventure-R-9.jpg)

and this:
(https://i.ytimg.com/vi/KmVcj6OUaPI/maxresdefault.jpg)

I like the side panels on the Tenere 700, not and the nose of the 1190.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:59 - 19 November, 2018
Ok, I have made a decision. I have number of projects on the go at the moment and I just dont think I have the time to invest into something this new to me at the moment.

I have decided to opt for a plan B, refit the main fairing, and have a go at making some new side panels  to fit.

I didnt want to fit the original headlight, on account that its shite, so I pulled it apart and inserted the projecter units, and stumbled accross something I think looks pretty cool!

(https://i.imgur.com/pMhqPRy.jpg)
(https://i.imgur.com/5WKElTq.jpg)
(https://i.imgur.com/ApewBGQ.jpg)

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:49 - 20 November, 2018
Johnny 5.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:53 - 20 November, 2018
Not a bad compromise  8)

I still think that malteasers tub should get a look in though  ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:54 - 20 November, 2018
thats my new crash helmet
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 09:22 - 20 November, 2018
It needs a red nose
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 20:12 - 20 November, 2018
(https://data.motor-talk.de/data/galleries/0/47/5409/21155010/morbidelli-v8-4-3663809232820792762.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:35 - 20 November, 2018
LoL
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:42 - 20 November, 2018
What about the latest KTM jobbies? Jobbies being the keyword. 🤮
(https://www.mandp.co.uk/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/9/4/9470w.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 07:26 - 21 November, 2018
What about the latest KTM jobbies? Jobbies being the keyword.
(https://www.mandp.co.uk/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/9/4/9470w.jpg)
That’s a Baboon’s ar5e [filtered].
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 07:53 - 21 November, 2018
(https://data.motor-talk.de/data/galleries/0/47/5409/21155010/morbidelli-v8-4-3663809232820792762.jpg)
pmsl now thats just rude  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:00 - 21 November, 2018
That’s a Baboon’s ar5e [filtered].

PMSL

I was just about to say I'm sort of torn on whether I like it or not, but you just made my mind up  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:19 - 21 November, 2018
its the most technologically advanced baboons ar5e [filtered] on the planet. lean angle sensitive and lights up round corners, and the middle of it is an air duct that passes air over a  massive heat sink.

Wonder if I with explode if you are stood in standing traffic for too long.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:24 - 21 November, 2018

Wonder if I with explode if you are stood in standing traffic for too long.

I would expect it to have a wheel speed sensor and thermocoupler to the lights and reduce light output for thermal management reasons when standing in traffic - or if the battery is starting to not be happy.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:39 - 21 November, 2018
Over thinking it a bit maybe. It's a heat sink, it soaks up the heat when stationary which is then dumped to the air when moving.

Simples.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:51 - 21 November, 2018
That's generally the purpose of heatsinks  :D

I quite like this:
(http://www.carpe-tdm.net/ipb/uploads/monthly_11_2018/post-180798-0-11773600-1542749648.jpg)

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 15:04 - 21 November, 2018
Over thinking it a bit maybe.

This stuff happens on my over a decade old car... it exists!

Well thermal cutout and intelligent use of lighting based on battery monitoring. Cleverer light stuff is based on yaw, steering and speed inputs too these days....
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 15:50 - 21 November, 2018
I quite like this:
(http://www.carpe-tdm.net/ipb/uploads/monthly_11_2018/post-180798-0-11773600-1542749648.jpg)

I'm currently working on making Kylie a single seater, but trying to keep away from the cafe racer seat as I think it's been done to death, but that I don't mind.

I've cut the rear foam off and re-stapled the cover to just the rider seat and got the rear covered in spray foam (now hard) to try and shape into a cowl type affair to fibre glass over.

That's the principle, but may still make a complete balls up of it yet.  The tail unit will be pulled back too so it doesn't over hand the rear wheel :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 19:06 - 21 November, 2018
What about the latest KTM jobbies? Jobbies being the keyword. 🤮
(https://www.mandp.co.uk/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/9/4/9470w.jpg)
is that a vagina¿
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:01 - 22 November, 2018
(https://data.motor-talk.de/data/galleries/0/47/5409/21155010/morbidelli-v8-4-3663809232820792762.jpg)

RolF.

I want one. Makes me laugh every time I look at it.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:21 - 22 November, 2018
new ecu has arrived
(https://i.imgur.com/Uygel6u.jpg)

Fully customizable, and doesnt give a flying toss about any emissions regulations or safety power limiters in lower gears for plebs that have no control.

I'm going to pull the engine out shortly, give it a good going over, valve clearances, internal inspection etc, then I will be possibly fitting those 42mm throttle bodies and doing a bit of head porting.

Should be a nice setup once its done.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 13:24 - 22 November, 2018
Is that your desk at work?

Is it an old door?  ;D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:26 - 22 November, 2018
Is that an aftermarket jobby (<edit> well it's obviously aftermarket - I mean is it a copied, reprogrammed version of the original or an entirely new ECU)?

Sounds good being able to customise it, will be keen to hear how it performs :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:43 - 22 November, 2018
yes its my desk. shocking isn't it!  The cellotape is on the edge to stop me slicing my forearms to bits

This is a stand alone ecu, completely replaces the stock ecu, but its comes with a plug a play loom and a default map and settings loaded to get you away. - no mucking about, it will run from the off.

its capable of running loads of different bikes with up to 8 injectors, has all the setting for various things like coil pack resistances and injector timing/angle etc. Some of it is a bit beyond me at the moment but it will be fun learning.

What sold it for me is that it has a quickshifter and traction control built in to it which is nice.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:56 - 22 November, 2018
Assuming you haven’t robbed anyone at the winter MotoGP test - who makes this kit and isn’t it amazing that it’s available “over the counter” ?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:52 - 23 November, 2018
the company is called Ignitech, based in Czechoslovakia, they do a lot of programmable ignition units that a lot of the TRX guys have bought and used with great results.

They do this unit, and although relative unknown, a few of the aprilia rsv users have jumped across to them after they have been battling with getting their ecu's chipped.
most report an instant improvement in smoothness and power delivery even with the base map supplied.

The stock ecu has to consider things like rules for emissions and stuff for all countries and some have stupidly tight and stupidly pointless rules, and things like protecting the masses. This ecu is just a way more advanced version of the stock one, it has:

a basic injection map, and ignition map
secondary injection map for a second set of injectors if required
a multitude of compensation maps for both ignition and injection for manifold air pressure, air temperature, acceleration pump, start cranking voltage drop etc
Gear dependant correction maps for fuel, ignition, traction control, and
Injector phasing map, so I can alter timing of the injectors when they fire in the stroke, based on how fast the engine is spinning
Autotune facility with a wide band lambda setup.
Exhaust servo control. (not bothered about)
Intake service control (now this is interesting for variable trumpet length)
Gear shift light output
quickshifter controller (rpm and gear dependant dwell times)
Wheelslip based traction control. Not super advanced but as a safety measure on the road it will work well.

its got a lot of stuff on it. Looking forward to getting stuck into it. plus if I ever change bikes I will take this with me. its not bike dependent


Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:49 - 23 November, 2018
Sounds great.

It might not be something I should tinker with though as I looked at their website and couldn't even work out the pricing system  :-X
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:08 - 23 November, 2018
they aren't particularly user friendly in there website, however the ecu it self is super easy to setup, on the software there is a drop down where you choose from list of bikes, and the map has all the setting for the cam pickups and all the other shit that I wouldnt be able to easily work out.

Thats why I bought it over something like a microsquirt. its more expensive than a microssquirt but it is literally plug an play. 
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:01 - 24 November, 2018
The variable trumpet length wassisname could be useful.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 10:01 - 24 November, 2018
Especially when he really gets excited and properly gets in to it... :o

Having had my ecu’s “brain sucked out” and re-mapped and dyno’d for final setup my thinking on the precision electronic fuelling gives is transformed. When that’s combined with the next level of response needed on track that Coxy’s after with the ability to adjust it yourself I can’t help but laugh selfishly and think how we’ve come full circle. There’s a romantic view of carbs (which I hold dear for all those bikes I’ve owned) where the feel is lovely but earning that through jetting and adjustment takes time and experience to get even close to good when looking for power and response and has always ended with expert help and cash for dyno time.
Having a basic map with the “regulations” removed is a natural first step and to now be able to electronically adjust “cleanly & swiftly” is a small step for a man but a giant leap for a kind man in his bike shed. I’m assuming the auto tune facility helps fill any holes programmed in error relative to the Lambda?

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:02 - 24 November, 2018
Yeah the flexibility of modding fuel maps blows carbs out the water.

When I had the Daytona 955i, the open source mapping software was my first experience of fu  :censored ing about with mapping and was great to be able to change the character to a small extent without the pain of getting the carbs out and messing with jets etc - unfortunately a situation I'm in currently with the ZRX.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 11:39 - 24 November, 2018
EFI FTW  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:25 - 28 November, 2018
that's what I couldn't get my head around with carbs, how can you tune them when changing one thing has a huge ranging effect on everything in the local area  (of the map) around it. With injection if you have a flat spot then you just alter the values in those specific cells with virtually no effect on the rest of the map.

On a sidenote, one for CB - did you replace the stator on the TDM900? I am pulling the engine out and going to give it a good going over. It seems stator failure is a relatively common occurrence on high mileage 900s.

I was thinking of tearing the engine apart and going for a full rebuild, but I have been advised that as its running fine, just leave it alone.
I am going to do a compression test and if its good I will leave it at that. It doesn't smoke or even burn oil that I have noticed, although I have only done about 2000 miles on it since i acquired it. she's leading a pampered life
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 11:54 - 28 November, 2018
Never replaced the stator in that one but I did diagnose the over all problem with that issue. The ones that burned out were due to a bad casting of the core.
A rough edge or surface would wear through the paper base layer and cause a short.
If the core was fettled before a rewind it was OK after.
As for a rebuild, the engine should be solid. The only thing it will need is valve clearances but you might want to talk to tts first as it has re profiled cams in it iirc, so the clearances might be different from standard.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:58 - 28 November, 2018
did you check the casting on this engine?

I will be taking the sides off shortly anyway so I will have a good look at it. I thought the stator wasnt a moving part?

I will check the clearances when the engine is on the floor.

I'm still 50 50 whether or not to attempt to fit these 42mm throttle bodies. It would mean I would have to match the port on the head to the shape of the new TB's. Question is, can I do that without removing the cylinder head...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 14:05 - 28 November, 2018
Not checked that one because you would have to unwind it down to the choir to check so you only check when they go but they only last 40000 miles if they're bad and that one has been good so far.
You should be able to port the head easily enough so long as you can be sure you've got it all cleaned up after.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:43 - 28 November, 2018
its how I stop aluminium dust making its way into the bores is the problem.
I am thinking lining the inlet tract with grease and a tight fitting rag in each inlet. that way if any minute particles get past then they will be captured in the grease.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 19:24 - 28 November, 2018
Along those lines, I always used a well oiled rag .

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 23:42 - 28 November, 2018
My 2p's worth

On my Triumph I stuffed the crankcases with rags and "rasped the cases" to get a starter clutch to fit - a day off of work with a filed 10mm spanner to have something slim enough to tighten a nut on a spline end. An oily rag and a hoover sorted the swarf from entering the oil system.

A mate replaced the shell bearings on the crank of his TDM850 with the motor in-situ. He attacked the motor from the underside.

On my Triumph I took the engine out and stripped and cleaned it and re-assembled the "barrels" and head without the swearing and shouting that is normally part of Triumph "in-situ" work.

The first two examples are achievable but can make you question your sanity, logic and sense of reason



Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:34 - 29 November, 2018
I will assess the situation when I pull the engine out the frame. I might do that at the weekend.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:03 - 4 December, 2018
This project seems to be getting pulled back considerably in its scope.

I am now reduced to a lighting change, engine strip and paint, new exhaust fabrication, and if I am lucky some custom side panels. 

headlight part is about done:
(https://i.imgur.com/JCbQixL.jpg)

(https://i.imgur.com/c21QsdR.jpg)

(https://i.imgur.com/DhOwj4c.jpg)

Next job is to make a bracket for the new DRL that replaces that pointless parking light.

Then the engine comes out.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 15:31 - 4 December, 2018
I'd be tempted to trim the headlight lens out of the unit and then fit it over the projectors to finish the look and weather proof behind the fairing.

Will mean losing the headlight for future use though I guess so depends on what you want long term or if you're selling the unit to recoup some cash back.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:12 - 5 December, 2018
I have already chopped the front glass up to make the shroud so it fits in the hole. 

I would have gone that however I wouldn't be able to adjust the alignment once the glass is in place.

There's nothing in there that needs waterproofing, however I was considering using some sort of black mesh over the front just for the crack.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:22 - 6 December, 2018


(https://i.imgur.com/c21QsdR.jpg)



It reminds me of the Mekon a bit...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 16:18 - 7 December, 2018
It reminds me of the Mekon a bit...
Racist
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:36 - 7 December, 2018
The William Hague Mekon a la Steve Bell is my friend I’ve got loads of friends who are Mekon
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:17 - 10 December, 2018
no idea what you are talking about so moving on!

on a whim on friday I decided balls to it and removed the engine out of the bike to give it a good clean valve clearance check and paint.

(https://i.imgur.com/J57BqP3.jpg)

(https://i.imgur.com/8hH3cBL.jpg)

(https://i.imgur.com/wEUhojH.jpg)

(https://i.imgur.com/d10yGs0.jpg)

daily commuting is not good for bikes! The gunge was 40mm thick in places.

I attacked it with some degreaser a wallpaper scraper and about 3 full kitchen rolls.

frame is on the way to being clean:

(https://i.imgur.com/12zyVE1.jpg)

The engine doesn't have much in way of paint left on the front face of it. I am currently half way through getting all the crap off it.

(https://i.imgur.com/isoAqDn.jpg)

(https://i.imgur.com/RoHgciT.jpg)

(https://i.imgur.com/KppL8Fg.jpg)

had a quick look inside at the ported head, and managed to accidentally drop some mud down onto the back of the valves:

(https://i.imgur.com/IWTH8mC.jpg)

(https://i.imgur.com/rgCGgw2.jpg)

I will recover that later.

Now that I have made a start I think I am going to persevere with these larger throttle bodies. the majority of the port matching will be done in the throttle to head adapter. I've got them so why not.



Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:28 - 10 December, 2018
Excellent stuff  :D

I could probably do with dropping Kylie's engine and giving it a good going over like this, but I think all that road grime is what's holding most of it in place ;)

I have thought about doing the valves though, I checked when I got it and most are fine, but a couple of exhaust clearances were at the limit, so should probably get around to sorting that.

Will keep an eye on this for pointers ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Sidestand on 12:20 - 10 December, 2018
I need to drop the engine on my niner at some point - it needs a good respray as it looks like its got leprosy
Or maybe an STD, as Waspy owned it for three or four years

Anyone know the Yamaha paint code for the gunmetal grey engines ?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:22 - 10 December, 2018
or the one for the mingin champaigne coloured frames?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:25 - 10 December, 2018
or the one for the mingin champaigne coloured frames?

I just went for spraying mine black so it looks more like the later frames which I prefer.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:26 - 10 December, 2018
me too. I was considering getting mine powder coated. Was the finish tough enough on yours?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:40 - 10 December, 2018
So far it is - but I used a 2 pack epoxy paint that I had left over from my kit car days.

It was a bit thick for the spray gun and I ended up having to brush it on which was a PITA and ended up needing some work to sand back and smooth out as you'd imagine, but the finish is really tough. 

For the engine I just used a high temperature black stove paint which has also held up pretty well and gave a nice matt finish.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Sidestand on 21:55 - 10 December, 2018
Got the details here on the JBX site - that man has a page for everything TDM  8)

http://www.tdm-yamaha.heliohost.org/index.php?page=CCD

The link to RS Bike Paint on there is a goldmine - they do paint matches for just about every bike ever !
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:11 - 10 December, 2018
You don’t hang about Cody - well done
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:47 - 11 December, 2018
current status:

(https://i.imgur.com/sSpvjhK.jpg)

I am feeling like this is going to be a black on black bike.

OR

black everything with white tank and side panels.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:52 - 11 December, 2018
Blimey, even the subframe off - defo get it all painted up :)

You're inspiring me to think about getting Kylie stripped like this next year.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 09:21 - 11 December, 2018
For anything in the firing line of road crap - I don't think powder coating is the way to go. After some research etc. (was thinking for rear suspension/drive-line subframe on my car) I'd be using an epoxy (this in fact: https://www.bilthamber.com/epoxy-mastic) - and not getting it powder coated. Powder coating is for show car scene imho - quick, looks good, and that's all it has to do..a show car doesn't really put up with road abuse!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:21 - 11 December, 2018
its literally a couple of hours work to strip a bike to nothing.

I accidentally got a bit of black gunge stuck to the bottom of my slipper last night and subsequently there are little black marks all round the house now. 

I am not very popular at the moment
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 09:26 - 11 December, 2018
blame the dog?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:50 - 11 December, 2018
every time I have tried to paint something with a brush it goes badly wrong.

My bike wont be ridden through winter, and when I have had powder coating done in the past its never blemished at all.

My original TRX frame is still in good nick years later.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 10:05 - 11 December, 2018
Mat black Witt gloss black always looks good, or mat black and glossy navy blue?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:08 - 11 December, 2018
I accidentally got a bit of black gunge stuck to the bottom of my slipper last night and subsequently there are little black marks all round the house now. 

Yep been there, I scrubbed the carpet with thinners to get the oily mark out, which then made the house stink the whole night, so got it in the neck a second time  :-X
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 20:38 - 11 December, 2018
When I first did the "sticky sprocket cover gunk" I did it properly. I came back into the house with my mum shouting at me and pointing at the black spots going up the stairs on alternating treads on one side and coming back down on the other side so each step had a black spot.

I don't know if there's a cleaning product on earth that is designed for that shite!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:36 - 12 December, 2018
yep thats basically what I did. Emma even knew I had been in to turn the bath off and also into the bairns rooms to check on them.

I was not popular! that said she must have some magical power because its all gone.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:39 - 12 December, 2018
Bosh.

(https://i.imgur.com/k9YGKZi.jpg)

(https://i.imgur.com/SVGsybB.jpg)

ming
(https://i.imgur.com/WOcnkZV.jpg)

(https://i.imgur.com/pY153oc.jpg)

Now I just have to cover up the bearing races and its ready to be sent off for powder coat.

start on the engine next.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:54 - 12 December, 2018
(https://i.imgur.com/SVGsybB.jpg)

Would have loved to see a time lapse of the bike slowly dissolving to this :)

Great work fella.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:14 - 12 December, 2018
I can do a really rapid time lapse of about 3 images if that's any good for you?  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 09:30 - 12 December, 2018
I like how the only tool I can see is a claw hammer! (http://emoticons.datahamster.com/hehe.gif) (ok, I can spot a few others too, but mostly I can see a general purpose claw hammer!)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 22:54 - 14 December, 2018
I like the champagne colour frame.  :-X
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:08 - 17 December, 2018
you'd probably be the only one  ;D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 17:30 - 17 December, 2018
Unique and special.  That's me.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 20:53 - 17 December, 2018

As for a rebuild, the engine should be solid. The only thing it will need is valve clearances but you might want to talk to tts first as it has re profiled cams in it iirc, so the clearances might be different from standard.

Sent from my SM-G950F using Tapatalk

I hope you are correct here as this is what I measured for the clearances tonight:

 

    E1 006, E2 007,                                         E3 007, E4 008

 

I1 008, I2 008, I3 008,                              I4 007, I5 008, I6 007

 

way way WAY less that the factory specification of  0.15  to 0.20 mm on the inlet and 0.23 to 0.28 mm on the exhaust

 

so either this is by design or I need to replace every shim on the head

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 21:44 - 17 December, 2018
If that measured data is in imperial then the inlets are OK but I'll grant you the exhaust is a bit tight .17 to .20.
I'd still be inclined to speak to tts though as high lift cams do tend to run tighter clearances.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:18 - 17 December, 2018
oh my god. I am a windalicka.

was looking at the wrong values on the feeler gauge. those are imperial measurements....

what a bell end

the kent clearance specs for the tdm850 is .015mm inlet and exhaust. if thats the case then everything is A OK :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:25 - 18 December, 2018
Better a windalicka now than when all your old shims are laid out on the bench.  ;D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:35 - 18 December, 2018
very true.  thank the lord
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:54 - 18 December, 2018
oh my god. I am a windalicka.

was looking at the wrong values on the feeler gauge. those are imperial measurements....

Lol, we've all been there  :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 09:14 - 18 December, 2018


oh my god. I am a windalicka.

was looking at the wrong values on the feeler gauge. those are imperial measurements....

what a bell end

the kent clearance specs for the tdm850 is .015mm inlet and exhaust. if thats the case then everything is A OK :D

Just checking, is that another typo?
You've stated that Kent clearances are  0.015mm, shouldn't that be 0.15mm?

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:24 - 18 December, 2018
yes its another typo. can you stop picking on me please
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:14 - 18 December, 2018
I need some help.

one of the exhaust studs sheared off when I removed the exhaust, I attempted various methods that I have tried and tested to remove the stub, none have been successful so I resorted to drilling it out.
I have got about 8 to 10mm in and now not a thing will touch it. I've bought new cobalt drill bits and they hardly make an impression, often you can see where the cutting edge of the drill has been damaged.

I am using cutting oil and turning the drill at low rpm. 

Am I missing a trick here or something?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:25 - 18 December, 2018
Have you got a Dremel type tool?  If no better idea's you could try a little grinding bit in one to slowly grind out the remains.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 14:04 - 18 December, 2018
Good call there Rob.
@coxy
Not picking on you but when it comes to numbers you have to be accurate ish
As for the stud, you should stop drinking in gay clubs if you end up drilling them until your tip is damaged
As a last resort you could weld a tapered T bar to it if you have a tig welder and the heat spill hero it come loose.
BTW not all cutting compound is created equal I only use the brown tallow based rocol rtd.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:09 - 18 December, 2018
I've order a bunch of tungston carbide drill bits. hopefully they will do the job before they explode into fragments.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:23 - 18 December, 2018
metal galling. I managed to do this to an alu bolt!!!

Er, I gave up to be honest...

You're effectively looking at carefully "milling" out the remains really.

Is this a 10mm stub below flange level? If the stub is above flange level, there's a few options remaining, if it's below, er, good luck!!!!!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 14:25 - 18 December, 2018
The problem now is that the bottom of the hole is glazed and hardened, you might want to remove that if possible with a rotary burr.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:39 - 18 December, 2018
I guess absolute worst case is totally drilling it out (oversize type affair) and fitting an oversize bolt.

Guess you could try some heat - see if the differing rates of expansions/contraction are enough to break the bond....although there is quite a bit of risk here.

I once got a stub out by welding a washer to the stub, then a big nut, and then a rattle gun - but it depends if you can get enough weld on there...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:43 - 18 December, 2018
Another good tip I saw was now you have a reasonable depth of thread to play with, get a bolt that fits and pop it in your lathe and drill down through the centre to create a threaded tube.

Then you insert this into the thread and it acts as a really nice central guide which can you drill through with a drill bit a tiny bit smaller than the one you used in the lathe.

That way, it keeps the drill aligned and prevents catching the thread as you get deeper.  Using a left hand drill bit is a good idea too as it might catch and unscrew the remaining crap out.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:47 - 18 December, 2018
My 6 pen'orth. I'm guessing welding isn't an option. Zippys washer idea seems perfect.
I tried cobalt bits, load of shite.
Just use hss jobber bits. Hss is the key. High speed steel. Don't use too slow a speed.
I would try to heat to red before I started drilling though, then use some oil to lube.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:06 - 19 December, 2018
The issue is if it's already drilled out 8-10mm, you'd never get to heat it to red as the rest of the block will soak the heat.

Same problem with the washer idea, as you wont be able to weld a washer on when it's inside the thread to a depth of 10mm?

I think grinding with a dremel or carry on drilling will be the only option.  You only need to get to a depth that the new stud will hold on to enough thread for the headers, another 5mm or so and you'll probably be fine.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:30 - 19 December, 2018
A new head or JB Weld  8)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:36 - 19 December, 2018
blue tac
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:35 - 25 December, 2018
Job done. Drilled out and helicoiled. It was hell.

Back onto finishing the clean up operation

(https://i.imgur.com/YA1CV5w.jpg)

(https://i.imgur.com/2kK3ipK.jpg)

Engine is pretty much ready for paint. I plan to remove all the covers and paint them separately, then do the block.

Merry Christmas everyone
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:41 - 25 December, 2018
Hmmm I may be able to drop my bike off at some time .............
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 13:21 - 26 December, 2018
Can't remember if it was blue or my other tdm but one of them had a bad filter housing bolt that barely bit properly so while you are about helicoiling you might want to check them.
Iirc, in the first of the last two pictures it will be the one in the 4 o'clock position around the large circular part of the housing.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:04 - 26 December, 2018
Cheers cb I will check. Ive changed the oil and filter on it and i may have a vague recollection of one not nipping up but i cant remember. I'll sort it.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:50 - 27 December, 2018
There has been many bodges I have committed and not needed to "remember" - principally through not selling something to someone I remain in contact with. The old Strumpet I sold with my cam-cap head bodge is going to be found by the new owner who I am in contact with.  8)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:17 - 27 December, 2018
hahaha ready la :D

this bike had nearly 100k on it, its not faired so bad considering. Nothing a bit of time and graft wont rectify, unless cb eventually informs me that the conrods are held together with gaffer tape  :D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:04 - 3 January, 2019
I removed the generator cover last night and checked the stator. It looks brand new.

there is some white dust in the camber where the cables pass through, I am guessing this used to be white grease many years ago? the cables all look in god condition.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 12:42 - 3 January, 2019
That's good news, that's why I'm convinced that the issue was poorly manufactured cores.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:56 - 3 January, 2019
honestly it didn't show any signs of use let alone wear.

One of the reasons I took it off was that I was going to remove all covers and panels from the engine and paint them separate, but having removed them I am not sure its such a good idea. Theres a lot of stuff exposed that I dont really want to get contaminated.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:16 - 17 January, 2019
long time of inactivity.

I now have the frame back all cleaned and powder coated. They have done an excellent job.
(https://i.imgur.com/3gbcrr4.jpg)
(https://i.imgur.com/yPIRAHd.jpg)

I've also had a stab at painting the engine. I have some bits to touch up but generally its gone pretty well also.
(http://i.imgur.com/8Ck5BRV.jpg) (https://imgur.com/8Ck5BRV)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 15:24 - 17 January, 2019
That frames come up lovely  :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:40 - 17 January, 2019
it has. its like new.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 15:54 - 17 January, 2019
Looking nice, can't wait to see how it looks when it's finished

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 21:44 - 17 January, 2019
Shitty weather due...time for more workshop activity  ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:31 - 18 January, 2019
I assume you are giving each bolt a good clean of it’s thread and any Allen socket headed bolt is given a baby bud  and a firm wipe with scotch cloth before the correct application of anti seize or locking compound and precise torque?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 17:27 - 22 January, 2019
naturally..... ::)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:52 - 22 January, 2019
That's the level of nerdiness I got to with the Yamaha and now the new Strumpet - I like to get to know my machine on an overly personal level...  ;D
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 20:45 - 22 January, 2019
I've read about people like you.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:59 - 23 January, 2019
The “register” isn’t accessible to the public?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:13 - 9 February, 2019
At long last I have finally managed to get a day in the garage to progress the 900 project.

so, I finished painting the engine:

(https://i.imgur.com/4UFBZt9.jpg)

Did some more cleaning up of parts.

(https://i.imgur.com/Gbwku3r.jpg)

(https://i.imgur.com/Cp2Epde.jpg)

(https://i.imgur.com/GxBHqYE.jpg)

whilst I was there I replaced the swing arm bearings and one of the bearings in the suspension linkage

started to build it all back up:

(https://i.imgur.com/CqFfhEA.jpg)


I had a rear wheel from a YZF750 kicking about from an old track bike I used to own, offered it up, and its a direct replacement! happy days, I can now run a 180 rear tyre. only drawback is that its pink!

(https://i.imgur.com/OxyYdYf.jpg)


last thing I had a look at today turned out to be quite interesting. I was going to make a start on cleaning up the throttle bodies, they are a bit minging:

(https://i.imgur.com/UIC1RBh.jpg)

then just for the crack I decided to offer up the 42mm F800 throttle bodies on the engine:
They look so good. They may have to stay there!

(https://i.imgur.com/ZrFL9zx.jpg)

I have the ignijet ecu so tuning it to the bigger throttle bodies will be a relatively straight forward process. Would be a shame not to do it now I have gone this far.


Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:26 - 10 February, 2019
Looks more Magenta than pink.  ::)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:02 - 10 February, 2019
Lovely work, nice inspiration for what I have ahead with the FJ.

Those TBs look perfect on there ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 10:55 - 10 February, 2019
Looking good. What size are stock TDM throttle bodies?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:35 - 10 February, 2019
Stock ones are a piddly 38mm. I haven't done the calcs but these would probably be able to flow 50% more air.

I am not chasing big power figures, however my experience with fitting a larger throttle bodies on the aprilia mille shown that the gains were everywhere. And they were 51mm throttle bodies so bigger again
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:53 - 10 February, 2019
An old friend who had an NWS framed TRX had a YZF spare for the rear but kept the original on it for track use - 180 will look good on the TDM

Is it just cost that Yamaha would use 38mm?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:02 - 11 February, 2019
Dunno, you could argue that the smaller tbs have higher gas speed at lower revs providing better torque, but that doesn't hold true in my experience.

Interestingly the super tenere still has 38mm tbs. Everything else is much bigger.  Having sat and mulled it over I think I am going to clean up and fit the stock tbs for now, mainly because of time constraints. I am going to have to make myself a fuel rail out of stainless steel. I think it's doable but it will take time and i want the bike roadworthy by March. The good thing is I can build the new tb setup off the bike and swap it over when it's done.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:19 - 11 February, 2019
Dunno, you could argue that the smaller tbs have higher gas speed at lower revs providing better torque, but that doesn't hold true in my experience.

That was my thinking, since the TDM doesn't rev particularly high (for a bike engine), I thought maybe the wider TB's aren't needed as air flow doesn't become so restricted like it would with a higher revving engine, so they concentrated on the lower torque as priority instead.

Could just be the TDM was never meant to be marketed as a powerful bike, so they cut costs and just stuck TB's in that simply did the job though.

Just an assumption though, I'd be really interested to see if the bigger TB's make a decent difference and more importantly, would the difference be worth someone investing in the fettling for ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:54 - 11 February, 2019
Yes my thoughts exactly, so I looked at the F800 engine. Redlines at 8.5k just like the tdm.

I'm not chasing power at all really. I just like the idea of using the later technology and seeing what effect if has. If I do it I am going to do it properly and manufacture some proper head to TB adaptors that match the profile of the tb mouth with the mouth of the engine inlet, which isn't round at all.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Sidestand on 21:18 - 11 February, 2019
Did you use rattle can or a proper spray to paint the engine Coxy ?

And what colour did you use ?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:28 - 12 February, 2019
It was a rattle can, well 2 rattle cans.  I called into my local paint shop looking for some engine paint, he told me a very reputable engine builder he knows uses a BBQ paint and it works very well. I had no reason to doubt him as he wasn't actually selling me anything.

It has the high temp properties, cures with heat and is durable. Time will tell as to whether it will hold up to the british weather. 

When I sprayed it on I was a bit concerned as it looked brown! however when it dried it changed to a matt black.


anyways, attempting to keep some momentum I managed to get another hour in the garage last night.
The front engine mounts actually float in the frame and are clamped with pinch bolts. The original fame slider/spacers were old and rotten, so I used them to keep the internal surfaces free from being powder coated and made some more up:

(https://i.imgur.com/7C99PvU.jpg)

(https://i.imgur.com/xZ7Wqcr.jpg)

(https://i.imgur.com/vre53DA.jpg)

(https://i.imgur.com/f9HafeT.jpg)

(https://i.imgur.com/ccqaYGH.jpg)

Job done, the engine is now securely mounted, the rest of the rebuild can continue.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:27 - 12 February, 2019
Looking good.  Can't wait to see how the finished bike will look - almost a shame to take it out and get dirty.

I used BBQ paint on the TDM engine.  As you say, once cured comes up a nice solid black colour and is pretty tough.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:32 - 12 February, 2019
The paintwork is going to let it down unfortunately.
Some of the plastics are showing their age, I am going to try and create fibreglass replicas of the fiaring infills, so I can eventually make a carbon fibre option, and I am still going to redo the side panels in my own design.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 20:05 - 12 February, 2019
Don't get carried away....

(https://assets3.thrillist.com/v1/image/1474703/size/tmg-article_default_mobile;jpeg_quality=20.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:20 - 13 February, 2019
lovely.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 19:35 - 13 February, 2019
 :o OTT
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:10 - 13 February, 2019
Front mudguard is all wrong.  :'(
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:27 - 13 February, 2019
You all knew I was being sarcastic right?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 00:16 - 14 February, 2019
I think I did
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 07:37 - 14 February, 2019
You all knew I was being sarcastic right?
beauty is in the eye of the beholder... who's to say whether you have my immaculate taste...or not??
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:54 - 14 February, 2019
this place is deep
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:17 - 14 February, 2019
It's deep in something alright ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 17:48 - 14 February, 2019
this place is deep
Has he started sharing Jim?

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:42 - 15 February, 2019
no pictures but I cleaned and refitted the plastic undertray using all new stainless bolts, and I cleaned and started to install the wiring loom into the bike.
its at that point you realise you should have installed the wiring loom before the undertray and you have to take it all back out again  :'(

Getting there though. I am putting off cleaning up these throttle bodies, but it will be done this week.

I've just ordered a new set of steering head bearings. they look like the originals, and if that's the case they have 97,000 miles on them - impressive.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 14:05 - 15 February, 2019
Yep, they're the originals.
Don't seem to have much trouble with head bearings. So long as they're greased they seem to last forever these days.
When you've finished the tdm do you want to pop down for a weekend and give mine a once over?
Coffee and cake provided you can even borrow my secretary if you want. She's a great conversationalist and has a wicked sense of humour.

(https://i.imgur.com/ZzyvvyM.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:18 - 15 February, 2019
I bet you drop your pen a lot.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 14:34 - 15 February, 2019
Unfortunately that's not what she wears at work.
Asked her what she did for Valentine's and she said " take away, wine and my favorite vibrator and spent the night ringing the devils doorbell".


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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:09 - 15 February, 2019
I think she needs a pay rise to get some clothes that fit her.

Is she actually your secretary as if not its a very elaborate and detailed ruse
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 15:20 - 15 February, 2019
I don't care, just keep posting the pictures ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 15:41 - 15 February, 2019
Nah, just some random from the inter web.
What was said is true though.
My secretary is a scream.
When I did my leg she offered me the spare room, save me driving with the cast on, Gill was fine with it.
As Gill knows I don't tend to eat unless she makes me she phoned Emma (my sec)  and said to make sure she cooks for me.
Emma said "I don't know about cooking but I'll be sure to make him eat something even if it's just eating out".
I'm sat across the desk from her and nearly spat my coffee at my monitor.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 16:22 - 15 February, 2019
you search that image on google and it just comes up as "girl"!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 22:10 - 15 February, 2019
you search that image on google and it just comes up as "girl"!
sounds accurate to me
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:11 - 18 February, 2019
current status. Starting to look like a bike again:
 
(https://i.imgur.com/y5YNnKe.jpg)
 
(https://i.imgur.com/Ejfp4AD.jpg)
 
(https://i.imgur.com/sBcuYcZ.jpg)
 
(https://i.imgur.com/oh06VLU.jpg)
 
Theres quite a few jobs I would like to do on the bike, but the weather is getting better so I need it roadworthy asap. I will end up having a 'phase 2' of the restoration/modification.
 
The biggest job I have left to do is the exhaust. I could refit the standard exhaust, but its really minging. I have a 44mm 2 into 2 system for a TRX850 but the 2 down pipes are the wrong shape and it just wont fit.
Options are:
 
sell it to fund another exhaust system
modify/make new downpipes to mate to this system
fit the old shitty system and just dont look at it. 
 
that system on ebay was interesting, it was a 38mm system to start with the same as stock, and halfway down the down pipes it opened out to 42mm.
 
another option would be to modify the existing pipes to copy that setup. Shouldnt be too difficult.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 16:16 - 18 February, 2019
another option would be to modify the existing pipes to copy that setup. Shouldnt be too difficult.
Now I’m not normally a betting man, but I’ve got a bag of popcorn that says you’ll modify it...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:52 - 18 February, 2019
I see your bag of popcorn and raise you one tube of Smarties. The system must be modified and cleaned up and them painted to hide anything but moreover to at least compliment the effort on the frame and motor.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:42 - 19 February, 2019
Do Smarties still have a letter embossed on the cap?

I always wondered what that was for when I was a kid.  Presumably you can collect them and they spell smarties, or any words using those letters if you feel like going crazy.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 09:08 - 19 February, 2019
You could spell BUM if you were patient enough for the right letters.
I liked flicking the lids.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:28 - 19 February, 2019
We'd put the lid back on the empty box and then smack it so it fired the lid like a pop gun.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 12:01 - 19 February, 2019
I used to fill the tube with warm liver and errrrmmmm
Yeh, never mind.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:29 - 19 February, 2019
Yeah, exhaust mods bro, FTW.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:16 - 19 February, 2019
I liked flicking the lids.

Euphemism?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 03:44 - 20 February, 2019
.(https://uploads.tapatalk-cdn.com/20190220/0d08e0de15ad1269564756e21fb43bb5.jpg)

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:11 - 20 February, 2019
back on topic you amazing bunch of weirdos.

Did another hour on the bike last night. Rivetted the chain up, and fitted the stock throttle bodies. I started connecting up the wiring harness, all went back together pretty easily.
I've given the stock carbs a cursor clean up to remove all the thick crud that was baked on them, but they are not to the standard of the rest of the bike. I am ok with this as they will be getting removed at some point.

really starting to come back together now. its amazing how quickly these things start to move.

I found a lockset for a 2002 R1. From 28 quid from China, I reckon I could modify to make work. then I get back to having 1 key for all things. 

Also ordered a new set of silicon coolant hoses, they came today. I figured the originals will have seen better days. they were quite hard.

I am ordering the bends to make my own exhaust headers. How hard can it be...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 15:55 - 20 February, 2019
I am ordering the bend to make my own exhaust headers. How hard can it be...

Yaay!

What's that, you need a TIG welder?  ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 21:10 - 20 February, 2019
I’m with Zippy! ^^^
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 23:28 - 20 February, 2019
I have a tig, yet to explore and master it.  :-X
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 04:26 - 21 February, 2019
I just bought a new tig set, arrives on Friday.
4.5 fekin grand
Pictures to follow.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:38 - 21 February, 2019
 :o

I have a tig set. its one of those chinese ac/dc sets. seems to work well.

The trick with making exhausts is making sure the cuts are good enough that the mating surfaces have no gaps when you push them together. then you can tig it up with no filler wire. As soon as I start putting filler wire in it stops looking so neat.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:59 - 21 February, 2019
How's TIG compared to MIG in difficulty - my MIG welding is still very 'hobby' level but got better and ok for what I use it for.

Probably not worth me investing in TIG yet, but if those Chinesium ones aren't too expensive maybe something for the future.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:16 - 21 February, 2019
I find once you get it tig is a more relaxed process. with mig there's shit flying out the end of the gun whether you like it or not. Tig welding you add the filler rod at your leisure.

I am no expert by any means but I get by. the likes of CB will probably look at my welding and roll his eyes but certainly for mild steel tig seems pretty straight forward. I don't have a pedal to adjust the power, that's the next purchase.

Stainless is ok to weld, not as easy as mild but I cant quite put my finger what it is.

Aluminum welding is an absolute nightmare. really really hard, and more times than enough I have melted my work piece to a steam formless blob. Need to practice more as I would love to be able to make ally parts

CB needs to chime in here with valuable  welding tips and advice now  :D

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 10:35 - 21 February, 2019
A five year apprenticeship is the answer.
It's one of the few jobs left where there is nothing like practice and experience to increase skill and quality.

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Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:57 - 21 February, 2019
So it looks like a cheap machine off Amazon and 10 minutes blasting in the garage with a lot of scrap metal produced :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:01 - 21 February, 2019
sorted. if you are pushed for time 5 minutes will suffice
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:16 - 4 March, 2019
Been quiet for a while, just slowly working my way through the bike cleaning and replacing bits as required.
I have given the throttle bodies a basic clean. They are clean but quite tarnished. I couldn't be bothered to go right through them given I will be fitting my new ones at some point.

(https://i.imgur.com/Xbzug6z.jpg)

current status

(https://i.imgur.com/ngzXsS6.jpg)

Trying to find space for the extra length of cabling for the ignijet ecu has been problematic. Should be worth it in the end.

(https://i.imgur.com/z8UpW2p.jpg)

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:09 - 4 March, 2019
How much extra cabling is needed?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:41 - 5 March, 2019
no not really. its a plug an play adaptor loom, which plugs into the original ecu. It it just adds a extra 30cm to the loom length that I have to tuck away somewhere.

The new ecu does a little burst of the cooling fan when the ignition is turned on. 

in the back of my head I am thinking they have wired up the cooling fan where the fuel pump should be... we will see.
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 20:57 - 5 March, 2019
Can't you shorten the loom adaptor bit? Actually, 30cm isn't a lot bit if you need the space
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:27 - 6 March, 2019
see the bottom picture where yellow wires come out the ecu. folow that forward, you will see some more yellow wires at the front. that is plugging into the existing ecu plug on the loom.  doesnt seem like a lot but the original plug should be down where the ecu is.

its sorted now anyway. perhaps I was just being a bit of a fanny.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:49 - 6 March, 2019
Looking good though, I see you've made a start on the downpipes  :thumb
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:45 - 6 March, 2019
Well thats another story.

I did make a start, and I have found that I can cut and make the bends quite accurately. However I had difficulty welding that many joins so close together. I did the first turn and it looked not up to the standard I require. so decided to go and buy some bends.

Then someone came and bought my TRX 2 into 2 system and effectively provided me with the funds to purchase that set of performance headers that were on ebay.  So I did that.

I also got these back yesterday:
(https://i.imgur.com/L3vAZOO.jpg)

(https://i.imgur.com/ysbPD3R.jpg)

very nice. Although the YZF rear wheel fits perfectly and lines up central, I have discovered I need to make some custom spacers for the rear brake caliper to fit as its about 3 to 4mm to inboard. I will sort that with some lathery.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:43 - 6 March, 2019
Sprocket aligns also?

What are those Bridgestones they look like good summer road and odd trackday use?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:44 - 12 March, 2019
this is the infamous post in the flesh:

sprocket lines up perfect yes. I am actually using the tdm900 sprocket carrier, spacer and cushdrive as its identical - therefore the chain has to be line up correctly. the wheel is smack in the middle of the centre line, I just need to do a little jiggery p0kery with spacer to put the brake caliper carrier in correct position. I am guessing that the brake disc on the yzf750 wheel is about 5mm inboard of the TDM one.

Nothing that is insurmountable, or more than an hours work really.

after that I basically have a few body panels to throw on, fit an exhaust and she ready to go.

oh yeah I need oil and coolant adding too - must remember that...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:00 - 12 March, 2019
so not that exciting.

in the interim I have finished and filled the cooling system, and had to take steps to sort out the rear caliper.
It wouldn't be my bike if I didn't have any completely custom parts on it, I have had to make some new spacers on the right hand side so the caliper carrier sits square over the top of the rear disc.

basically this is the problem:

(https://i.imgur.com/Ce05MLH.jpg)

now that the caliper carrier is slightly more inboard, the swingarm mounting point doesnt line up.

So I did this:

(https://i.imgur.com/S5hUHef.jpg)

Getting it welded up this morning. I am nowhere near competent enough to attempt a job like that with the potential consequences of it failing, so I have farmed it out to a welder fabricator mate.

In hindsight I could have also spaced the brake disc off the wheel, but I think this is a better more permanent solution.


Now this is quite interesting (to me):

I thought I had mentioned that I had abandoned the exhaust job as it wasn't turned to the standard I wanted. all those welds so close together was causing a lot of heat distortion and it was looking like a bit of a frankenpipe. then I managed to sell the TRX 42mm 2 into 2 system which gave me the funds to purchase that system from Greece off ebay.

I have got talking to that guy, he makes loads of performance parts for the tdm, over there they use them as drag bikes, run them on methanol or turbo them. 

Was talking to him about my plans for throttle bodies, he was saying don't give a lot on their own, but combined with other mods they release a reasonable amount of torque on the low mid range (unexpected) and a couple of ponies up top. That is perfect to me. I love the mid range punch the bike has and any beefing that up would be great.


Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 15:18 - 12 March, 2019
TDM drag bike? That’ll be fun... not sure about methanol though, be difficult to find a filling station when you’re on tour...
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:46 - 12 March, 2019
(https://i.imgur.com/yms6Los.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 17:45 - 12 March, 2019
The TDM is popular with older Greek women who often have facial hair, hence “drag bike”
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:38 - 13 March, 2019
(https://i.imgur.com/yms6Los.jpg)

Mmmmmmmmmmm.  :kiss
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:43 - 15 March, 2019
these arrived today. Top quality.


(https://i.imgur.com/j2aZhZS.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 10:47 - 15 March, 2019
noice!
I see you have a desk upgrade too. 😆
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:50 - 15 March, 2019
no thats not my desk.

Mines still covered in celotape
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 13:17 - 15 March, 2019
Yum
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 14:26 - 15 March, 2019
Looks very nice. Looking forward to seeing them fitted.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:29 - 16 March, 2019
Fitted. Need to make up a link pipe, shouldnt be a problem

(https://i.imgur.com/uC4knC5.jpg)

(https://i.imgur.com/wAOQ32H.jpg)

I fired it up this morning. good news, brand new ecu and it fired up first time and settled down to a tickover, with no end  cans on it sounded like a top fuel drag racer.

good stuff

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 16:56 - 17 March, 2019
Good news on the ECU and will look forward to whatever mapping you create and what it gives you for rideability and throttle response.

An old friend who had "that" NWS framed TRX once met me at the Red Lion at Avebury. He just had the headers with no pipes and it sounded like something off of the MotoGP grid..... I was not impressed. Off he went on the back wheel. Later that day I was told the story of how he was pursued and stopped by Plod and the bike seized. tw@t.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:04 - 18 March, 2019
Police state innit.  :hitler
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:31 - 18 March, 2019
Looking good - great that it fired up no problem.

How will you set up the mapping for the new TB's?  Do you have an AFR or take it down the local dyno?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:00 - 19 March, 2019
I'm not wholly sure about that. The headers have 3 ports of lambda. The stock one at the bottom and one fairly close to the top in each downpipe.  If I could get some sort of data logger that logged afr against Tom then I could tune each cylinder myself. II might look into that
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 11:18 - 20 March, 2019
A Rasser Pi could do it Coxy, if Chris could teach us Python we'd be well on the way to all this kinda stuff ;)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:22 - 20 March, 2019
i am a software delevoper by trade, so I really should be looking at this myself. The problem I have is time scales.
I really dont have time to develop and test a datalogger unit at the moment. I have been meaning to build one for my track bike for years, and I have progressed about as far as an asthmatic ant with some very heavy shopping.
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 11:26 - 20 March, 2019
Can't be doing with that C++ crap (Sorry +'ers) but Python seems a bit more logical and there's tons of libraries out there. When I get some time I'm going to start doing some, now I have the links from ET I'll be starting one of those Massive Open Online Cock things.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:28 - 20 March, 2019
Data logger would be good if you can measure throttle openings, revs AFR etc.

I have an AFR gauge I hooked up to my old kit car to tune it when I moved it to bike carbs, and have used it on the TDM and now ZRX, but I have to do it the old fashioned cumbersome way of taking it for a rag and simply seeing if I need to go rich/lean at certain throttle openings.

Admittedly easier with carbs as you simply go needle heights or jets rather than working on an entire fuel map, but at least with the mapping you can tabulate it and see what's going on exactly at which points  :cheese
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:38 - 20 March, 2019
yeah with injection you really need to see whats happening at each load cell in the map. which is difficult when the bike is accelerating through them really quickly.

with the logger I can go for a ride, then come back and analyse the data to isolate the cells and see whether they need adjusting or not.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:26 - 20 March, 2019
When you took your swingarm off, did you replace the bearing because it was shot, or simply might as well while it's all off?

Just wondering on the best thing for the FJ when I whip it out.  It all feels fine, so tempted to simply clean up and regrease, but there's a logic to changing them when it's off to save doing it again in the future.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:44 - 20 March, 2019
mine were completely shot. seized solid and rusted to bits. I am surprised I couldn't feel that when riding it.

thinking about maybe swing arm bearings are just a big con!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 15:20 - 20 March, 2019
Didn't know they were that bad, sorry.
Agree about them being a con though. Nothing wrong with good old phosphor bronze bushes and grease nipples.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 15:21 - 20 March, 2019
Ok, will just see how they look when I open the can of worms  :wink

£35 for a set of roller bearings, not too bad if I need to replace them.  Need to see how the shock is too though, YSS make a decent looking cheap replacement.

Anyway, sorry will get out of your blog with my FJ ramblings  :wink
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:18 - 20 March, 2019
Didn't know they were that bad, sorry.
Agree about them being a con though. Nothing wrong with good old phosphor bronze bushes and grease nipples.

Sent from my SM-G950F using Tapatalk

No worries at all CB the bike has inter galactic miles on it I fully expected to find a few things that needed sorting, and as I said if I hadnt stripped everything right down I'd have been none the wiser!

I'm having a bad time with it at moment. Ordered some new exhaust straps, they are too small. Tried to drill out the snapped rear bleed nipple. Bollocksd it up and now it needs back filling and tapping. Inadvertently put the wrong oil in the magura clutch lever and destroyed the seals. It's been a rough few days!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 13:36 - 22 March, 2019
#firstworldproblems
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:02 - 23 March, 2019
hahaha very true.

new exhaust end can position:

(https://i.imgur.com/8zLOy2N.jpg)

(https://i.imgur.com/zzDEZaK.jpg)

(https://i.imgur.com/7QmcpUa.jpg)

its a little more aggressively angled than the normal tdm end cans but i think it works really well with the lines of the bike.

new link pipes
(https://i.imgur.com/VmSyRPS.jpg)

i think i am just going to weld them up so the link pipe to the end can is one piece with the header. i dont see the point of having clamps and stuff there when its never going to move.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:19 - 24 March, 2019
 :thumb
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 07:55 - 24 March, 2019
Will the angle of the end can prevent you fitting the panniers?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:23 - 24 March, 2019
Check out the first photo of the series. Panniers are fitted!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 08:28 - 24 March, 2019
He's got the outskirts on in the first picture Al.
I agree in principal about welding the link pipes but it might be awkward getting to the rear caliper and suspension/swingarm bolts for servicing purposes.
Wouldn't want to remove the whole exhaust system just to grease the suspension linkage.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:46 - 24 March, 2019
That's a valid point. Didn't think of that.

I suppose worst case if I weld it up then the header down pipes come apart  from the collector underneath the bike
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 18:31 - 24 March, 2019
Upswept pipes take 5 years off of the bike
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 18:49 - 24 March, 2019
Nice, perfect angle for the cans. I thought I'd like to do that with mine but can't find a link pipe or have the skill to tweak it.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 18:55 - 24 March, 2019
I made some high level pipes for my first tdm.
Made from scratch, silencers and all.
(https://uploads.tapatalk-cdn.com/20190324/2edcc3bc4b7a9911f8db0cd95e967839.jpg)(https://uploads.tapatalk-cdn.com/20190324/ac8c4627cb1d874ffbbea6b3152471d6.jpg)(https://uploads.tapatalk-cdn.com/20190324/4c7fef36e78d9821f9f235728c9abebf.jpg)(https://uploads.tapatalk-cdn.com/20190324/16f29b3b5c16d9645ece2918d5a759cd.jpg)(https://uploads.tapatalk-cdn.com/20190324/b0a7e4d4364fe33b4b1d192c81f97f6e.jpg)

Sent from my SM-G950F using Tapatalk
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 16:31 - 25 March, 2019
done.



(https://i.imgur.com/N9iUGco.jpg)



(https://i.imgur.com/m8Nmuhc.jpg)



I've actually ended up with them a bit lower than I was originally planning but its still fine.  Fired the bike up and its so quiet. 

I let it run up to temperature for a basic test to make sure the ecu is behaving and all seems to be good.



just need to build up the body work now and sort out that hydraulic clutch setup.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 16:35 - 25 March, 2019
What clutch set up have you got?
I was thinking of converting the faz

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 16:37 - 25 March, 2019
I've only just noticed your bolt tub and realised it's the same one I got off my missus from the washing machine tablets  :cheese

Also wondered about the clutch.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 18:50 - 25 March, 2019
Yes I have about 10 of those tubs. Nicely stackable and readily available.

're clutch setup, I did this on the trx track bike. I used a magura clutch lever as used on many dirt bikes, linked to a hydraulic pull rod. It's awesome on the track bike so i repeated it on the tdm, only I made a glaring error in that the lever is not designed to clear stock switch gear, which wasn't a problem on a track bike, but i am changing the left hand switch gear to an apico dirt bike setup
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 12:02 - 26 March, 2019
Pfff. who needs zausts?

(https://proxy.duckduckgo.com/iu/?u=http%3A%2F%2Fwww.actumoto.ch%2Fwp-content%2Fuploads%2F2014%2F12%2FYamahaMT-09Tracerdetail_12.jpg&f=1)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:48 - 26 March, 2019
you. I see the wheelie bin sized mid box/collector in the background.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 16:32 - 26 March, 2019
Y'see I like that look and it's easy to clean and service the rear end.
Don't like the size of the collector but at least it's down low.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 22:14 - 26 March, 2019
Can't really see the collector tbh, it's pretty hidden under there.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 07:56 - 27 March, 2019
its a neat solution, but will postulate its not the best route for engine power output.

otherwise superbikes would have them as well.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:40 - 27 March, 2019
Yeah it's more for sound etc.

Cans have been having to get bigger over the years, they can fit more of an ugly baffling into that size box and then market it as something cool not having an exposed silencer.

The fact people like to swap them out for a sminky light weight Akra system etc and show it off says it all really.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:18 - 27 March, 2019
The new GSXR1000R end can is comical.

Pretty sound thinking though as all the cat and crap that you dont need will get dumped when you replace the end can,
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 19:04 - 27 March, 2019
My Strumpet's cat is forward of the rear pipe link as is the Lambda - the Lambda was removed during the ECU remap - the cat remains with standard silencers and the legislation derived flat-spot at 4k banished
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 20:18 - 27 March, 2019
its a neat solution, but will postulate its not the best route for engine power output.

otherwise superbikes would have them as well.
well I probably agree, but it's more powerful than my R1200GS was.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:43 - 28 March, 2019
they certainly are. they are a stonkingly good power plant.

I love mine in the track chassis
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:12 - 4 April, 2019
This hydraulic clutch install is becoming a pain in the ar5e [filtered].  I've eventually got it working, needs a good test run before I head up to scotland and risk getting stranded.



current setup with new switch gear:



(https://i.imgur.com/JWImIHl.jpg)



I need to modify the wiring, and I need to buy a mirror clamp, but otherwise its getting there. once this is done its only bodywork that is left.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 10:21 - 4 April, 2019
, needs a good test run before I head up to scotland and risk getting stranded.

Bring a cable setup with you spare!?  :dontknow:
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:32 - 4 April, 2019
Certainly looks pretty sminky  :thumb
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:17 - 5 April, 2019
nice smooth action.  Not really necessary, but its the little things that make a bike feel better put together.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 09:27 - 5 April, 2019


nice smooth action.

I find Astra glide works for me.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:27 - 5 April, 2019
I just had to google that.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 14:34 - 5 April, 2019
I was using KY Jelly to get my subframe bushings in (pretty much the same stuff as the manual says).

One of them wouldn't stop slipping out either!  :ohyeah

(https://live.staticflickr.com/923/28540516787_058470eeaf_b.jpg) (https://flic.kr/p/Ku2BiD)
195 (14-07-2018) (https://flic.kr/p/Ku2BiD) by Chris Reeves (https://www.flickr.com/photos/zippyonline365/), on Flickr
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:40 - 5 April, 2019
I'm saying nothing  :whistle
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 14:54 - 10 April, 2019
That's the trouble, make it easy to slip in and it just as easy to slip out.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 19:24 - 10 April, 2019
Guinness does the same according to Waspy!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:09 - 10 April, 2019
403 FORBIDDEN
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 15:58 - 12 April, 2019
PMSL... io error.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:55 - 18 April, 2019
nothing much done on the bike the last couple of weeks what with dealing with thieving nob heads, but I will be having a morning on it tomorrow to see if I can get it running and on the road.

Shouldnt take too long.

I really do want to fit it up with some mk1 tdm bodywork, its much nicer looking.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 12:06 - 18 April, 2019
Yeah I quite like the Mk1's, I did see somewhere a picture where a guy fully fitted Mk1 bodywork to a niner.  Looked a pretty good job too.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 13:25 - 18 April, 2019
this one:

(http://www.carpe-tdm.net/ipb/uploads/monthly_07_2018/post-180622-0-63451300-1531214396.jpg)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:04 - 18 April, 2019
That's the fella  :thumb

Actually I wonder if I could move Kylie on to something like that in the future (already have the Mk1 lights on it), would need to make a frame for the front fairing to bolt onto but not impossible  :tink
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:07 - 18 April, 2019
if I am doing it then it will be a simple task of copying it.

Shouldnt be too difficult to knock up a couple of fairing support frames.

whats your headlights like? If I remember correctly the mk1 headlights were largely useless as a method of projecting a beam of light forward.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:15 - 18 April, 2019
Seem ok to be honest but I haven't ridden on unlit back roads since fitting them, so not had a chance to really test them.

Also I have a pair of 20W LED aux lights fitted to the engine bars that really throw out a lot of light, so they probably over-ride the beam anyway - seem ok though and seem no worse than stock niner lights, although that's not difficult.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:27 - 18 April, 2019
that is true. I used to ride round with my full beam on with no complaints at all
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:56 - 18 April, 2019
My RSV had twin high beam projectors and a single headlight, to see in the dark on a sports bike I had to ride with my finger on "flash" as both couldn't be switched on at the same time. I nearly had a head-on outside of Oxford when I lost sight of the road after changing gear and losing enough light to see the road line and found myself on the wrong side....
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:17 - 24 April, 2019
I think they are finally getting better but any bike  older that 5 year old, you may as well save some electric and not bother with lights.

Anyways. I have finally got a bit motivation back and look!

(https://i.imgur.com/2lqKLjH.jpg)

(https://i.imgur.com/HwRhUSq.jpg)

Ready for a test ride. Currently wearing its old clothes. I will look at bodywork later on in the year when I have more time.

I am coaching the the kids rugby tonight so probably wont get time to get out on it, but I will definitely be out tomorrow.
I need to see what state of tune the ECU is in, if it will run ok, and how much fettling in needs. 
I need to look into tuning options, from what I know there is the lambda autotune setup on the ecu. My exhaust has a lambda port on each header so I can autotune each cylinder individually.
Or I could just book it on the dyno for a mapping session.

In other news I did a bit of MX at the weekend. cant have my son outdoing me, although I have a lot more respect for him now because that shit isnt easy!

(https://i.imgur.com/9Vh3LlS.jpg)

(https://i.imgur.com/mOHWdyJ.jpg)





Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:52 - 24 April, 2019
You both look to have the same amount of air beneath you
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:29 - 25 April, 2019
he was going way bigger than me. This was the only picture of me that made me look like i knew what i was doing
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: ChrisG on 17:45 - 25 April, 2019
Ready for a test ride. Currently wearing its old clothes. I will look at bodywork later on in the year when I have more time.

Bugger, I was back in the uk at the weekend and completely forgot to have a rummage in the garage for the Mk1 faring bits.  I'm there this weekend too, you still interested if I have a rummage?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 18:35 - 25 April, 2019
Definitely am mate!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 19:05 - 25 April, 2019
Ready for a test ride. Currently wearing its old clothes. I will look at bodywork later on in the year when I have more time.

Bugger, I was back in the uk at the weekend and completely forgot to have a rummage in the garage for the Mk1 faring bits.  I'm there this weekend too, you still interested if I have a rummage?
no photos allowed
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:05 - 27 April, 2019
First ride complete, all good so far!

The ecu map is pretty good out of the box, its doesn't do anything untoward the manners are decent. I suspect some fine tuning would lead a bit more punch from about 2.5krpm, but I cant really complain. no soot on exhaust, and it pulls really hard.

Only really negative was that chinese clutch slave cylinder is a touch slow to return and if I am gunning in it can make the clutch slip ever so slightly. That and I had a bit of play in the throttle cable which is my pet hate.

Cant complain really!

(https://i.imgur.com/NTuKsTy.jpg)

(https://i.imgur.com/BDhsCse.jpg)

(https://i.imgur.com/9BvRziv.jpg)

(https://i.imgur.com/JE0AN09.jpg)

few little tweaks to finish off but I am very happy with the outcome.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 11:28 - 29 April, 2019
Looks good  :cool
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 11:54 - 29 April, 2019
Yeah it's a shame to take it out and get it dirty  :thumb

Quite like the valve cover being left silver, gives it a little 'accent' on the engine.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:31 - 29 April, 2019
I wish I had that powder coated instead of spraying it with a rattle can.

I have a spare one that I am going to get powder coated and i'll fit it over the winter.

Might be on for a scotland trip this weekend!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 14:31 - 29 April, 2019
Isn't hindsight wonderful thing.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 15:58 - 29 April, 2019
Isn't hindsight wonderful thing.
Wish I’d said that!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:59 - 29 April, 2019
me too
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:47 - 1 May, 2019
So I hooked up the ecu to my laptop tonight, as I'd forgot to even check the settings for the throttle position sensor.

Lo and behold it was out. At a closed throttle it was showing 10% throttle opening. I think this might sort out that tiny bit of puffiness coming from a closed throttle.

Test ride tomorrow. I am going to put the bike on the rollers for a morning mapping session.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:17 - 1 May, 2019
That’s a dyno session? And is that you and the ECU building the map in conjunction with the operator?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:14 - 2 May, 2019
Will be interesting to see if you can squeeze a nice bit of extra poke out of her.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:45 - 2 May, 2019
Yes I would operate the laptop, with the expert setting it up and instructing me to make the changes.

I know the software better than the dyno guy, I've done a lot of research on it.

THAT SAID.  having made a few tweaks after the last ride out, namely tightened the throttle cables to get the free play out and calibrated the throttle position sensor values on the ecu, the bike is utterly amazing now.

I cant believe a generic map on a standalone ecu can feel so good. The small amount of fluffiness at low revs must have been down to the fact that at a closed throttle the ecu thought I had a 10% throttle opening, which effectively meant it was overfueling through the lower part of the rev range.  The bike is super clean and crisp now and its got impeccable manners.

Another thing. When I rebuilt the bike I set the forks 10mm through the yokes to speed up the steering, as everyone does. testing riding the bike I found the front end not to be as confidence inspiring. Before I could feel the tyre biting into the road, and just didn't get that feeling with the bike. So as part of the tweaks I pushed the forks back to the stock position. what a difference. that extra bit of pressure required on the bars really transmits the feedback to what the front end is doing.  we are not weaklings, that extra bit of effort to turn the bars means the feedback through your hands is amplified.

I am 50 50 whether I am touring Scotland this weekend on the bike, or doing some more offroading again. Its a tough life!

picture from my desk this morning:

(https://i.imgur.com/QFkF6gM.jpg)

Really liking the new lights. I think I may even just leave the 900 setup on there as the lights really set it off.

What I am considering doing is making a set of lower 'wings' that fit to the bottom of the side fairing panels and changes the lower lines of the fairing.   
 
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 12:43 - 2 May, 2019
 :eat
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 21:18 - 2 May, 2019
Told ya, that engine rocks.
I tried that with the forks too and came to the same realisation but TBH if the damping was easily adjustable I think you could make it work. Because you have shifted the weight forward I think you need a click or two more compression damping.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:17 - 2 May, 2019
its really quick now CB, with the ecu and the new headers it seems to push that little bit harder.

very impressed. as a road bike is got more than enough power now. very happy.

Maybe one day I will find a nice set of super tenere usd forks to install, but that would be purely for asthetics and the bike feels so planted on the road.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:19 - 2 May, 2019
i meant to ask - whats the crack with the seat? is it lowered? does it have anything special in it?

i don't plan on changing it as its comfortable and i love the ergonomics of the bike, just interested.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 22:23 - 2 May, 2019
CB farts hot seat foam melting farts when he rides

Good to have the ECU working well so soon and clean throttle response from properly adjusted cables, it makes it so much easier to ride and control. Mr Yamaha does tend to know how to set his geometry correctly. Have the forks been restrung or revalved if not serviced? I’d be off riding around Oban on it!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 23:23 - 2 May, 2019
I made the seat myself. I'll post some pictures tomorrow.
I wanted a sharp down slope to take the stress off the lower back when out playing all day .
I've done something similar with the Fazer seat but I'm not fully happy with it but I have put a gel insert in it so that helps.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:05 - 3 May, 2019
ecu update. on the gas its truly incredible how well the bike feels. I'll put it on the rollers at some point mainly to check that its fuelling ok, more power would be a nice side effect but it really doesn't need it.

since setting the TPS range in the ecu I do however have a little bit of a stutter running a constant throttle between 2000 and 3500rpm (around 5% throttle, ie rolling along in the 30mph zoen or 40mpg zone. 

I also have a bit of popping on overrun which given I have no exhaust leaks as its now 1 piece, must be lean on the overrun.

I have gone into the map last night and increased the fueling a touch at the 5% to 10% throttle range to see what effect that has.

Ive also adjust the compensation map as I think it might have been on warm up enrichment a bit too long.

Finally, I have increased the cranking fueling as when I was using it yesterday it seemed a little bit harder to start when it was hot. I am used to half a turn and bang, not a 2 goes.

I do enjoy having the ability to tweak the ECU.

Ive even looked at any of the other functions on it yet. I have a quick shifter to wire in, and I need a set of wheel speed sensors so I can enable the track control, not that it really needs it, but if it saves my ass in a lot grip situation just once then its worthwhile.

Other features are MAP sensor input for forced induction application and N2O controller.
There is also a pit limiter, which are all completely useless but hey ho.




Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 11:02 - 3 May, 2019
CB farts hot seat foam melting farts when he rides

Good to have the ECU working well so soon and clean throttle response from properly adjusted cables, it makes it so much easier to ride and control. Mr Yamaha does tend to know how to set his geometry correctly. Have the forks been restrung or revalved if not serviced? I’d be off riding around Oban on it!

I rebuilt the forks last year, not sure on the spring rates but the forks have racetec gold valves in them. I've not adjusted anything, it seems to work really well out the box. The feedback and pressure thing is interesting but whilst it really helps on the road for getting a feel for the front end is doing, my TRX track has a super steep moto2 level steering head angle and that makes the bike super responsive and adjustable for lines and direction change. super fast steering, and yet no instability at all. maybe I should start a moto2 team up - whos with me?!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Matlock on 13:29 - 3 May, 2019
maybe I should start a moto2 team up - whos with me?!

Me! I'll make the tea and "look after" the brolly girls.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 13:36 - 3 May, 2019
I'd be up for that but it'd need a 1200 cc motor in it to haul my fat ar5e [filtered] around with any alacrity.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:28 - 3 May, 2019
Its all coming together. 

2 bike team, you can be the A rider CB, but given the regulations  I am afraid you are going to have to go on a diet of bog roll and water for few month to drop some timber.

I am thinking zipster as the number 2 rider, on account that he weighs about as much as my labrador and hes used to crashing things. 

Mattlock is the term pervert, Nog and ready can be crew chiefs, and anyone else I haven't mentioned can be cheer leaders.

Gary could be the brolly girl(guy), although I'm not sure how the team pervert would feel about that. He might have to start harrassing other teams, which could be a valid strategy
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: celticbiker on 16:54 - 3 May, 2019
Gary standing next to me on the grid holding a brolly and wearing a pink bikini.
Good grief, it's my idea of heaven.
On another unrelated topic, I'm just gonna go take a shower.

Sent from my SM-G950F using Tapatalk

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 17:55 - 3 May, 2019
Gaz just text me to say he'll get on all fours on the grid to wedge the front wheel to keep the bike upright and he'll wear "big pants" to keep the tyre hot
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 22:40 - 5 May, 2019
bwahaha classic!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 14:31 - 7 May, 2019
snags.

So I washed the bike, yesterday, went to start it up, it ran for about 20 seconds, coughed, spluttered and cut out. then wouldnt start at all.

I spent all day mucking on trying to get it going again, before eventually refitting the stock ecu to which it fire up first time.

Long story short I managed to soak the new ecu at the connector block and it didnt like it. Dried it off and it all seems fine now.

Any advice on the best way to weatherproof connectors? Once dried out I sprayed it all liberally in white grease, but I am thinking I need to shield it somehow. I ride in scotland - it rains all the time there.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 14:42 - 7 May, 2019
This is probably one of the problems you have from having the headlight area open to the elements.

It's a tricky one as make it too water tight and then sometimes it's worse as any water getting in can't get out either.

I personally like a good wrapping with SA tape to keep the worst out though.

An alternative might be to get some sort of plastic box to mount the ECU inside of and put drain holes in the bottom.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 16:07 - 7 May, 2019
nothing to do with the headlight, apart from the front its all still sealed at the back.

Its more to do with me using a pressure washer to clean the bike and blasting it back through the orifice at the back of the side fairing.
not ideal but I am fairly sure had that been the stock ecu it wouldnt have suffered. 

I might wrap the lot up in self amalgamating tape so its completely air tight. I know what you are saying though sometimes thats not the best plan as if it does leak theres no where for it to go.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: E.T. on 17:07 - 7 May, 2019
What about not using a pressure washer on bike?    :teach
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 18:31 - 7 May, 2019
Tricky...  My old XTZ would happily short it’s coil because of the design of post and connectors were too close. Years of differing green and tape combos gave way to a simple wrapping in bubble wrap and cable ties to make the water path next to impossible
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 06:51 - 8 May, 2019
Can you retrofit your aftermarket ecu into the stock ecu case and use it's more weatherproof design?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 08:41 - 8 May, 2019
nothing to do with the headlight, apart from the front its all still sealed at the back.

Its more to do with me using a pressure washer to clean the bike and blasting it back through the orifice at the back of the side fairing.
not ideal but I am fairly sure had that been the stock ecu it wouldnt have suffered. 

I might wrap the lot up in self amalgamating tape so its completely air tight. I know what you are saying though sometimes thats not the best plan as if it does leak theres no where for it to go.

Fair enough, good that the headlight isn't an issue then - yeah maybe just go with SA tape then all around the junctions.  It's fairly resistant and easy enough to get off if you need to remove in the future.  Maybe some silicone grease in the joint before taping too, just in case any does get in as a second line of defence.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 10:59 - 8 May, 2019
the current plan is to A) not pressure wash the bike anymore, in my defence I only did it as i was pressure washing the offroad bikes, and they get in such a state they have to be done. 

and b) smear vasaline everywhere adn tape it up. 

I was considering extending the loom and relocating the ecu to the back of the bike under the seat.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Matlock on 12:27 - 8 May, 2019
Gary could be the brolly girl(guy), although I'm not sure how the team pervert would feel about that.
I withdraw my application forthwith.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:38 - 9 May, 2019
looks like gaz has been snubbed.


laste night I smeared vasaline liberally everywhere on the ecu connector block and wrapped it up in insulating tape. There isnt really any space for water to get in now. Should be ok i would have thought. I might still extend the loom to relocate the ecu completely out the way.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:55 - 9 May, 2019
Sounds like a plan.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: AlunL on 20:26 - 9 May, 2019
I’d stick to that Coxy, extending the loom could be making more problems for the future.
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 13:43 - 10 May, 2019
Gary could be the brolly girl(guy), although I'm not sure how the team pervert would feel about that.
I withdraw my application forthwith.

How unfair!

Coxy, I'd stick it in the box with a hole in the bottom where the cables come in, small hole in each corner on the bottom, have a biccie an a cuppa. Water is a bitch, as long as you can keep most out. And a bit of vaseline on your contacts never hurts.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 21:56 - 10 May, 2019
had the bike out for a blast tonight.

the bottom end is completely sorted, however the top end feels likes its a bit flat between 5000 and 6000rpm.  I think its a bit lean. I am going to add a bit of fuel in that rev range at 80% to 100% and see what effect it has.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 00:24 - 11 May, 2019
Not having the slightest ability with an ECU I went to BDS, if I was doing it myself I’d go to JHS. My 850’s JE piston, flowed head, Stan Stephens (Ray Sringer) cams, TTS & PDQ rebuilds, Dynojet carbs, K&N, Dyna, Yoshi/Gibson blah, blah builds blew up 500miles after the slightest thing that didn’t work for another thing. Yams big twins were shite. Motors designed to trot along on carbs. OVER racing team in Japan couldn’t make them work. Injection for regulatory purposes was fine to a point. Keep it rich and under stressed IMHO!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 23:59 - 11 May, 2019
i think I am going to invest in a wide band lambda setup to monitor the mixture.

was out again today, all was fine for the first hour or so, i was bimbling back through the villages to get home and the bike started misfiring on low throttle openings, then progressed to missing at bigger throttle openings.

when I got home I plugged the laptop in and had a look. I had disabled the inlet air pressure sensor as I forgot it had one. That is used for idling and very light throttle control.  I have re enabled it, and I am going to have a look to make sure its piped in properly. 

I hope thats what it is, I am pinning my hopes on the fact that the missing at bigger openings is because the plugs were getting fouled. 

The nagging doubt in my head is saying why didnt it do it all the time.  the only difference what that the air temperature dropped considerably when this started to happen.

I'll get there.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 00:29 - 12 May, 2019
Did you try switching it off 'n' on again?
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 12:13 - 12 May, 2019
Lolz

On speed triples I've read dozens of posts with peeps freaked by similar symptoms usually sometime after doing something around the airbox where there's eight vital connections including the air pressure sensor, air temperature sensor and manifold pressure sensor.

As someone unsophisticated in this area having owned three injected bikes from three manufacturers with three variants of assorted sensors. In time I'll better understand how alien ECU's function on alien machines - presumably through software set to accept data from an array of available inputs. Given the control ECU works in MotoGP and you're doing something similar on your Yam I might have to soon start calling you Jeremy Burgess!
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:31 - 13 May, 2019
I was one of those triumph people who had that problem. I built a bike for my dad from a reframed cat B breaker, but some of the parts had already been sold off, including the pipework at the back of the airbox.

At low throttle openings and low engine speeds its more accurate to meter fuel out based on manifold air pressure, on the triumph it was an utter pig without it, no power at all, then it would lurch forward like a horse that had been smacked on the ar5e [filtered] with a shovel.

The pipes on the 3 cylinders had to be the same length also, quite important.

Anyways I have ordered my wide band lambda set up to do some tuning on the road.

when it goes it goes pretty hard. so much so that I think the clutch is now slipping occasionally under 100% throttle.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 21:28 - 14 May, 2019
Clutches are pricey all in but a simple solution even a Jeremy Kyle guest can get right
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:08 - 15 May, 2019
this arrived today:
(https://i.imgur.com/kTI9kgH.jpg)

wideband lambda with controller unit to plug directly into my ecu for mapping.  should allow me to see what is going on and get it mapped up on the road.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:24 - 21 May, 2019
so, misfire sorted, almost.

if I crack the throttle at 2.5k rpm when its hot it can stutter. no where near what it was like, but its still not acceptable to me.

So, I set my autotuning thing up and headed out. The bike has a flattish spot at 4000 to 5000rpm, then at 5500rpm it goes mental. a big step in power output.

I ran up and down the a19 accelerating through this rev range, and it couldnt really tell any difference.
So I came back and connected the laptop and confirmed it had autotuned nothing. So when I checked the manual it appears autotuning only happens with the laptop connected. erm, thats going to be a problem! 

So my plan is to get a usb extender, stick the laptop in my back back with the power mode set not to shut down with the lid closed, and go ride. A bit weird for an autotune setup but when it rome.

Proper fast and furious style riding along fiddling with my laptop. Going to try that tonight.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 10:01 - 21 May, 2019
When I had the power commander autotune on the FZ1 it built a trim map separately to the actual fueling map, so you could see where it had decided that more or less fueling was needed.

You could take out any odd results and then accept the trim which would rebuild the fuel map based on the new data.  Would have thought it would have worked in a similar way.

I guess that was specifically designed for on the fly bike tuning whereas this is designed more for dyno guys who would be running the autotune with the laptop connected while ragging it on the dyno.

On the road it's a pain though as any throttle fluctuations cause dodgy results, so you have to find nice clear road where you can do a clean roll on throughout the rev range.  I think it said only to accept minor changes in fueling each time you do a run and after a few runs it should be getting there, but see how you go, that might be better software with it tied in directly to the lappy.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:16 - 21 May, 2019
That's pretty much the same as this one. I have the option of updating trim maps, or mapping direct to the injection tables if I want.

I have purchase a USB extension lead, so I should be able to keep the laptop connect with it in my backpack.


My exhaust has 3 lambda ports - the stock one in the middle, and one much higher up much closer to the head in each header pipe. The plan is to build a map that is pretty close to to the ideal, then, split the injection map so there is one for each cylinder, and individually map each cylinder with a much finer set of constraints.

I should end up with a very nicely mapped bike that is specifically mapped for the small differences in each combustion chamber.

I might also stump up for some high performance coils as a belt and braces setup. I'm fairly certain the bogging/missing I am getting is caused by not enough 'accelerator pump'  at low rpm. so you snap the throttle open and it the low air speed in the tbs makes all the fuel drop out of suspension. There are various settings in the compensation maps for this. I don't want to muck on with them just yet before I get a decent base map.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Readmarx on 12:38 - 21 May, 2019
Apps and updates and compatibility and cables and blah blah blah

And filters and seals and jets, needles and float heights and blah blah blah

Did Bill Gates just reinvent the wheel!?


 :eat

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 12:46 - 21 May, 2019
and I quote:
'The line it is drawn
The curse it is cast
The slow one now
Will later be fast
As the present now
Will later be past
The order is
Rapidly fadin'.
And the first one now
Will later be last
For the times they are a-changin'.

Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 13:22 - 21 May, 2019
Certainly beats pulling ZRX carbs off to feck about with jets and needle heights every five minutes  :bag
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 15:25 - 4 June, 2019
Thought I would provide a little write up about My findings on the new ecu.



Firstly, as previously mentioned my engine has been lightly tuned, including:

raised compression
fast road cams
ported head
I have rebuilt the bike over the winter and refreshed virtually everything on there.

I decided to treat the bike to a custom ecu given the old power commander on the bike gave up the ghost.
The Ignijet ECU is a standalone ecu, which means you do away with the stock ecu altogether, unlike the Power Commander which is a piggy back ecu and intercepts and modifies the signals the stock ecu sends.
The advantage of a stand alone ecu is full control of all areas of engine management. With a piggy back ecu you always have the stock ecu underneath trying to conform with its original brief of emissions, noise and safety regulations, so you will always have things such as reducing the power output in lower gears, dips in certain sections of the power/torque curve where it had to conform to some noise or emission regulation etc
The standalone doesn't care about any of that. It has a fully customisable ignition and fuel map, and can also split the fueling maps for individual cylinders, and both the ignition and fueling tables can be setup for each gear if you want to.

I decided to buy the wide band lambda setup and see if I can build a map myself using the autotune function. It took me a while to get it working, nothing was happening until I realised the autotune function actually happens on the laptop not the ecu, so I eventually got myself a setup with a laptop in a back pack on my back. 
I developed a tuning process on a long straight slightly uphill section of local dual carriageway, where I could do some top gear roll on's with varying constant throttle openings. The gradient providing a bit more resistance to the engines speed increase.
I did a few of these runs up and down, and headed home to see the results. The laptop records the values in a compensation map, which you can then choose to apply or not.

I have done this process about 4 times now and the adjustments are getting smaller an smaller every time I head out.
The results are quite impressive. Where it was a bit hesitant or flat, it was identifying and adding or taking away fuel as necessary. The net effect is the bike is super smooth from 2000rpm upwards. Its got that buttery smooth throttle uptake that carbs have, and it pulls like a train from 4000rpm onward.
The engine feels much stronger everywhere, and its also a lot smoother, which i didn't expect. Vibrations are much reduced. in normal cruising  conditions.


The map is pretty much sorted now, all hesitation and flat spots have been elliminated, and I tuned the the engine to a nice safe 13.8 to 13.5 AFR.
I need to have a look at the ignition map now, I think I can retard the ignition a touch on the full throttle maps as I should have better cylinder fill with the tuned engine. This is going to be a bit of an experiment as I have not really messed around with ignition maps, but I'll report back my findings.

Jobs left to do is installed the quickshifter and enable the function on the ecu, and over the winter I am going to fit front and rear wheel speed sensors and enable the traction control feature.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Vu Ja Dave on 01:01 - 5 June, 2019
Don't forget to put some stickers on.
Title: Re: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: BashplateAlAssad on 08:08 - 5 June, 2019
Sounds like you're doing some magic with it Coxy :)
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 08:56 - 5 June, 2019
I've got a couple of niggles which I am not sure whether its the ecu or something else.

occasionally when it is hot it develops a bit of a misfire when rolling on the throttle. I am going to tighten the parameters up for the autotune, currently it is making fairly big steps, in its adjustments. This was by design to get it into rough shape. the next stage of the plan was to set it to make much finer adjustments. I think the steps I am currently tuning on are too big and its jumping either side of optimum.

I rode it into work again today, it was misfiring a touch, interestingly where it is misfiring in the map is where its now suggesting adjustments. So either the values are wrong or the misfire is causing odd results. I'll apply the changes before I ride home tonight
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Rob the Nog on 09:02 - 5 June, 2019
Yeah that's where it gets hard to diagnose, the misfire will bugger up the fueling reading, so the autotune will look to change the mapping but will be thrown out by the amount of fuel to add/subtract. The values either side of the misfire should help to show if there's any odd numbers though. Just trial and error until you get the smooth map.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: Zippy on 09:33 - 5 June, 2019
If it’s just when hot, I’d expect it to be more likely something on the ignition side than the fuel side, heat breaking down insulation causing shorts etc. Happen on the rx-8 with older coil leads etc. coz they get really hot, just adding some more insulation between the coil leads often solves it. If it was fuel side, then I’d expect it to be a bit more consistently misfiring? Although I guess given you’re still effectively developing the tune, it’s all a bit trickier to diagnose. And it may be the ignition system is fine but just can;t quite cope under these new conditions.
Title: Re: Coxylaads Road Bike Thread thing split off blog topic thingy
Post by: CoxyLaad on 09:49 - 5 June, 2019
well exactly. I could refit the stock ecu and I bet the misfire would disappear. but does that mean the there is a problem with the ecu, or the ignition map on the ecu, or is that the way the coils are driven by the new ecu is causing the problem.

I have been doing some research on relationship between the cylinder fill, flame path and ignition advance. on part throttle the engine has poor cylinder fill, which means the flame path is slower as the mixture is not as dense, therefore to get it to reach optimum burn at the correct time the spark has to fire earlier, hence more advance. So when I open the throtlte if I am getting more mixture in than the stock advance map is expecting and the advance is too much then I may be getting some pre ignition because of too much advance? I think pre ignition is a bit more subtle that what I am experiencing.

I have replaced the leads and plugs, it might be time to just replace the coils so I can rule them out. I presume they have been on since new therefore will have nearly 100k on them.