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View Full Version : What do you do when both your ADV bikes are in bits?



CrazyFrog
19th April 2009, 15:31
Okay picture this..... I'm sitting at home this morn with severe cabin fever after looking after my new baby and partner for the last 3 weeks, spending most of my time inside, just being a new Dad and helping out where I can.
And then she says......."Hey, why don't you go out on the bike this morn", OMG, music to my ears! Uhhh, ok then, why not, I say.
The plot thickens.....I've been so preoccupied doing the new Dad thing, that I haven't had time in my man-cave to tinker with either one of my bikes, which are both in bits. No time to muck around putting bikes back together, I have a 2 hour window of opportunity, not to be wasted.........
So, I drag out the trusty scoot, my fave little city blaster, the Gilera Runner 180 2-smoker, kick it over and I'm off!
Waaaaa - F..kin- Hoooooo!:headbang:
So I'm heading down the highway, yep she's all good for highway riding, it'll cruise happily at 120kmph, and max's out around 140 clicks, I'm rolling happier than a pig in shit.......

CrazyFrog
19th April 2009, 15:34
But I feel I need something else......... time to take that dang scoot ADV'ing!!
I turn off the highway and head up a nearby forestry road, lay down some mean rear wheel drift marks and head for the top, the mighty scoot taking it all in it's stride.
Could have done with some 12" knobblies, and some more front end travel, but the rear end was great with the new Bitubo shock I installed a couple of months back. I dunno how I'd get on doing river crossings, but gravel roads were a doddle, I just gotta watch them pot-holes. Seemed to ride nicely on the gravel between 50-70kmph, even on those wee 12" wheels.
Bloody good fun, but a do miss the DRZ!

junkmanjoe
19th April 2009, 16:28
what a blast, must have looked so out off place, scooter up in the forest....ya just need to tast bugs aye mate.
i not had my bike for nearly 2 weeks, im going nutty :2thumbsup

Waihou Thumper
19th April 2009, 16:41
On your new addition!
Is that 640A back together yet?

NordieBoy
19th April 2009, 17:41
Go the Gilera!

:woohoo:

buggsubique
19th April 2009, 17:50
If I had a trophy or a medal I would give it to you! That's awesome!

PS you freak me out!

MyGSXF
19th April 2009, 17:58
:lol: classic!!! GO that man!!! :2thumbsup

congrats on the little one!! :baby:

Box'a'bits
19th April 2009, 19:16
We seem to have similar taste in bikes. :2thumbsup

I also have a 640a, and a Gilera 180 Runner (same colour & year). The Gilera has been on a number of Kiwi's (from Wellington) & blitz's the gravel road into the site. Very comfortable of long trips if you put your feet back onto the pillon pegs..........:headbang:

Where did you get the biturbo shock & how much (if you don't mind my asking)? This is currently on our shopping list here. The Gilera seems to have lost damping in the rear, especially if we take a pillion.

Whats up with the KTM?

Cheers

Steve

CrazyFrog
19th April 2009, 21:04
We seem to have similar taste in bikes. :2thumbsup

I also have a 640a, and a Gilera 180 Runner (same colour & year). The Gilera has been on a number of Kiwi's (from Wellington) & bitz's the gravel road into the site. Very comfortable of long trips if you put your feet back onto the pillon pegs..........:headbang:

Where did you get the bitubo shock & how much (if you don't mind my asking)? This is currently on our shoping list here. The Gilera seems to have lost damping in the rear, especially if we take a pillion.

Whats up with the KTM?

Steve

Hey Steve,
I upgraded the shock after my stock standard spring broke?!! The rest of the shock was okay, but original springs were a bit crap. The Bitubo shock I bought was from UK (www.pmtuning.co.uk) and they ship to NZ no problem. It cost 73. 00 GB Pounds, shipping was an extra 20 GBP, so worked out to be NZ $245 at the time with the exchange rate, but this still worked out way cheaper than buying one thru Scootling or Scooter eMotion in Aucks for around $500.
It's improved the stability no end, but now I wish I could do something with the front forks, they bottom out occasionally (esp off-roading!!! LOL)
I've also upgraded the engine pivot bushes which has taken the slop out of the rear end making the handling much more responsive.
I love this scoot, it's got so much herb for a little'un, and it's fantastic in the tight winding stuff. I've had it out on some decent roadies too, mostly around the top of the south, Yeah, it's pretty comfy on the highway and cruising speed is not an issue. My mate and I (sames bikes) occasionally embarrassed bigger bikes in the Buller Gorge and the Takaka Hill, but we'd never win the straight line war. :2guns:
The KTM has an issue with starter solenoid or something in wiring between solenoid and starter motor....niggly bloody electrics basically.
I just need some time to source the problem really, need to get my hands on a multimeter, shouldn't be a biggie.
Cheers.

blackballs
19th April 2009, 21:22
:scooter::first:

CrazyFrog
19th April 2009, 21:30
:scooter::first:

Scoots RULE!!!!!!!!
I know no shame..........:clap:

bart
19th April 2009, 21:51
Awesome man :clap:

topo
19th April 2009, 22:33
GO the mighty scoot:2thumbsup

Box'a'bits
19th April 2009, 22:44
Hey Steve,
The Bitubo shock I bought was from UK (www.pmtuning.co.uk) and they ship to NZ no problem.
It's improved the stability no end, but now I wish I could do something with the front forks, they bottom out occasionally (esp off-roading!!! LOL)
I've also upgraded the engine pivot bushes which has taken the slop out of the rear end making the handling much more responsive.
I love this scoot, it's got so much herb for a little'un, and it's fantastic in the tight winding stuff.
Cheers.


Just now placed an order with PM Tuning for the Biturbo shock, pivot & swingarm repair kits. :banana: See what you've started!! The handling has been getting sloppy, and I figured that these were the culprits (quite aside from the shock)...:weep:

Need to put some time (& money) into servicing the Gilera. Mandy uses it all the time - I'm not allowed nr it mostly (.....except if there is a problem).

Ours is not as tidy as yours - Mandy's dropped it on one side (not badly, but in hindsight we should have claimed insurance), & the exhaust is getting pretty scruffy. Lives outside under a carport, cause Mandy doesn't like to struggle with the garage door :(.

Got issues with MY 640a starter, as well. Getting used to kick start. E-start works if the bikes warm, mostly. Battery's reputed to be new, but its a Koyo, & I have my doubts. Electrical & starter issues seem to come with the territory with these bikes..

warewolf
20th April 2009, 11:35
Well done that man! Go the scooter :scooter:



Got issues with MY 640a starter, as well. Getting used to kick start. E-start works if the bikes warm, mostly. Battery's reputed to be new, but its a Koyo, & I have my doubts. Electrical & starter issues seem to come with the territory with these bikes..That's a bit harsh, they don't seem to have any more or less electrical issues than any other bike. The only regular failure seems to be the ignition wires at the connection to the key switch - as happens on many other bikes.

What's wrong with your e-start? There is an issue with the starter clutches on the later bikes. If you catch it early you might be able to save it with a $10 fix.

Box'a'bits
20th April 2009, 18:17
Not a starter clutch issue. More around how many amps the starter takes to turn the bike over with, & whether there is spare to actually fire the bike.

Battery was reputed to new when I bought it Nov '08, but the PO had the bike for a couple of years & did sod all kms on it. So could have been older & discharged a few times.

Need to check it out with a multi meter to see if it's just a crap battery, or the starter, or a solenoid issue. Start issues come & go, which confuse the issue.

This can be a bastard on the trail - haven't sussed left foot kick starts while mounted yet. Need to do the neutral lock out mod as well. No issues kick starting the bike when I'm off it.

Cheers, Steve.

Unit
20th April 2009, 18:23
Wel I hope Mr DMNTD gets hold you you CrazyFrog cause you make the world of motorcycling what it really is, any two wheels and having fun. He's in your town tonight on my 14 on a bit of a check out the SI buzz.

NordieBoy
20th April 2009, 18:52
Scoots RULE!!!!!!!!
I know no shame..........:clap:

It's also too big for the DB1K small bike challenge :D

warewolf
20th April 2009, 21:01
Not a starter clutch issue. More around how many amps the starter takes to turn the bike over with, & whether there is spare to actually fire the bike.

Battery was reputed to new when I bought it Nov '08, but the PO had the bike for a couple of years & did sod all kms on it. So could have been older & discharged a few times. Hmmm sounds like weak battery if the problem is only first thing in the morning, but if it happens during the day when the battery should be nicely charged, maybe not. Unless a sub-spec battery has been fitted to save dosh. I priced one up last winter, it was the second-most expensive one listed.


This can be a bastard on the trail - haven't sussed left foot kick starts while mounted yet. Need to do the neutral lock out mod as well. No issues kick starting the bike when I'm off it. When warm the bike should kick-start easily. Seated using left foot with hot bike, I set the lever about 10-15cm past TDC. This gives your leg an easy run for the first part of the swing, plus you don't need much speed or vigour in the kick.

Box'a'bits
20th April 2009, 22:31
Colin, the Koyo is the correct spec. But it may not be a strong battery. Charging o'night doesn't seem to help at all.

Ran the Orongorongo Station ride 2 weeks ago without lights, & it generally fired okay, then. The confusing thing is that at other times, sometimes it fires, sometimes not. Doesn't help if it hits compression in the early part of the start cycle.

As I said, I need to investigate (with a multimeter), & not just work around it.

Steve

Waihou Thumper
21st April 2009, 19:06
Not a starter clutch issue. More around how many amps the starter takes to turn the bike over with, & whether there is spare to actually fire the bike.

Battery was reputed to new when I bought it Nov '08, but the PO had the bike for a couple of years & did sod all kms on it. So could have been older & discharged a few times.

Need to check it out with a multi meter to see if it's just a crap battery, or the starter, or a solenoid issue. Start issues come & go, which confuse the issue.

This can be a bastard on the trail - haven't sussed left foot kick starts while mounted yet. Need to do the neutral lock out mod as well. No issues kick starting the bike when I'm off it.

Cheers, Steve.

Is still the original battery for a 2002, it kicks over first time on the e-start, still very strong.
I had one issue, when I hit the e-start it would start and then keep whirring over. This was more of a wet water issue, a short under the dash. Have never found the problem but we bridged the solonoid, starter and it is perfect now....No biggie

Neutral lock out mod? I kick start the bike regularly, it is handy to keep it in practice....

Box'a'bits
21st April 2009, 19:28
As I understand it, the bike comes with a number of 'safety' features which include lockouts that prevent the engine starting when in gear.

I have already bypassed the sidestand lockout.

The neutral lockout mod allows you to start the bike while it is still in gear. (selecting neutral is always fun when stalled on a hill :bye:). http://www.advrider.com/forums/showthread.php?t=298887, post 6.

Steve

Padmei
21st April 2009, 19:50
while no expert on batteries, a few auto elecs have told me that overnite chrging doesn'y work a lot of times as the batt needs a deep charge for a few
days- a mlti meter won't pick that up. doesn't take much for a good batt to become crappy by not being held at full charge

Woodman
21st April 2009, 20:42
Wel I hope Mr DMNTD gets hold you you CrazyFrog cause you make the world of motorcycling what it really is, any two wheels and having fun. He's in your town tonight on my 14 on a bit of a check out the SI buzz.

Hey, which route did he take to nelson , as he couldn't make his mind up on the ferry last night.

warewolf
21st April 2009, 23:56
As I understand it, the bike comes with a number of 'safety' features which include lockouts that prevent the engine starting when in gear.

I have already bypassed the sidestand lockout.

The neutral lockout mod allows you to start the bike while it is still in gear. Ummm isn't this what the clutch switch is for? It is on most bikes. Pull the clutch in any gear, thumb the starter, be on your merry way before you even stop rolling. Jaybo's mod eliminates ALL lockouts with one mod, it is not just a neutral lockout. Such simplicity is great for his desert/safari race bikes, overkill for us street riders.

All this stuff is pretty normal on all bikes. Either the stand has a switch to detect it is down (typical jap setup), or it flicks up automagically when the bike is not weighting it (typical euro setup) usually smacking your shin in the process, and/or letting your nice shiny Dewcarti have a little lie down when the wind gusts.

My bike has no sidestand and therefore no sidestand lockout ex-factory. :bleh: To be honest, I don't know why you would want to start the bike in gear with the sidestand down. You'd want to be landing pretty big jumps to get the sidestand to flick down far enough to trigger the switch...

As a final thought; my 2T EXC has an almost identical clutch lever. One of the differences is that it is missing the bump that triggers the clutch switch on the 640, as it has a different type of switch on the EXC. Intriguingly, the EXC emergency plastic levers are the right shape to suit the 640. If you have clutch switch issues then maybe you've got the wrong lever fitted? I'll bet the EXC one is cheaper.

warewolf
22nd April 2009, 00:02
a mlti meter won't pick that up.A battery needs to be tested under load. A battery that charges fine, looks fine, tastes fine, measures fine with the multimeter can still be f*cked. Ask me how I know.

MXNUT
22nd April 2009, 09:50
To be honest, I don't know why you would want to start the bike in gear with the sidestand down. You'd want to be landing pretty big jumps to get the sidestand to flick down far enough to trigger the switch...

I was having a problem with my DRZ that whenever i rode it through water it would cut out for a few minutes. This was strange as my previous off road only model had been in water twice as deep with no problems.

I finally figured out that this was the side stand switch getting full of water and causing the ignition cut.
I have since bypassed the switch and had no further problems.

NordieBoy
22nd April 2009, 10:17
You'd want to be landing pretty big jumps to get the sidestand to flick down far enough to trigger the switch...

Some dirt/crud in the sidestand pivot and heading over a medium size bump and the stand moved down a bit.
The crud stopped it moving back up...
Took a few minutes to work out why the engine had died.

Another + for WD-40 :D

warewolf
22nd April 2009, 11:51
Hmm, I must have been real lucky with my DRs, never had that problem. Cutting out on a water crossing would not be nice... fair call.

Box'a'bits
22nd April 2009, 19:21
Ummm isn't this what the clutch switch is for? It is on most bikes. Pull the clutch in any gear, thumb the starter, be on your merry way before you even stop rolling. Jaybo's mod eliminates ALL lockouts with one mod, it is not just a neutral lockout. Such simplicity is great for his desert/safari race bikes, overkill for us street riders.


My bike will only start if the bike is in neutral. This is a pain on any difficult trail. Pulling in the clutch makes no difference, hence the interest in removing that lockout.

Maybe before I start down this track I should see why that is....

Steve

NordieBoy
22nd April 2009, 19:42
My bike will only if the bike is in neutral. This is a pain on any difficult trail. Pulling in the clutch makes no difference, hence the interest in removing that lockout.

Maybe before I start down this track I should see why that is....

Steve

Sounds like your clutch switch is broked.

Woodman
22nd April 2009, 19:57
To be honest, I don't know why you would want to start the bike in gear with the sidestand down.

It is handy for oiling the chain while propped on the sidestand with the back wheel spinning in gear. Can't do that with the sidestand lockout.

warewolf
22nd April 2009, 21:24
My bike will only start if the bike is in neutral. This is a pain on any difficult trail. Pulling in the clutch makes no difference, hence the interest in removing that lockout.

Maybe before I start down this track I should see why that is....Good plan. That is one thing that has been broken on several used bikes I've acquired. The DPOs had the same complaints you have. It's usually the first thing I fix!! Can't stand riding a bike that won't start on the run, esp. a new one that you are prone to stalling.

warewolf
22nd April 2009, 21:25
It is handy for oiling the chain while propped on the sidestand with the back wheel spinning in gear. Can't do that with the sidestand lockout.Maybe we should compile a list. 101 reasons to bypass the sidestand lockout :D

Woodman
22nd April 2009, 21:33
Maybe we should compile a list. 101 reasons to bypass the sidestand lockout :D

Bike needs to be able to be started in any gear with stand up or down and clutch in or out.

Box'a'bits
17th May 2009, 17:41
Hey Steve,
I upgraded the shock after my stock standard spring broke?!! The rest of the shock was okay, but original springs were a bit crap. The Bitubo shock I bought was from UK (www.pmtuning.co.uk) and they ship to NZ no problem. It cost 73. 00 GB Pounds, shipping was an extra 20 GBP, so worked out to be NZ $245 at the time with the exchange rate, but this still worked out way cheaper than buying one thru Scootling or Scooter eMotion in Aucks for around $500.
It's improved the stability no end, but now I wish I could do something with the front forks, they bottom out occasionally (esp off-roading!!! LOL)
I've also upgraded the engine pivot bushes which has taken the slop out of the rear end making the handling much more responsive.
I love this scoot, it's got so much herb for a little'un, and it's fantastic in the tight winding stuff. I've had it out on some decent roadies too, mostly around the top of the south, Yeah, it's pretty comfy on the highway and cruising speed is not an issue. My mate and I (sames bikes) occasionally embarrassed bigger bikes in the Buller Gorge and the Takaka Hill, but we'd never win the straight line war. :2guns:

Cheers.

Got the shock, swingarm pivot kit, & engine pivot kit for the Gilera 2 weeks ago. Wasn't quite as cost effective as Crazy Frog Experienced. Freight was GBP 64!! and GBP prices have increased somewhat for both kits & the shock.

Attempted installation last Sunday afternoon. The swingarm kit & shock were an easy install.

The engine pivot bushes were another matter. Should have been a press out job, but the bushes were well glued in. Heat, pressure, & pounding won't shift. Had to drop the engine & transmission out of the frame, which was a major. Eventually tore the inner bush getting them out, ground back some of the residual rubber, welded a bead on the inside of the metal portion of the bush (to shrink it). Then the outer dropped out piece of cake. The new bushes are all metal affairs, so will be solid (no movement aside from the pivot plane).

Now have the bike back on the road (which has pleased Mandy, & Katherine given that the bike is their sole form of transport). The refurb has tightened the whole bike up, to the extent that the weak point is now the front end.

I have dropped some preload on the rear shock, to restore some of the rake, to stop the front pushing. But (like Crazy Frog) I suspect now I'll need to play with the front damping & preload to even things out. The fork seals are due for attention anyway.

Doing a service has also shown a number of areas needing further attention, but has overall improved the bike's pick up (amazing what a clean air filter will do for you). Just won't be passing sports bike on the inside quite yet...

Cheers

Steve