Aurora Rally 990 Build

As Good or Better Than Riding?

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1coolbanana
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Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Fri Dec 29, 2017 9:06 pm

After some long conversation with some guys on ADVrider about fork valving, shim stacks and the infamous "midvalve" my OCD got the better of me.
Some guys were kind enough to provide with their stacks on there 9XX's so I put them all together and modified them based on my weight, riding style etc and came up with another trial.
I bought a whole stack of shims so here we go.

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This gave me the chance to put the right springs in that came from Slavens in the US.
The springs are the right length now at 485 mm X 0.60 kg mm.
I also wanted to increase the fork travel slightly to the nominal 250 that I was after.

New midvalve stack

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New rebound stack on the other side of the piston

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New spacers on the damper rod to give me the 250 travel Im after

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New base valve stack

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Made new spring spacers to compensate for the spring length and travel changes and I get the 250 mm unpreloaded

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Once preloaded to nominal, it comes out to 256 mm which is the 250 plus 5 mm bottoming clearance.

And Im really busting to try this out asap.

For anyone interested, this is where its at now.

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EDIT: This setup is too hard, not enough float and got rid of some shim double ups on the base valve and added second staging.
Cowabunga dudes .......

braaap!
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Joined: Sat Dec 31, 2016 4:14 pm

Re: Aurora Rally 990 Build

Postby braaap! » Sat Dec 30, 2017 2:28 pm

1CB, g'day!

Following the (re) build so far and the coming Aurora upgrade with anticipation...
cheers!

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1coolbanana
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Joined: Wed Sep 23, 2009 5:14 pm
Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Sat Dec 30, 2017 6:49 pm

Great to see you here mate :thumb:
Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Mon Jan 01, 2018 11:44 pm

Last minute decision, doing an overnight ride with a couple mates so had to get the UHF setup.
Great to have comms at a dust free distance

Same setup as the last couple of 9XX's and works well for me.

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PTT button on bars

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Cowabunga dudes .......

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1coolbanana
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Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Sat Jan 06, 2018 3:56 pm

Had a great first ride out.
1000 klms in two days really gave me a chance to test things out.
I really had a ball.

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One thing that came to light is that the front end is too stiff as is.
Need to make it softer in the high speed especially as during the long haul its a little tiring.
Need a bit more subtlety and plushness especially as I plan to travel light with this bike.

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Will be having another go as soon as the weather settles as is forecast for 40+ for the next few days

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Cowabunga dudes .......

Andrew2
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Re: Aurora Rally 990 Build

Postby Andrew2 » Sat Jan 06, 2018 6:31 pm

Sorry I couldn't make it Marc. Hopefully next time.

The middle photo is my kind of road.

anydavenow
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Joined: Fri Aug 18, 2017 1:43 pm

Re: Aurora Rally 990 Build

Postby anydavenow » Mon Jan 08, 2018 9:25 am

Great photos!

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1coolbanana
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Joined: Wed Sep 23, 2009 5:14 pm
Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Tue Jan 09, 2018 9:37 pm

For years Ive used KTM stock bars, 950, 990, 1190, all the same.
A bit narrow and a funny bend.
For years by the end of a big day, I suffered from hand, wrist and shoulder pain, sometimes chronic.
I just assumed it was me and old age!

This time around I tried some Pastrana High FMX bars as I thought some extra 50 mm width and higher, different shape bend would help.
These bars ended up the same height as the original bars WITHOUT the Rox risers and are a totally different shape bend as well.

Well.......what a revelation!
1000k's on in a couple days and I had no discomfort to speak of and are so much more comfortable, sitting or standing.

Highly recommended, very happy with these :thumb:

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Cowabunga dudes .......

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1coolbanana
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Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Sun Jan 14, 2018 9:28 pm

After numerous shim stack attempts and a couple more iterations with varying results I tried Johnf3's stacks posted in THIS thread with a few mods.

http://advrider.com/index.php?threads/f ... ng.722590/

Wasnt too far away from the stacks I thought were too hard and harsh, at the top of this page, just ended up with more float and removing some double up shims.
Also added some two staging to the base and reb, whether thats an improvement remains to be seen.

Went for a 40klm rural road ride and so far its the best result Ive had so far. so, many thanks John :-)
Looking forward to giving it a proper go on the usual dirt and gravel touring I do :-)
Certainly makes the back end feel pretty crap, but it is high k, original, 15 year old shock!

The hardest part by far is transferring what you feel to an appropriate action on the shims!

Pretty happy with it atm, need another over night test ride :wink:

This is were Im at, comments appreciated :-)

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Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Wed Jan 31, 2018 6:34 pm

Well....Im still waiting for Aurora parts, getting a little frustrating but what can you do.

But the new shock has arrived so ..... :thumb:

The shock Ive been using recently is a 2003 Adv shock, with 230 mm travel and 380 mm eye to eye length.

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This is replaced with the Wilbers custom, 255 mm travel; and 385 mm eye to eye.
This shock can be now altered to 280 mm travel and 395 mm length if I wish to later.

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Original 210 travel, recent 230 travel and new 255 mm travel shocks

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Its only increased the ride height by 10 mm and is length adjustable and I currently have 278 mm clearance :thumb:

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As for Aurora.....waiting waiting waiting :x
Cowabunga dudes .......


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