790R....Here We Go Again

As Good or Better Than Riding?

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1coolbanana
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790R....Here We Go Again

Post by 1coolbanana » Tue Feb 04, 2020 11:48 am

New build time, here I go again, down the rabbit hole.......

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Cowabunga dudes .......

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1coolbanana
Posts: 1924
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Re: 790R....Here We Go Again

Post by 1coolbanana » Tue Feb 18, 2020 11:48 am

It was with great pains that I had to sell my Aurora 990 :(
Due to the nature of all my injuries particularly my right arm, I just couldnt ride it for any length of time without a lot of pain that was just making riding too hard and not pleasant.
Borrowed a bike for a couple of weeks with electronic cruise control and OMG, it made so much difference that Im hoping this is the way forward for me to stay on a bike, at least for a while.

Enter 790R
Hopefully its not too brutal for me, but it feels so light and manageable, really, quite a lot smaller and lighter feeling than anything else Ive owned since a 640 Adv.

First impressions is very good, just like the test ride, super light feel, handles extremely well and nimble, heaps of power and an amazing low COG.

First things first and pull it apart and take the useless junk off and add a few essentials and maybe a few fun bits :D

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Need a rack.....modified re machined an old B&B I had that had been on an 1190 I think

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A side stand enlarger

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And a low front guard staright of an 1190R, high guards are not for me or the riding I do, not interested in getting covered in crap

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Also added this to the front guard to give it a little more height, just a 20 mm lift

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Cowabunga dudes .......

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Tue Feb 18, 2020 11:56 am

Few more important things....

GPS mounting and wiring.
Made a mount out of some bits I had, a modified Vanasche mount and a RAM ball and a socket, wired up to an accessory circuit and were good to go :thumb:

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First proper ride, so far very impressed :yo:

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Cowabunga dudes .......

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1coolbanana
Posts: 1924
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Re: 790R....Here We Go Again

Post by 1coolbanana » Tue Feb 18, 2020 11:59 am

TCM head straight to protect against broken mounts, this should fix all potential issues.
Essentially a reinforcement plate for the tower mounts on the steering head which are a known failure point.

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Cowabunga dudes .......

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Tue Feb 18, 2020 12:14 pm

1190R 25 mm Risers fit too :thumb:

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Commonly refered to as a "CRAP FLAP" , to cover the big hole where debris and leaves get in behind the bash plate, a friend makes these so that another box ticked

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And another minor thing, got a small generic axle puller and made a split bushing to suit the 28 mm ID of the axle

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Cowabunga dudes .......

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Tue Feb 18, 2020 12:27 pm

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Cowabunga dudes .......

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Wodger63
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Re: 790R....Here We Go Again

Post by Wodger63 » Thu Feb 20, 2020 6:59 am

Looking good, I must say I prefer the aesthetics of the low front guard.
Plus it must add some stability when on the H'way.

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Thu Feb 20, 2020 11:33 am

Some bits arrived :yo:
Get rid of that "sewing machine with buggered big ends" sound :)

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Sounds sweet, without the baffle, not loud but thumps nicely :thumb:

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Cowabunga dudes .......

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Thu Feb 20, 2020 11:45 am

With all the talk about burnt out clutches and clogged oil jets I thought Id take a look.
Its a 15 minute job from start to finish so better safe than sorry.
The entire clutch assembly is quite isolated from much external lube in this engine design especially with the oil level being so low in the sump and splash lubrication would be minimal.

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It really looks a lot drier than it should be, friction surfaces had the faintest wiff of oil and the jet did not appear clogged.
The original spec is 0.3 mm.
This is the same jet size that has been lubing LC8 clutches for about 20 years and the common practice for those has been to drill the jet out to 0.50 mm.
This provides theoretically 3 times the oil flow compared to the 0.30 mm

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I actually drilled it to 0.40mm which doubles the flow and went for a ride, it felt smoother and quieter.
Took it apart again and it appears to be more oily

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But still not like a 990 for example so I went ahead and drilled to 0.50 just like the previous model LC8's

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See how this goes but Im sure it will be fine and a big improvement.
Will check again after the next ride.
Cowabunga dudes .......

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1coolbanana
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Re: 790R....Here We Go Again

Post by 1coolbanana » Thu Feb 20, 2020 12:40 pm

Bugger, couple of warranty issues...
Moisture in the dash :?
Warranty replacement on the way.
And an oil leak near the countershaft.
Not a show stopper just an inconvenience.

The dash is a rather pandemic problem and KTM are supposed to be using a new supplier which doesnt leak.
I guess Ill find out soon.

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Also an annoying oil leak which Im hoping is the counter shaft seal and not the sump gasket.

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Cowabunga dudes .......

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