Aurora Rally 990 Build

As Good or Better Than Riding?

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1coolbanana
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Aurora Rally 990 Build

Postby 1coolbanana » Wed Nov 01, 2017 9:08 am

The start of a new project :D

For months Ive been anguishing about which way to go.
Decided not to go single cylinder as my riding is now only long distance dirt touring.
Ive broken way too many bones over the years and now its time to relax, chill out and smell the roses.

Theres nothing on the market that floats my boat as much as the 9XX series bike so a new project is under way.
The 1190R is a spectacular, capable and awesome but its big, a lot bigger than the 9XX bikes and has never given me the "smiles per mile" that the 9XX did.

The plan is to find a good stock low k 9XX and build it into exactly what suits me and the riding I do.
Once I saw the Aurora Rally 9XX, that was enough for me.

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That was inspired by Chris Cork and his current Dakar race bike, the 950

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So here we go again :dance:
Cowabunga dudes .......

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1coolbanana
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Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Wed Nov 01, 2017 8:29 pm

Found myself a blank canvas I thought would be perfect.
South African import, 2009 990 Adventure, low k's, only 9000 on the clock and completely original and I was assured its immaculate and never seen dirt.
Sounds perfect for the project.
I bought this sight unseen other than some average photos.
As it arrived and although the pictures look good, it soon became apparent that it was not as advertised.

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Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Thu Nov 02, 2017 9:13 am

Preparing for the Build.....

The first thing that was apparent was that every panel, piece of plastic, had scratches and scuffs, crash abrs and swingarm have deep scratches.
Baked on red concrete mud on front and rear headers, grazes in the bash plate.
Lots of corrosion from what appears to have never been washed or cleaned properly.

Not a huge deal but, not how advertised or promised.
The more I poke around, the more you find, more signs of bodgyness and some mods that have been removed and put back to stock.
Books are conveniently missing too.

Anyway, theres nothing I can do about it now so best forget and move on with the build.
The good news is that doing a dealer search uncovered that at least the k's seem original.

First good clean up discovers a few secrets

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Axles jammed by grit and mud
Front guard obviously torn off by mud buildup has been badly repaired
Caliper slider pins seized with grit, mud and rust.
Brake pads soaked with grease or oil!!!
Huge hole cut out of rear guard (probably from a tool tray), bodgied up and hidden.
Disassembly damage on forks and shock, so mods done there.
Clutch pushrod and ball at the slave cylinder rusted out

See what else we find.

More cleaning up

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Cowabunga dudes .......

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DustyWheels
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Re: Aurora Rally 990 Build

Postby DustyWheels » Fri Nov 03, 2017 6:52 pm

Looking forward to following this,I'd love to have room, in my shed and bank balance, for another 990.
I might ride like crap, but I'm having fun, I think

2010 KTM 690 Enduro
2012 KTM 990 -

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1coolbanana
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Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Fri Nov 03, 2017 7:47 pm

So all the pads are replaced with Metal Gear Sintered, all the slider pins un-seized, cleaned and lubed and fluid bled and flushed...
That should take care of the brakes.

The clutch pushrod ball cannot be bought, you can only buy a complete slave wghich sucks but I have a spare original slave.
Got the ball out of the spare, cleaned up the existing slave and pushrod and were good to go :thumb:

While I was messing around I figured Id check the usual things starting with water in the swingarm and drilled a drain hole...
Guess what :lol:

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Dumped the oil and filters, clean up the oil jet and drill it out to 0.40 mm

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Time to rip headers and shock off and chip away at some of the red concrete

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Scrubbed up ok

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As did the shock, but its evident that the shock and forks have been apart by the scars so not sure if thats good or bad yet

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Moving right along

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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 » Fri Nov 03, 2017 9:17 pm

Got a bit more done tonight.
Got the Akra 2 - 1 on and sorted.
Shame about all the dints in it, so much for being perfect :?

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Hooked her up and did a bit of tuning.
Uploaded one of my previous tunes which should suit this very nicely, refitted the stacks I machined previously and did a sync and full adaptive reset.

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Removed some of the clutter of SAI (SAS)

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The different length stacks I machined for a smoother ride and more bottom end

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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 Nov 04, 2017 11:04 pm

Time tro strip and clean the subframe to fit the new plastics as some twat decided to cut a huge hole in the original one!

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Replaced with a new one

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Started on the front end, cleaning up the front axle. seals and bearings.
To my surprise, the steering head bearings were completely rooted but they didnt feel bad

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And strip them all and replaced the bearing and cups.
Luckily I have a spare set here :thumb:

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Pretty easy job, just time consuming, another couple hours blown!!

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New bearing in

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And time to prepare for the Scotts BRP by removing the ignition lock from the top clamp

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And the get the BRP ready

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All buttoned up :D

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Cowabunga dudes .......

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Wodger63
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Re: Aurora Rally 990 Build

Postby Wodger63 » Mon Nov 06, 2017 9:52 pm

You don't do things in half measures, do you?
Great work mate, you shouldn't be bored for a little while. :popcorn:

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Tue Nov 07, 2017 9:17 am

Another big night...
Setup the wiring and temporary GPS mount, temporary as in until the Aurora front end gets fitted.

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Chucked on the rally pegs that go from bike to bike and the old B&B rack :D

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Cowabunga dudes .......

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1coolbanana
Posts: 1792
Joined: Wed Sep 23, 2009 5:14 pm
Location: NW Sydney

Re: Aurora Rally 990 Build

Postby 1coolbanana » Tue Nov 07, 2017 9:24 am

The new purge reverse module from Ken Allen arrived so time for a fuel pump rebuild and mod.

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The pump looks a little nasty for only 9k klms, but who knows what they put in the petrol in South Africa!
Cant imagine what has caused this brown discolouration!
This is the pump that came out compared to my equally as old spare

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Rebuilt it with new O rings and filters using my spare and kept the brown stained one for a spare.
Fitted the reverse purge module as well.

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Cowabunga dudes .......


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