Aurora Rally 990 Build

As Good or Better Than Riding?

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Mon Dec 18, 2017 9:03 pm

Centre stand is about 20 mm too short currently

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so went to see the welder up the road to get my centre stand lengthened.

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All sorted and at the 245 R spec length

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Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Mon Dec 18, 2017 9:24 pm

:yo:

The wheel that Ash's custom built for me arrived.

Haan 990 hub, custom spokes, laced onto KTM tubeless 21" rim :D

Bit of an experiment as I dont think anyones done this on a 990.
Many "hard" guys will scoff but thats ok, this is what I want to suit my riding (and age)

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Fitted the rim band and gasket seal to the centre

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Fitted a conventional tyre valve.
No one could tell me if these can take the place of the TPMS sensors that go into theses rims but dimensionally these seem to fit the bill so its all a bit of an experiment right now.

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Fitted the Motoz Mk2, after hating the Mk1, I hope this isnt a mistake!
I would have fitted a GT723 but no stock atm.

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This is a sweet looking hub :D
I was surprised that it came with bearings, seals and even beautifully machined black anodised axle spacers!

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Im going to leave it for a couple days and make sure it hold pressure before stripping the other wheel and fitting discs etc

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Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Wed Dec 20, 2017 7:45 pm

Woohoo!
It holds air :lol:

Under 40 degrees here today so was able to finish the tubeless wheels off with the completed front.
Hmmm, did I go too far, bit too flash :ne_nau:

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Cowabunga dudes .......

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DustyWheels
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Re: Aurora Rally 990 Build

Postby DustyWheels » Wed Dec 20, 2017 8:07 pm

Me likey , ........... :dance:
I might ride like crap, but I'm having fun, I think

2010 KTM 690 Enduro
2012 KTM 990 -

Andrew2
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Re: Aurora Rally 990 Build

Postby Andrew2 » Wed Dec 20, 2017 8:14 pm

Nice work Marc :clap: . I keep looking at the welder and wanting to push that bit of tubing back on the bench a bit more :shock:

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Wed Dec 20, 2017 8:23 pm

Im surprised how much slack is in the disc bolt holes and you can easily bolt it up with a few mm of runout

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Setting up the discs...
They are very awkward to get right because they are floating discs as well!
Got them running pretty good though, less than 0.1 mm

Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Wed Dec 20, 2017 8:26 pm

Andrew2 wrote:Nice work Marc :clap: . I keep looking at the welder and wanting to push that bit of tubing back on the bench a bit more :shock:


Yes, I know, it was driving my OCD nuts.
BUT, never mess with a tradies stuff :lol:
Cowabunga dudes .......

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Sat Dec 23, 2017 2:45 pm

Went for a little ride this morning just to see how it felt after all the work.

Pretty nice :thumb:

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Anyway, I had a bit of time to kill so I though it was a good a time as any to replace the clutch pushrod.

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New and old
How it gets like this on a bike with less than 10k klms is beyond me! :ne_nau:

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While I was putting it back together, its a good time to machine the front face of the pressure plate to smooth out the rough casting.

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And now we have a nice machined surface to look at through the window instead of a rough cast one (yeah, yeah....OCD, I know :lol: )

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Cowabunga dudes .......

Andrew2
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Re: Aurora Rally 990 Build

Postby Andrew2 » Sat Dec 23, 2017 5:19 pm

I'm thinking it may be best not to know any of the bikes history mate judging by some of the parts you're removing/fixing.

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1coolbanana
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Re: Aurora Rally 990 Build

Postby 1coolbanana » Sat Dec 23, 2017 5:30 pm

Andrew2 wrote:I'm thinking it may be best not to know any of the bikes history mate judging by some of the parts you're removing/fixing.


Nothing serious though, just lots of little things that I want to get right.
Most of which probably wouldnt bother normal people :lol:
Cowabunga dudes .......


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