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volimoto customs
เข้าร่วมเมื่อ 4 ต.ค. 2021
My goal on this channel is to share my journey of starting up my custom motorcycle workshop and building custom bikes as well as to bring you guys motorcycle related content, from making my custom DIY workshop lift, to showing you around the largest motorcycle show in Europe.
Bought a KTM SuperDuke 990, but it had some issues…
2008 KTM SuperDuke 990 motorcycle restoration. I diagnosed the problem stemming from a failed water pump which is a well known issue for these LC8 engines, but this one was noticed way too late and cause all kinds of other issues. I took the engine out and completely apart so I can fix anything needed. I got the engine sorted and assembled the bike.
Hope you enjoyed the video!
Music in this video is licensed through Audiio LLC.
Music in this video 🎶
-Adam Simmons - Rain and Thunder (Instrumental)
-Kyle Church - Good life (Intstrumental)
-Kyle Church - Slow down (Instrumental)
TIMESTAMPS
00:00 Quick intro of what's coming
01:18 Start of diagnosing the problems
11:35 She purrs again but we have issues
12:37 Start disassembly of the bike
15:12 Engine is out / we can start taking it apart
26:00 The LC8 engine case is split in two
28:05 Valve job
31:56 LC8 engine assembly shall commence
45:25 LC8 engine water pump rebuild
46:40 Swingarm bearings had something to say
47:50 Engine is going back into the bike
51:45 First startup after rebuild - didn't go to plan
54:03 Chain install and riveting
55:17 Getting her back on the road
Hope you enjoyed the video!
Music in this video is licensed through Audiio LLC.
Music in this video 🎶
-Adam Simmons - Rain and Thunder (Instrumental)
-Kyle Church - Good life (Intstrumental)
-Kyle Church - Slow down (Instrumental)
TIMESTAMPS
00:00 Quick intro of what's coming
01:18 Start of diagnosing the problems
11:35 She purrs again but we have issues
12:37 Start disassembly of the bike
15:12 Engine is out / we can start taking it apart
26:00 The LC8 engine case is split in two
28:05 Valve job
31:56 LC8 engine assembly shall commence
45:25 LC8 engine water pump rebuild
46:40 Swingarm bearings had something to say
47:50 Engine is going back into the bike
51:45 First startup after rebuild - didn't go to plan
54:03 Chain install and riveting
55:17 Getting her back on the road
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Why am I a LC8 addict? It’s both expensive and painful but the awards when it runs is so good it’s worth every penny of pain!🤣😂
I have 990 sm , since 5 years very happy but maintenance it’s like a porche , to put back in place this angine will cost between 1k 1,5k if u do the job
Yeah, tell me about it! I got her fairly cheap because of it’s issues, but I didn’t expect to have to replace so many things so the cost added up quickly.. probably ended up the same as if I just bought a known good one, but at least I have the piece of mind now, knowing I’ve gone through and fixed all the issues.
I really appreciated this video and the time put into showing us your work! I have always loved these super dukes since working as a 14 year old sweeping floors in my local KTM dealership. I hope to own one someday soon, however the last one i test rode had the most uncomfortable seat of my life! I bought an XSR900 instead.... keep up the good work mate
Thanks so much for your comment! Really cool that you worked at a KTM dealership as a kid! And enjoy the Yamaha, those XSR900s look amazing!🏍️😎
Thank you for that excellent video, now I think I'd better change my water pump. Too bad you didn't video the timing change swap as I'd really like to see that. I have to do mine soon. 2011 supermoto R 990.
Thanks a lot for your comment! The supermoto R sounds very fun! Yes, I was really short on time so I ended up just doing the timing chain replacement off camera… to be honest the hardest part if it is removing the woodruff keys from the balancer shaft. The rest is pretty straight forward.🏍️
I'm on my second 950SE since 2015, and still smitten by the way these engines and the bikes they drive behave -- or rather misbehave. This was a superb account of a rebuild on a beautiful machine. I like the way you work, sir. Thorough, clever and relaxed. And I know that refreshed motor with be happy not to have 8L of oil in it and you seeing to its future health. Bravo!
I would absolutely love to have an SE as well! They’re awesome! And thanks so much for your very kind comment! I’m glad you enjoyed the video!
@@volimoto SEs do come up for sale, and there are a few SE FB pages where we owners keep up with each other -- only 3,000 or so were made, it's a small universe. I have a friend with an SM, which I've had a few quick little rides on. It's geared low, and goes like a bullet. He rides it on the track and says he passes more people than on his Aprilia track bike. This iteration of the LC8, though it had it's gremlins, is quite extraordinary. I think you will love riding that bike. You can also notch up the HP by 10% with a few mods.
@paulfenn5060 I know it’s an entirely different ballpark but I just acquired a Yamaha XT600 ‘86 (1vj) for dipping my feet into the offroad world. It hasn’t run for 10 years and I’ll have to rebuild the engine from ground up due to worn output shaft, etc. I’ll be doing some modernization to it, brand new wiring harness, and maybe suspension upgrade and some nice LED lighting and a digital speedo. I’ll be making a video of it at some point, but it’s not on the priority list right now with all my other projects slacking behind. Maybe at some point I can get myself an SE… I also looked at just finding a 990 adventure😎🏍️ thanks for the info!
@@volimoto Good luck with that project. You have a vastly different constitution than me. I get panicky and frustrated with mechanical work and make costly mistakes as a result. Thus I give my knowledgeable friend beer to keep my beast running well. That said, it's long past time to check the valves on my SE, everyone's too busy to help, and there's no way I'm doing that myself -- I'd have a fn nervous breakdown...
Very interesting video, i own a SD990 2007 with 27000Km and i have not had any issues other than the water pump, i replaced it and that was it, im very satisfied with it and i am planning to keep it for a long time, thanks for the video and cheers from Costa Rica😊
That’s awesome to hear you have been running trouble free. 😊This bike would have probably been fine had the previous owner noticed earlier the water pump failure. It must be beautiful riding in Costa Rica! I’d like to visit there one day😎 thanks for your nice comment!🏍️
Good job 👏🏻
Thanks so much for your nice comment!🏍️
My 2007 superduke has a lot of upgrades it was used. Full exhaust, an org rear sprocket, haven’t counted the teeth to check for o.e.m. My experience is when I let off the throttle the engine has immediate engine breaking ( engine compression.) the touchy throttle can be handled with controlled technique. The engine breaking is so effective I basically never have to use the brakes. Cool, but strange and can get annoying. Many times I’ll ride in one gear higher sometimes to dull the engine breaking maybe 4th-6th have less severe engine breaking. A torquey beast.
I also had noticed that quite often I can ride just by engine braking into a corner. It’s certainly a fun beast!😊
My 990 just gave out, how much did this run you and you make it look easy lol
I think this entire rebuild was almost a 1000€, not counting of course my work. Thanks a lot for your comment!
I have a used 2007 990 superduke. Gas 25 mpg economy. Drinks oil about as fast as it drinks gas. No oil leaks. The throttle is like holding back a caged predator. Love the torque of the ktms so I got a 2024 ktm 390 duke, all the torque of a ktm but better throttle response and 52mpg
Any supporting mods to warrant the demand for more fueling? I'm running pod filter and a high flow open muffler. Could it just be that your bike is not in need of added fueling?
Hi there! There is no demand for more fueling, and no other mods. That’s exactly the issue. These injectors based on spec should deliver the same volume, just result in better combustion with the finer spray pattern. The problem is exactly that I don’t understand and can’t figure out why is there more fuel with these injectors.
Amazing build mate!
Did you do the video on fork choice
I never made the video. With the build taking so long due to many other projects going I also keep re-evaluating my choices and I do think I’ll probably replace the forks with a pair from a 390 adventure instead. The triple tree and the rest is good as is, but I miscalculated with the diameter of the wheel and I’d like some more clearance between the bottom of the triple tree and the wheel.😊
Very good video and thorough work. Would be good to see another video for the timing chain replacement.
Did you actually change the valve guides or only the seals?And what was the problem in the first place,only that the previous owner put nearly 3 times the amount of oil in the engine?
The problem was that the water pump seal had failed but the PO didn’t notice and that had caused the problems with the bearings and the nasty gunk everywhere. I didn’t need to replace the valve guides, but the seals were britle so those did get replaced.
There's a sale of this bike and was looking for some details on the engine. You covered all the basis. Thanks!
Test ride it, it’s fast but very jerky at the throttle. Can be tamed but after 2 hours you are just hanging on for dear life. At first it seems very cool but the engine compression gets annoying
There are a lot of forum discussions of the jerky throttle and some have more issues than others. Mine is actually pretty good, but I just fitted the different throttle tube from the RC that has a progressive profile. There is the issue with the closed loop/open loop switch around 3000 which results in some jerkiness, but if everything else is good with the bike it shouldn’t be too bad. There’s also some option to play around with the sprocket ratios… I’m also thinking about going for a smaller front and larger back because below 50kph I can’t use 2nd gear with the original gearing.
@@michaelrieser9928 Not sure whether its the profile of V-twins in past generations that gives that vibe. Have ridden 1000cc cat bikes and you will always have to hang on to dear life. No doubt about this one.
@zergothikaify hahaha, that’s true for sure! The bike’s very torquey!
@@volimoto Nice update. I doubt that the change of gearing will solve the jerkiness but hey, it's all up to individual expertise. 2nd gear change under 3000 rpm may not click it properly. Prolly you have to rev above 4k to get that smooth change. The older they are, the stubborn they will be till you hear them sing.
Très beau travail bravo
Excellent video, would love you servicing my sdr. Great mechanic!
Thanks so much for your very kind comment. Much appreciated😎🏍️
Hi . Creat info i have a cb750/4 k5 and hd to replace left hand controls. The new 1 has diffrent coloured and smaller guage wire and connectors. Is changing connectors save with the diff guage wire or try and rewire hand control all opinions are welcome .
Really nice and informative video. I myself own a 950 SMR which also had (among others) the issue with the waterpump. I hope you enjoy riding the 990 just as much as working om it.
Thanks so much! Yes, the bike is really fun to ride! 😎
every german TÜV inspector would jump in a circle, if he would see this. Lul
🤣🤣 well, good thing I ain’t going anywhere near Germany! But jokes aside… It would probably pass a “custom” inspection.
Thankyou
Excellent video. How many km/miles had it done?
Thanks a lot! Bike had 43000km when I bought it. 🏍️
Oh wow! Oh wow! Oh wow! 🤣
Very nice job, well done! Could you please make another video on how to adjust the Throttle Position Sensor ? Greetings from Germany 👌
I have had the same experience as you with a 1986 K75C. I will contact the seller who are experts in Kbikeparts. They ran rough on the bike and I returned to the old injectors. I will try the Bosch you suggested if I need new ones. Thank you for this video.
What kind of a digital torque wrench was that?
Hi! It’s an SW-Stahl 03926L Digital torque adapter. Works quite nicely. It’s 6-30Nm and there’s also the higher torque option: 03927L which is 27-135Nm.
@@volimoto Thanks! Have you tested accuracy of it? Right now I'm using standard cheap "clicky" torque wrenches calibrated with a fishing scale. It's a bit scary sometimes.
@Jaszczur-sp2tx I haven’t actually tested the accuracy, but I’ll try to remember to do so and report back to you. I’m away from home for the next week, though. Btw! I’m planning on buying a small 1/4” clicky torque wrench, 2-26nm for some of these jobs because although the digital adapter is great, there are situations when it simply cannot fit due to it being so tall.
@@Jaszczur-sp2tx There's nothing wrong with a "clicky" torque wrench - Norbar has some of the best in the business. It's really a matter of how well the mechanism is designed and manufactured. Digital is great for a workshop where time is money and there could be noise and distractions, so a big digital display and a loud bleep is better than trying to read the markings, then listening and feeling for the click.
im changing timing chain tensioners soon and would like a tutorial from you. Good work!
Sure thing! Are you only changing the tensioners themselves? Or chain and guide rails too? The tensioners you can do without much disassembly, the chains and guide rails is a bigger project. Glad you enjoyed the video!
@@volimoto im only changing the tensioners
@Lanc321 is it also a superduke? Because it can be done without taking anything apart! The only reason you could is to actually be able to measure the chain elongation/guide wear. I think on the adventure or smt you need to remove some fairings and maybe the oil tank. The removal of the oil tank helps on the superduke too, but I could do it without, it’s just a bit more annoying. I actually have some home made manual tensioner in right now because I messed up the tensioners and had to do something quick so I could join my friends for a trip… so it’s gonna be nice to get everything replaced and also back to hydraulic tensioner!
@@volimoto yes its a superduke like yours. im gonna do it this weekend. how did you mess up the tensioners? they are very expensive where I live (95$ each)
@Lanc321 I was experimenting with a small spacer because I was trying to determine if it’s camchain noise I’m having and ended up compressing the tensioners too much and bent the ring that holds the two pieces together. But they were also a bit work out anyway.. €105 here… I ended up ordering them from the US from KTM world for 45$ through a package forwarding company and with the guides together it’ll be half the cost as it would have been here even when I pay the taxes. Shipping was surprisingly cheap for a small box!
Such a good motorcycle! Had 3 in total. 2008, 2012 SDR and a 2014. My favourite of all time.
That’s really awesome! Hope you never had issues with the water pump! It’s super awesome! The only thing I wish it could do better is pillion comfort so my girlfriend would be more comfy for some longer rides. But I mean, this bike is not about that, so it’s okay.
@@volimoto The only issue I had was the rectifier for providing stable current from the generator. Had to replace that on the 2008. Had a few SMTs too and they had no issues at all. Very happy with KTM.
@b0bl00i That’s awesome! I really have gotten to like this engine through working on it. I’m considering getting either a 990 adventure or a 1090 adventure to add to the stable.🏍️
@@b0bl00i What was the realistic fuel consumption? I have a 2008 690 SMR and I'm thinking about getting an SMT
@@Jaszczur-sp2tx SMT is a great motorcycle. Good engine, fun, wheelies well and is comfortable. It's the LC8 engine with 18L (or 19L?) tank, can't remember exactly. I think you can easily get 200 Km per tank if you're not pushing to hard.
Very nice job, it's good to see that this bike is gonna have a good owner now haha 8LITERS WAS ABSOLUTELY INSANE
Thanks a lot! It was really insane! No wonder the engine couldn’t turn over with the cylinder filled with oil… glad you enjoyed it!
Good job !! Good video and a good work on the bike. Continue like that !
Thanks so much! Really appreciate the kind comment! Glad you liked the video!
Saludos desde Colombia
Buen trabajo 👍
Great video! What kind of grease do you use on the rubber seals?
Hi! It’s grease I got with the rebuild kit, but I’m fairly sure it’s “red rubber grease” (It’s a brand also) and is meant to prevent drying out for natural and syntetic rubbers. Some don’t recommend actually greasing the sealing rings on the piston, lt of people instead use brake fluid there, but using a very small amount of this rubber grease makes more sense to me. Hope this helps!
Where do you get the resevoir hoses? I got a new resevoir on eBay and it sweats brake fluid, like it is eating through
Hi! They probably included the wrong material of hose. Try looking for EPDM hose. Depending on where you’re located maybe you can find it in your local auto store, or just order some online. It’s fairly cheap.
@@volimoto thanks! That’s the kind with the metal threads lining the inside right? Looks like black rubber hose, fuel line hose?
I think it’s just “rope” and not metal inside, but could be also that there are versions with metal mesh. Don’t use normal fuel hose. Generally what’s fuel and oil resistant is not brake fluid resistant and you might end up with the “sweating” action on them. Look for specific brake fluid resistant hose, which EPDM is. You can just google “epdm brake hose” and I’m sure there’ll be some available near you. I hope this helps!
Thank you! I’m doing a 1998 T595 also. With much less expertise! 😂
It’s an awesome bike! I can’t wait to have some more time to get back to working on it! I’m planning to instead of uploading tiny sections at a time just finish the bike quick and upload a full video of the restoration/assembly. Good luck with yours and let me know if you need help with anything specific!
سلام
Ich hab von Power Brick EV14 bestellt aber die sehen nicht wie Ihre Injektoren aus ?! Die sind genau wie Originale Injektoren aber mit 4 Loch !!!
Es wäre sehr nett wenn Sie mir sagen können um die von Powerbrick sind oder von Bosch ??
"Hi! Das ist wirklich interessant! Ich habe die EV14s von Thom bei KPartsHolland bekommen, aber soweit ich weiß, haben sie früher dieselben Injektoren verkauft. Ich habe gehört, dass sie versucht haben, einen besseren Ersatz zu finden, also hast du vielleicht schon das Gute bekommen? Wann hast du sie gekauft?"
@@volimoto ich hab die gestern gekauft und hab ich mit Thom gesprochen, offenbar die sind Neu und auf seine Webseite hab ich Bildern vol die Injektoren gesehen . Die Sind Neu und genau wie Originale Injektoren sind aber mit 4 Loch . Thom hat gesagt ich schicke die zu Power Brick auch . Ich dachte dass die Fake sind aber die sind wirklich Neubrand und Geil 👍🏻 Danke für deine Antwort .
They do deliver more fuel than the originals, and after a while of use the bikes ECU is supposed to control the fuel mix. So at first the mixture will be a little rich.
That’s true for the k1100s but K75 and early K100s don’t have O2 sensors or any feedback to correct the mixture.
@volimoto Dont know bout that. This was just the answer of a specialized injector shop.
GOOD JOB! 👍Many thanks for the plan
I am confused, did you compare three sets of injectors? What is the bosch part number for the third set that tested 108?
I have the EV14 injectors on my R1100 and they improved the power and smoothness of the engine. I installed a flex fuel kit, and that made the bike miss fire and be overall uneven running. But after new bosch platinum spark plugs and injectors, it runs very smooth now.
Really happy to hear it’s working well for you! I think it’d be the same for the K1100 as well, as both yours and that already have the more modern Motronic injection, and not the L-jetronic as the K75s and K100s. The R1100 is a nice bike👍🏻
What is flex fuel kit? I'm owner R1100RT 97', want replace stock injectors to smooth rough idle.
@zettaker2181 That is the same exact bike that I have. Mine is blue. 😀 The flex fuel allows you to put E85 (85% ethanol alcohol, 15% gasoline) into your tank. The injectors are kept open slightly longer to allow more fuel into the engine. I highly recommend the EV14 injectors, new Bosch spark plugs and throttle body sync to make your bike run better than new. I don't remember the part number of the spark plug but I can find it for you when I get home.
Very interesting video. I recently returned my K75S to the road after a 19yr hibernation. I am at a loss to explain my experience with fueling also. The fuel tank innards were all replaced with new parts, but i was not able to compare psi of old pump to new pump as old pump was long since deceased. Pressure regulator tested at roughly spec. Initially, the bike ran extremely rich on the original injectors. I removed them and cleaned, replaced orings and reinstalled, with no appreciable difference in the richness. As you say, embarrasing. I ended up balancing/synchronizing the cylinders and putting the bike on an exhaust gas analyzer. Long story short, I ended up with the air bypass screw about 7 turns out as opposed to an original 1 3/4 turns out from the stop. The bike starts and runs normally, requiring use of the choke/fast idle lever to maintain running while dead cold, reducing to no fast idle lever over a couple of minutes or so. Fuel consumption is somewhat normal from what i remember before hibernation. One simple test is to fully warm bike and allow to idle. Should be about 1,000 - 1,050 RPM. Push starter button with engine idling ( no danger of inadvertant starter operation/damage, starter is locked out automatically on K bikes ). You should observe a very slight RPM rise, about a needle width on the tacho, as the bike thinks its in a start scenario. If you get this result, you are somewhere near where you should be for AF ratio. Why is there such a difference with the air bypass screw over 19 years? Dunno, TBH. Is it different composition of fuel? Who knows?? Im thinking of dropping $$ on a new pressure regulator, just to rule that scenario out. Nice to have the bike as i remember it though, good fun. Tks for your video.
First of all, I’m happy to hear you resurreceted the hybernated K75S! I hope it’ll bring you a lot of joy riding it! - It’s very interesting that even after doing all the cleaning it ran so rich! Have you tried cleaning the MAF sensor? (i know it’s not really a true MAF in these bikes, but for the ease if it let’s call it that). Or maybe the little door inside is moving a bit stiff? I’m glad you managed to get it run properly! I wanted to put mine on a gas analyzed but couldn’t find anyone near who had one.. there was a workshop my dad used to work for that had in the past but when I asked they said they sold it some time ago.. Let me know if the fuel pressure regulatir does the magic! And thanks for your comment!
When you say "air bypass screw" are you referring to the screw to adjust the co-value on the airbox right above the motor?
@@dduncker5457 Yep, adjusted with an Allen key. And I made certain the air flow flap was free in its movement ( very gently ).
@@harrothepilotI forgot to switch TH-cam accounts. Thanks so much! I might need to replace my air box to do that because the idiotwhom abused the bike for 20 years put a bunch of jbweld and duct tape all over that hole.
@@daduncker20D aaaaaaargh. Oh no, good luck with that. Be aware also, that screw affects only low speed running, to about 3k rpm as far as I can assertain. But, that’s where my own problems were, around idle and off idle. Also check ur fuel pressure reg for 35 - 37 psi output and the air flap for free movement. Both can have an effect on idle mixture. Cheers.
Where can I get some fairings from
Хорошая идея, отличная реализация.
Don't be pretentious, against an army of Bmwtop engineer, I doubt you can improve performances ( without sacrifice of the durability, vibration....)stick to original parts at least on the engine side
Thanks for your comment. I think you highly misunderstood the purpose of the video.
In 1991 there was no 4 hole injectors...
Great work! The only thing I didn't liked about this video is seeing you work on the ground like that. I subscrided!
Thanks! Yes… didn’t really have a dedicated metal workshop area so did what I could. But the lift is for sure making my life a hell of a lot better at being able to work on bikes in a comfy position. :)
Amazing Lift, Very professional work, What is the thickness of the profiles you used? 3mm or more? Thank you.
Thanks very much for your kind comment! The base of it was 4 or 5mm I think, but the only reason is that’s what I already had laying around. The legs and top part is 3mm. I think the lift benefits from the extra thickness because the base is a lot more heavy, but I’m sure it’d work just as well with 3mm.
@@volimoto thank you very much.
Me encantaria poder comprar unas pinzas como las tuyas para evitar la perdida de combustible, me podrias dar una idea de donde comprar