I fixed the Tuono and now it's better than ever. Front forks and alternator sorted. Part 2 Road Test
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- Опубликовано: 12 сен 2024
- Dave's had the Tuono a year and a half now, and has finally managed to break it. So it's a golden opportunity to fix it and upgrade it.
The forks are getting treated to some better pistons and the known issue with the electrical generator is getting sorted.
Join Dave as he talks you through each step to making a better bike
For enquiries about the rotor upgrade email Dominik at schmutzi1990@gmail.com
For info about Obsession Engineering services
www.obsessionengineering.co.uk
Thanks for the video, being an older rider, at 70, riding my old Griso or V11 Lemans I find it's time for me to look for something lighter. Right now I have my sights on a second gen Aprilia Tuono 1000r. Being an older fella I do most of my own maintenance so I'm not afraid of working on my bikes. Still, I have a local Ducati shop rebuild the forks.
A tip with reinstalling the flywheel, put the locktite in the flywheel on the taper, that way it doesn’t get on the plain bearing when installing 👍
Hi Dave, I'm in the chemical business and I supply a lot of brake fluid around the world. Brake cleaner is bad for your health for sure, but GT85 is bad for your brakes. I know from experience even trace amounts of oil based contamination in brake fluid can wreck the seals, giving swelling and leaks. The seals are designed to be glycol resistant not oil resistant. So spraying oil based products in there such that some gets carried inside and on to the seal face probably isn't the best plan. One time probably won't hurt but doing it repeatedly, who knows. What I use is a strong water based household cleaner and a toothbrush, dry it off with an airline and wipe a bit of DOT 4 on to lubricate things. Don't dab your fingers in the brake fluid that's not great for the complexion either :-D
PS I thought I saw some Woodcraft crash bungs on the Tuono, I remember from the zx10 a few negative remarks regarding crash bungs.
That's very handy to know and I'll definitely try it out.
The Tuono crash bungs are far enough out of the way to not bother me, I removed the lower ones after I'd nearly broken my shin on one!
Or you can replace the stock shunt Rec/Reg with a series type like the Shindengen sh847, that allows only the required current to flow through the windings. Not good for lithium batteries though.
Another excellent video Dave. Love how you walk us through the little tips and tricks too. Keep them coming and stay safe. Best from Zurich
Great result Dave! Worth an apple crumble for desert! Glad the suspension work changed the feel of the front end 👌 Bike is looking sharp🥇 Thanks for your experience 🇮🇹
Very interesting vid,thanks Dave. Also looking forward to how you tune out the 'noise' as I'm sure it will useful in my case. I'll be awaiting further developments . Ian
Great video Dave, but the front wheel spindle nut is 80nm, you may want to back it off a bit.
I shall correct my workshop manual. Thanks
Odd to see you nip up the RHS pinch bolts before torquing the front axle. All that torque prevented from closing up the spacers and bearings when you did that, Dave.
Done on purpose. With the nut nipped already the spacers and wheel are already located, doing up the pinch bolts just stops the spindle turning so it's easier to tighten the nut
Good practical explanation again Dave!👍
Awesome loving the content Dave!
Nice one! Clutch fluid looks a bit funky dude
HI Dave
I really like your vids -- you keep it real as we used to say ! My question is did the generator rotor mod work ? Do you know what was involved in the mod? Who did the work?
Cheers
Nick
I think I put a link in the description for the chap who did the work. Although exactly what he did I'm not sure. Seems to have worked so far!
Hi Nick
Its me. I am weakening the magnets to perform as the aprilia uphrade wheel.
hi Dave...just a quick heads up...the manual states the front axle is 80nm not 120nm....
Quite happy to be corrected here, but shouldn't the spindle go in first before fully tightening all the bolts, to make sure the wheel runs true and the forks aren't twisted?
That's exactly what he did.
@@stekwack
Nope, he put the forks in the stanchions, then he said he torqued them up, before putting the spindle and wheel in.
Why would the forks be twisted? The forks and yokes are straight and the spindle drops straight through. Being as the fork bottoms can rotate independently of the tops putting the spindle in makes no difference.
If you're referring to the pinch bolts on the fork bottoms, I nipped the nut first to pull everything into position, then tighten the bolts so the nut can be easily tightened
@@obsession_engineering
Apologies for the sluggish response.
I had to get dressed today, and there have been other such things to deal with.
Yes, that's what I was referring to, but on reflection, it probably matters more with RWU forks more than USD forks, I think.
Possibly.
Maybe.
Hi Dave, could you post the company that downgraded the generator please as I may have to get mine done in the future,
Ps , love the channel 👍😎
It should be in the description
Great video Dave, one question: On the taper where you applied "generous Loctite" - why bother if there's also a keyway/key. What am I missing? thanks
I've considered that myself! It should lock on the taper, but mass production being as it is the tolerances probably aren't good enough to guarantee a snug fit, so the rotor could move. The key is only there to locate in the right phase, and isn't designed to be loaded
got it, thank you
Hi Dave really enjoyed this video, I have an 07 tuono and I haven’t done the stator upgrade, ap workshops offer a new corrective one for £1100 , just wondering what your cost came out as, thanks 🙏
The stator mod was 70euro, plus postage to Austria and back. Including the gasket, oil, etc you're around £200 in parts
Interested also, think mines playing up!😢
Get used to replacing that stator...I had an 07 Tuono and the stator failed a number of times...
Did you watch the vid? The whole point of the generator mod is to protect the stator
Hey Dave, what did you use for the crank locking bolt?
Just an m8 bolt with a bit of a taper ground onto the end. Simples
Hi Dave great work,how long is your m8 bolt and does it tighten up when it hits the crank then find notch? also do you know that puller we need soz for all the questions
Please can you tell me if there is an auto blipper for the Zx6r? I know it's not fly by wire, but is available or possible? I've tried researching, but can't find a clear answer....Thank you.
I've seen a company doing a stepper motor version but can't remember the details. I tend to do the blip manually on non blipper bikes, takes a little learning but a very handy skill
@@obsession_engineering yeah figured, thank you for taking the time to answer.
easy to sit here and comment but I have also done the stator/rotor replacement. Wouldn't it have been better, if you must use a rattle gun to seat the rotor, to have then backed off the nut before doing up with a torque wrench? Your wrench didn't seem to do anything other than click and even if your rattle gun tightened to the exact correct torque as specified for that bolt, once the bolt settles you have the added friction which means using the torque wrench at the correct setting, after tightening, does nothing. I see rattle guns in the car world which usually result in stretched bolts just waiting to fail
I was probably a bit eager in the edit and cut out the bolt moving with the torque wrench. Good observation though 😁
@@obsession_engineering I record most customer work they can't see (valve shims/electrical work etc) and I make THE WORST videos and find recording a pita but it is better than a stamp in a service book because we know how much proof that is! Great channel 👍
Yay first like for me :)). Prize please
Is that a 3/8' impact wrench?
1/2"
@@obsession_engineering thanks Dave. 👍🏻
At the end why does the throttle cable rotate with the throttle I find that a bit odd. 15:11. ruclips.net/video/IyQYbygLkGU/видео.html
Have you fixed the problem with finding neutral? You could be the next millionaire!
I wish! Not sure kicking the lever harder will make my fortune though 🤣
👍🏼👍🏼😉
I don't get the derating nonsense of the alternator. You could have a 1mw generator but it won't make a watt of power unless there is a demand for power. A 500w generator will not 'generate' 500w. The bike electrical system will draw the power it needs and if that is 100w that's all that will be generated by the alternator. If as you state the derated alternator is 370w then presumably that's what the bike requires. Thus the 500w generator will only generate 370w max. If the bike was taking 500w then that's probably used mostly for charging the battery and thus by dropping the max output of the alternator to 370w it's reducing the charging rate. If this is the case then it would be cheaper to simply put a power regulator in place to drop the draw.
All I know is the 500w generators burn out stators and the 370's don't. If aprilia fixed it by using a lower wattage there must be something in it!
I suspect that given the need to have a specific voltage for the charging system then amps might be a problem non the higher power alternator vs diameter of wire used for the winding. And as the existing casing and rotor and air gap requirements are fixed it would be impossible to make a 500w alternator with larger diameter wire so the only way to achieve it would be to reduce the power output and use less windings but larger core size. Basically more copper for a given watt.
Hi Mark
A generator with permanent magnets is working an other way than a car alternator.
The car alternator is regulating its output power by regulating the strenght of the electromagnets in his rotor.
On a generator with permanent magnets its only possible to shorten the phases (or disconnect them) to stop the generator from producing electricity. This short circuit produces a lot of heat in the stator coils (they have 0.6 Ohms). The weaker the magnets, the lower the output of the generator.
Das ist für euch Amis viel zu komplizierte Technik Ihr Daddelst da dran Rum bis gar nix mehr geht,und dann kauft ihr euch doch ne Harley.Abgesehen davon geht's bei euch nur geradeaus.Was wollt ihr da mit nem Kurvengerät?