VStar 1300 O2 Mod How To

Now you’re here and wondering just what this mod is all about, right? Well, have you noticed that when you ride your VStar 1300 at slow speeds in first or second gear that you seem to be getting a lot of surging? That’s because Yamaha has the fuel mixture set excessively lean in order to pass the 2010 and 2012 emissions requirements. But, heck, it’s not 2010 yet, let alone 2012. So why should I have to suffer for years? Well, you don’t have to suffer. That’s what this mod is all about. Not only will it eliminate most or all of the surging but it will also allow you to ride in higher (numbered) gears at slower speeds before you have to down-shift.   OK, so dude5 originally came up with the idea and gave it to me. That means, of course, that I did not steal it as he claims. How could I steal it if he gave it to me? I promised John (dude5) that I would not tell anyone about this and asked him if he planned to market it or post it on the WIKI. He said he was making his own FMS Fuel Management System that would sell for $100.00. He posted some pictures of a small black plastic box mounted on his handlebars. It has a couple switches and a knob on the outside. He was trying to find connectors that mate to the oxygen sensor. In the interim he had to cut and splice the wires.

Never mind all that history. However, if you look at dude’s FMS now, you’ll see he has added the O2 connectors that I told him where to buy.

The O2 sensor is a so-called narrow band sensor – like the ones in most cars. A narrow band O2 sensor can only tell you precisely whether you are above or below 14.7:1 AF ratio. That is its only purpose. You cannot measure whether you are at 12:1 or 13:1 or any other variation but 14.7:1 or if the ratio is lower or higher.

This is a very fundamental issue. Some other solutions use so-called wide band sensors that measure ranges up to 10:1-18:1 in discrete increments.

Why is this important to this story you may ask?

It turns out 14.7:1 is the most efficient AF ratio for various engine designs based on fuel consumption and emissions – not so in terms of power. The best AF ratio for these types of engines is usually around 13:1 +- 0.2 up or down.

As said earlier the O2 sensor can only be used for the 14.7:1 identification.

Now let’s have a look at a typical Yamaha FI map (very much the same as all other motorcycle manufacturers). The map has various AF ratios built into it. While cruising (usually below 10-20% throttle or less and less than a specific RPM e.g. 5000), maximum fuel efficiency (sounds funny when said in the context of a VMax) is the target – among best possible emissions. This is where the engine is mapped to a ratio of 14.7:1. It is this range and this range only that the O2 sensor data is used by the ECU to correct the AF ratio as it goes.

The primary reason for that is because gasoline based fuels burn hotter when you go over 14.7:1, and the increase in exhaust gas temps is dramatic and can lead to serious engine damage within a short amount of time. Of course, the 1300 is water cooled so that pretty well mitigates the heat issue.

For all the other ranges (>20% throttle and higher RPM) the manufacturers are not bound to emissions as much and therefore tune the engine for maximum power – which happens to be around 13:1. This is the range where the Yamaha ECU operates in ‘open loop’ mode. It has a map built in, it uses various air and vacuum sensors to correct the map for altitude and temperature but that’s it.

In addition the Yamaha ECU (same for Stratoliner, Roadliner, Raider, and the sport bikes) can be operated without an O2 sensor. It goes back to a default mode without trying to optimize for the 14.7:1 ratio.

What the following mod does is to move the output of the O2 sensor to a slightly richer than 14.7:1 ratio. This cures the over-lean condition. The ECU “thinks” it’s running at a 14.7:1 ratio when, in reality, we have moved the ratio to a slightly lower value.

Now for the mod itself. As some of you have already figured out (and some of the units I did not seal with potting compound so an enterprising individual could easily open it and see what’s inside), the “circuit” is nothing but a single resistor. The resistor is in series with the ground lead of the oxygen sensor. The trick is the value of the resistor and exactly which wire to put it in. I chose to use resistors with a value tolerance of 1% but cheaper 5% tolerance resistors should work just fine.

Let’s look at dude’s version below. You’ll see he has a resistor with some shrink sleeving over it to prevent its being shorted to the bike’s frame. On the end of each lead is a crimp on connector. You simply find the sensor’s ground lead, cut it, and crimp the two connectors, one onto each lead that was cut. The pliers show how to crimp the connectors.   Since he was not going to publish or market the mod, I decided to tell everyone how to do it. Then I remembered my promise. That, and the fact that you have to cut and solder wires, made me decide to try and make some available myself. I built a prototype and sold it to kapu7 for what I thought might be a fair price, $30.00. Kapu suggested that $50.00 would be more appropriate so it didn’t look like a cheap something that doesn’t work. He even suggested I might want to ask even more than $50.00. That’s how the price came about.   My mod is shown below dude’s. Notice that it is plug and play. You do not have to void your warranty to install it. Besides, it is very simple to disconnect for those occasions when you want to be EPA legal.

O2 Mod

O2 Mod

O2 Mod

O2 Mod

That’s just great you say, but what’s the value of the resistor and which wire do I have to cut? Looking at the O2 sensor connector (the one attached to the sensor) you can see two black wires, a white wire, and a blue wire inside some black sleeving. The white wire is the one you want. It connects to a black and blue wire in the mating connector. You can cut and use either the white wire or the black/blue wire.    My resistors are 825K ohms, 1%, ¼ watt precision resistors. I have several left. If you’d like one, send me a SASE (self-addressed stamped envelope) and a dime (pre 1964 is preferred) and I’ll send you one. Yes, I’ll lose about five cents each but there are no 15 cent coins that I’m aware of.    Looking again at dude’s device, it looks like he has the connectors directly connected to resistor leads. I don’t think that’s a good idea. The resistor and its leads are too fragile. I mounted the resistor on a circuit board and soldered stranded wire leads to it. Then I put shrink sleeve over it and potted the whole thing. Of course, I used connectors that mate directly to the connectors on the bike so no cut or solder is necessary.   You could use a piece of a popsicle stick. Drill two holes in the stick 0.3” to 0.5” apart and pass the resistor leads through the holes. Then solder stranded wire leads (20, 22, or 24 gauge wire) to each resistor lead protruding from the stick. Finally, cover it with shrink sleeving or a good quality electrical tape to strengthen and protect it from shorting (dude, you can use this idea, too). Then either solder or use some of the “bullet” connectors to connect it.

How To: Install A Dirt Bike Big-Bore Kit Part 1

How To Install A Big Bore Kit What You Need
By Karel Kramer
Photography by Alyson Fletcher

How To Install A Big Bore Kit What You Need

Increasing displacement is one of the most cost-effective ways available to boost the real-world power of your bike’s engine. These days, you have more options in your method of growing bore size than ever, from having the stock cylinder sleeved with a cast-iron sleeve to installing completely new cast or billet cylinders with a plated aluminum bore-just like a stock cylinder.

Regardless of the method used to boost the bore, the job of installing the kit remains the same. We used a 2007 Kawasaki KX250F and an Athena 290cc kit that includes a complete new cylinder. The Athena kit comes with everything needed for the installation. Even though we used a Kawasaki, any four-stroke is essentially the same.

01 Any time you begin engine work, start by draining the coolant as well as the oil. The coolant is a necessity, but the oil is just a good plan to eliminate the chance of a mess. Make sure the bike is good and clean before you start; you may want to rewash it after the tank and seat are off.

02 Remove the valve cover and the appropriate timing plugs. Use a T-handle to turn the engine to top dead center. There are marks on the ignition that need to be lined up to ensure the piston is at the top of the stroke. The manual will specify the correct marks and their position.

03 On the KX-F the coolant hoses are in the way, and they need to be removed for best access to the cylinder area. The constant heating and cooling of the engine sort of glues the hoses to the fittings. A right-angle hook like this will slide under the hose. Pull it around and it will pop the hose loose.

04 We removed the water fitting from the case for better access. It is sealed by an O-ring, so we used the hook again to retrieve the O-ring without damaging it. The Athena kit does not include this O-ring, so purchase one if it looks damaged or deformed.

05 Before you can deal with the head, it is a good idea to check the valve clearance. If they’re radically loose or tight, you’ll need to have the head rebuilt to prevent wasting the other new parts you’re installing. Write down the clearance so you have it for reassembly.

06 Remove the caps that hold the cams in place. These are high-precision parts with important clearances and torque values, so loosen the bolts a bit at a time in a crisscross pattern. Remove them carefully. Threading a bolt into the cam cover holes will help you lift them up gently.

07 There are usually parts under the caps that can fall into the engine, so lift the caps a bit at a time. Use a magnet to remove these steel clips that locate the cam bearings. You may want to remove the tappets and shims, but mark where they came from. Watch the dowels that locate the caps, too.

08 Before you can start with the cams, the cam-chain tensioner must be removed to allow enough slack in the cam chain to remove the cams. Start by taking out the center bolt and the spring that operates the tensioner. Check the aluminum washer under the center cap. If it is deformed, replace it.

09 Usually the tensioner can only go in one way, but we marked the top with a marker to make sure it would go back in quickly and correctly. If there is a gasket under the tensioner casting, it should be replaced whenever the tensioner is removed.

10 On this Kawasaki the head won’t come out easily unless the engine is rocked forward. We removed the head stay, engine mount plates and the lower engine mount bolt. We didn’t have to loosen the swingarm pivot bolt to rotate the engine forward.

11 With the engine rotated forward, the head has just enough room to clear this part of the frame where the head stay attaches. Unless the head can clear, it won’t lift high enough to pass the cam-chain slides.

12 Now you can lift the cams out. Begin by lifting the end on the exhaust cam, then angling it to clear the chain. There is no need to label the cams. The exhaust cam has the auto-decompression system, so it looks nothing like the intake cam.

13 While the cams are out, inspect the parts of the valve train for wear. Defined swirly marks like these on the face of the tappets mean it is time to replace them. This means the tappets are rotating in the bore as they are supposed to.

14 The lobes of the cam shouldn’t show any wear or serious discoloration. The bearing surface of the cam should be absolutely smooth and unmarked. The left side of the cam has a bearing, but the right side generally rides on aluminum protected by a high-pressure oil film. Any flaws mean the engine had a lubrication failure.

15 The same is true of the cam caps. The side that rides on the cam without a bearing should be perfectly smooth and show no wear. Otherwise, the oil film the cams are supposed to run on will not work correctly.

How To Install A Big Bore Kit Draining The Coolant

01
How To Install A Big Bore Kit Use T Handle

02
How To Install A Big Bore Kit Right Angle Hook

03
How To Install A Big Bore Kit Removing Water Fitting

04
How To Install A Big Bore Kit Check The Valve Clearance

05
How To Install A Big Bore Kit Remove The Caps Carefully

06
How To Install A Big Bore Kit Use A Magnet

07
How To Install A Big Bore Kit Cam Chain Tensioner Must Be Removed

08
How To Install A Big Bore Kit Mark The Top Of The Tensioner

09
How To Install A Big Bore Kit Rotate The Engine Forward

10
How To Install A Big Bore Kit Engine Rotated Forward

11
How To Install A Big Bore Kit Lift The Cams Out

12
How To Install A Big Bore Kit Inspect The Parts

13
How To Install A Big Bore Kit Inspect The Cam

14
How To Install A Big Bore Kit Inspect The Cam Caps

15

How to Change the Spark Plugs on Your Dirt Bike

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Basically, the ignition system must be capable of supplying the amount of voltage required to create a spark in the opening of the electrode. In practice, this means that there must be a considerable “reserve deignición” factors to take into account normal wear and spark plug ignition system. Book ignition, so … is the difference between the voltage available from the ignition system and the voltage required by the spark plug. Many factors can diminish the pool of fire “and cause loss of ejecución.Para that a spark plug to execute its core work of providing a high voltage at the appropriate point in the combustion chamber, it must comply exactly with the dimensional requirements of the cylinder in particularly when it is installed. Manufacturers generally use spark plugs with a diameter of threads on 8mm, 10mm and 12mm.

Note: The tolerance measures threads must meet the specifications set by the SAE (Society of Automotive Engineers) and ISO (International Standard Organization).

The condition and quality of the spark plugs are very important for reliable performance in motorcycle engines. Offered in the market different types of designs to meet different and varied purposes that might require a motorcycle. Remember to always consult the manual of your motorcycle for the proper selection and values on specifications.

Although the task of inspecting and change (s) spark plug (s) may sound a little intimidating at first instance, then a brief description of basic steps to make your next assignment. First, become familiar with the area to work, so it gives you an idea of how to make a much safer approach. Photo # 1 (0600) Make sure you have all the right tools to do the job (the sizes and variations of tools and accessories needed will depend on the make and model of the motorcycle). Photo # 2 (0646) Many motorcycles require the removal of the fuel tank and most likely the removal of the air induction system. Remove the main fuel supply (if applicable). Photo # 3 (0609) Remove the fuel tank. Photo # 4 (0618) Your next task will be to remove the “cover” of the spark plug, clean the area with a cloth, brush or air pressure to prevent any particles from falling into the cavity of the spark plug. Photo # 5 (0626) Carefully turn the cover until it releases from the spark plug. Photo # 6 (0628) In multi-cylinder engines, list the position of the cables. Motorcycle with the “cover” to the integrated coil, release the electrical connector, turn the release of the coil and spark plug. Proceed to inspect the “cover” for abrasions or fissures. Recommended lighting the spark plug cavity with a flashlight to inspect the possibility of a particle deposited on the inside, if any, to remove it using a vacuum or air pressure.

Place the tool and proceed to remove the spark plug. Photo # 7 (0652) should not be completely loose nor very strong. Inspect the spark plug, Photo # 8 (0654) if necessary clean and refurbish or replace. Use a solvent (not gasoline), clean with a brush or wire brush (being careful not to hurt the ceramics). This process will remove any contaminants on the island. Photo # 9.10 (0662 and 0664) Remove the solvent with a clean cloth or air pressure. Check the opening of the electrode, the spark plug gauge according to manufacturing specifications. Photo # 11 (0672) When installing the spark plug is recommended that you use a type of “atiseize” below the tip (not applicable to the first thread or near the electrode). Insert the plug into the cavity, begins to tighten by hand only. Recommendations of the manufacturing conforms to generally apply the following twists: 8mm (6-7 ft-lb), 10mm (7-9 ft-lb), 12mm (11-14 ft-lb). Photo # 12 (0642)

Note: When you are re-installing a spark plug used previously, where the washer is been compressed, the spark plug only needs to rotate ¼ turn after being adjusted manually.

Replace the cover over the spark plug, make sure that strong as it could go a particle somewhere open. Photo # 13 (0685)

Take the time to re-locate all the parts back into place. Remember connectors, clamps, etc.. Photo # 14.15 (0688 and 0691).
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How to Adjust a Dirt Bike Chain and Axle

Every motorcycle manufacturer does things a little different when it comes to attaching the rear wheel, but they are all essentially the same. Make sure to consult your owner’s manual for the proper torque specs and recommended chain tension.

Step 1.2
Step 1: A good coating of grease will make it easier to remove in the future.

Installation Steps:

Step 1: Axle prep
Once the wheel is ready to be re-attached to the bike, before inserting the axle, make sure that it is properly prepared. The axle should be cleaned of any grime or dirt and then coated with a fresh layer of grease. Most bearing or axle grease will do. Force the wheel up tight against the adjustment bolts and tighten the axle nut enough to hold the wheel in place, but do not cinch it down.

Step 2: Adjust the chain

Step 2
Step 2: Don’t forget to tighten the lock nuts when the adjustment is correct.

Loosen the lock nut on the chain tensioner on each side of the swingarm. Once loose, thread the adjustment bolts in or out to reach the desired chain slack (out to tighten the chain, in to loosen it). Use the marks on the axle blocks to make sure both sides are equally adjusted and the wheel is square.

Everyone has a favorite tip for the proper chain adjustment. We try to leave enough slack so that the chain is tight when the suspension is fully compressed. You can check this by leaning over the seat, grabbing the swingarm and compressing the shock to view the difference in tension. A friend can help get more compression and a more accurate gauge. If the chain becomes taught before the suspension is fully compressed, it is affecting the way your bike handles during a ride and creating unnecessary stress and wear on the chain, sprocket, axle and countershaft

Step 3.1
Step 3: The rag ensures your axle blocks are tight against the adjusters.

Step 3: Tighten the axle
Once you are satisfied with the chain tension, put a rag between the chain and sprocket on the top side of the swingarm. Rotate the wheel backwards to cram the rag between the chain and sprocket which forces the wheel tight against the tensioning bolts. Use a torque wrench to tighten the axle nut to the specified tension, lube the chain and go ride.

Click here for an additional video tutorial.

How to Change a Dirt Bike Tire

This guide is for rear tire changes. Performing a change on the front tire is very similar but requires less detail than a rear tire (no chain). If you can figure out how to swap out the drive wheel then a front will be a piece of cake. Having the right equipment is important and there is a host of products on the market that can help make this job easier. However, in order to serve even the lowliest garage monkey, this is an example of a good, old-fashioned tire change that can be performed at home or on the trail. So good luck, and remember that it gets a little easier every time as you get familiar with the process.

Tire Change Steps:

Step 1: Remove the wheel
With the bike on a stand, remove the rear wheel and set aside the axle, axle spacers, wheel spacers and washers where they won’t get in the way. Keeping track of them is easiest by putting them all together on the axle and screwing on the lock nut.

Step 2: Place the wheel on a hard  flat surface with the sprocket side down. Loosen the valve stem lock nut and then remove the valve stem core. Loosen the rim lock nut to the end of the threads but do not remove it. Use your fingers or a tire spoon to push the rim lock inwards so that you will be able to break the bead.
2). Loosen the valve stem lock nut and then remove the valve stem core.

Step 2: Deflate the tube
Place the wheel on a hard, flat surface with the sprocket side down. Loosen the valve stem lock nut and then remove the valve stem core. Loosen the rim lock nut to the end of the threads but do not remove it. Use your fingers or a tire spoon to push the rim lock inwards so that you will be able to break the bead.

Step 3: Break the bead
Break the bead on both sides. Use your hands to break the bead by pushing downward on the sidewalls. If too difficult to perform by hand, try using a tire spoon to leverage downward. If that also fails, stand with one foot on each side of the tire and press down and inward with your bodyweight. Make sure to spread the weight as evenly as possible on opposite edges to avoid bending the sprocket or brake rotor. Flip the tire back to the sprocket-side-down position when both sides have been popped.

Step 4: Starting opposite of the rim lock  place three tire spoons roughly four inches apart under the tire edge. Pry the first one over and tuck it under the brake rotor followed by the next two. Remove the first and place it another four inches beyond the third and continue to work around the rim until the entire side is free.
4). Start spooning opposite the rim lock, using multiple spoons to lift the edge.

Step 4: Spoon off the tire
Starting opposite of the rim lock, place three tire spoons roughly four inches apart under the tire edge. Pry the first one over and tuck it under the brake rotor followed by the next two. Remove the first and place it another four inches beyond the third and continue to work around the rim until the entire side is free.

Note: Larger spoons provide more leverage, but small, trail-sized spoons can be locked under the sprocket or brake rotor and act as a spare hand.

Step 5: Remove tube
Pull the tube out of the tire, replace the valve stem core. Inspect for signs of wear and set aside. Do not remove the rim lock or rubber strap

Step 6: We use the over-over technique which might seem counterintuitive at first  but with the sprocket side up  perform the same spooning action and pull the tire over the edge of the rim so that the wheel is completely inside the tire. Stand the wheel up and rotate it until the bead lock is at the bottom nearest the floor. Bounce the wheel to force the rim in to the tire cavity. This should create a gap at the top. Grab the rim and the tire above it and force it off the wheel. This will take a little muscle  but if the rim is deep enough into the tire it will flex and come about halfway off. This will allow you to pull the rim upwards and free of the tire.
6). Pull the tire over the edge of the rim using a little elbow grease.

Step 6: Pull the rim
We use the over-over technique which might seem counterintuitive at first, but with the sprocket side up, perform the same spooning action and pull the tire over the edge of the rim so that the wheel is completely inside the tire. Stand the wheel up and rotate it until the bead lock is at the bottom nearest the floor. Bounce the wheel to force the rim in to the tire cavity. This should create a gap at the top. Grab the rim and the tire above it and force it off the wheel. This will take a little muscle, but if the rim is deep enough into the tire it will flex and come about halfway off. This will allow you to pull the rim upwards and free of the tire.

Note: Setting the complete wheel and new tire in the sun for awhile before starting this process will help soften the rubber and make it more pliable.

Step 7: Inspection
Clean and check the rim, bead lock and rubber seal for wear or damage. Replace as needed.

Step 8: Starting with the sprocket side  spoon the new tire onto the rim. Start at the rim lock and push the bolt to create space for the tire bead to fit between. You should be able to force at least half of the tire on by hand before using the spoons. Note: Use Windex to lubricate the rubber. Window cleaner is slick but evaporates quickly once the job is done. Use it liberally and don’t be afraid to give the tire an extra quirt if it starts to dry out. Soapy water works as well  or in a pinch  like on the trail  just water is better than nothing.
8). Push the bolt of the rim lock to create space for the tire bead to fit between it and the wheel.

Step 8: Install new tire
Starting with the sprocket side down, spoon the new tire onto the rim. Start at the rim lock and push the bolt to create space for the tire bead to fit between. You should be able to force at least half of the tire on by hand before using the spoons.

Note: Use Windex to lubricate the rubber. Window cleaner is slick but evaporates quickly once the job is done. Use it liberally and don’t be afraid to give the tire an extra quirt if it starts to dry out. Soapy water works as well, or in a pinch (like on the trail) just water is better than nothing.

Step 9: Install tube
It’s a good rule of thumb to replace tubes whenever you change a tire, but if the original is still usable then it’s ok to re-install it. Locate the valve stem hole from the sprocket side. Insert a tire spoon as if you are going to pull the tire back off, fold it over and pin the spoon handle under the sprocket. This will create space for you to work in when trying to install the valve stem.

Flip the wheel over so that the brake rotor is up again. Place a foot in the middle of the wheel hub and squat down to provide pressure. Lift up on the tire sidewall with one hand and use the other hand to tuck the tube inside starting with the valve stem. Once the stem is through, use the lock nut to keep the stem from pulling back through the hole. Proceed around the rim making sure that the tube isn’t twisted or folded on itself. It helps to have a little air in the tube, but not enough to stretch the rubber. Once the tube is fully installed, adust it as necessary to make sure the valve stem isn’t crooked.

Step 10: Starting at the rim lock  place one spoon on either side and use your hand to push the rim lock bolt to create space for the tire. Spoon the tire into place and use the third spoon to move about halfway up the rim on either side in small increments. Make sure that the tire bead is pushed down into the rim well on both sides to allow the tire to spoon on with less resistance. If you find yourself fighting the tire excessively on the spoons  make sure the bead is pushed down. This can be the difference between a ripped bead  sweat and cursing or a simple installation. Don’t forget the Windex!
10). Anchor two tire spoons and use the third to move up the rim gradually.

Step 10: Finish spooning tire
Starting at the rim lock, place one spoon on either side and use your hand to push the rim lock bolt to create space for the tire. Spoon the tire into place and use the third spoon to move about halfway up the rim on either side in small increments. Make sure that the tire bead is pushed down into the rim well on both sides to allow the tire to spoon on with less resistance. If you find yourself fighting the tire excessively on the spoons, make sure the bead is pushed down. This can be the difference between a ripped bead, sweat and cursing or a simple installation. Don’t forget the Windex!

Step 11: Air the tire
Once the tire is completely on, check for any visual signs that the tube might be pinched. Once the coast is clear, add air until the tire bead pops on both sides. If stubborn, use some more Windex to help ease it on. Often pulling the valve stem core and completely flatting the tube once or twice helps if the tube is being extremely difficult. Once the bead is secure, adjust the tire to the proper inflation and tighten the rim lock and valve stem nuts.

Step 12: Install the wheel
Replace the wheel and make sure the axle is clean and has fresh grease. Adjust the chain as needed and go ride.

Bike courtesy of Oregon Motorcycle Adventures.

Dirt Bike Control Setup

April 10, 2009 by jesrod  
Filed under Dirt Bike, Dirt Bike Control Setup, How To

Paying some close attention to your control setup can help tailor a bikes ergonomics specifically to your own size and riding preferences. All this adds up to a bike that’s easier to ride and that means hopefully faster.

Handlebars - Your handlebars should be the first thing you consider for your control setup, as a starting point adjust your bars so that the grips are either horizontal or pointing down just a little. This will vary according to what discipline you’re racing, if you’re riding motocross or supercross then you’ll probably run your bars further forward than if you’re competing in an enduro or cross country event.

See if you can borrow a couple of different sets of bars to find out what manufacturer and particular bend suits you. You can also cut a small section off the length of the bars if they feel too wide (don’t do this to the pair of bars you borrow off your mate!).

Bar widths should be between 790mm (31.1in.) and 820mm (32.2in.) for a full size bike.

Bar grips should be glued on. I personally don’t glue mine, I spray the inside of the grip with contact cleaner and slide it onto the bar end, once the contact cleaner has evaporated I then tie wire the grip in the middle and at each end.

Lever setup - Lever positioning is an important part of your control setup. The clutch lever and brake lever should be angled down slightly so that when you’re in the attack position on the bike, your forearms should be in a straight line with the levers.

When you’re forward in the attack position you have greater control over the handlebars and also your body will weight the front wheel giving better traction for cornering and braking.

Position your levers so that when they’re pulled in the ball on the end is in past the end of your bars. This way in the event of a crash the lever will push into the handlebars instead of snapping off. Also tighten your perch bolts just enough that they hold firm but have them loose enough so that in a crash they’ll spin on the bars and not break.

If you find that your clutch pull feels too heavy you can fit a longer lever which increases your leverage or fit a different perch and lever setup which gives a lighter pull. Works Connection make aftermarket perch and lever combinations or a Honda CR item is supposed to be quite good too, spending a few bucks on your control setup will pay big dividends when you get on your bike.

There should be about 3-5mm of freeplay in your clutch lever. Adjust this and also the take up point (friction point) to suit yourself. After a bike has done some work you may find that the levers will wear and start to flop around in the perch. You can fix this by fitting a thin shim washer to the pivot point between the lever and perch.

Always keep your cables and perches well lubricated. You can use one of those nifty little cable lubricators that clamp to the end of the outer sheath of the cable, you then poke the plastic nozzle tube of your lubricant spray to the lubricator and force the lube in that way. If you don’t have one of those then you can just jam the nozzle tube in to the end of the outer sheath. Keep your perch pivot point lubricated with a good waterproof grease.

Check your throttle cable for play. They can stretch over time and you may not be getting full throttle when you twist it on.

Your gear lever and rear brake lever should be about level with the footpegs. Faster riders may run their brake lever slightly higher because they’re up on the pegs a lot and also so they can drag the rear brake slightly over rough terrain to improve stability. I used to run my rear brake lever a little lower when I was riding KTM’s because everyone I had (5 in all!) had a super touchy rear brake.

Setting Up Your Dirt Bike Suspension

The first thing to do when setting up your dirt bike suspension is to put the rebound and compression clickers for both the forks and rear shock in their standard position (your owners manual should tell you how many clicks out is standard), if you don’t have the manual just set them halfway between hard and soft.

If possible find out what the standard rear spring was for your bike and make sure that’s what is in it now. If you’ve bought your bike secondhand and the rider who owned it before you was heavier or lighter than you or was particularly fast then they may have put a different spring in it which can make dirt bike suspension tuning difficult, this can be the case for the forks as well.

To set the static sag on the rear shock you first need to set the preload.
Back off the locking ring and then you either tighten or loosen the main ring to increase or decrease the preload on the shock.
Put the bike on a stand with the rear wheel off the ground and measure from the axle nut to a point roughly above it on the bike (say, a mounting bolt for the muffler or a part on the rear subframe), now take the bike off the stand and let it stand upright.

With the bike off the stand now measure the distance between the axle bolt and the point on the bike itself.
Subtract that measurement from the distance measured when the bike was on the stand, there should be about 25mm of sag, if there’s more than that wind up the preload or if there’s less then back it off. This measurement is called static sag.

Now to set the laden sag (race sag). Take note of the measurement with the bike standing upright. Now with all your riding gear on sit on the bike in the attack position (head roughly over the crossbrace, elbows up and out and feet up on the pegs), have someone hang onto the bike for you and take a measurement again. The amount of sag should be between 90mm and 110mm, again if it’s more or less then adjust the preload etc.

You should be able to get it set up approximately to those figures, if it’s way out on either then that can indicate that it either has different springs than standard (if you bought the bike secondhand) or that you’re heavier or lighter than the model used by the bike manufacturers. They base their settings on a theoretical rider who is about 5’10″ tall and about 85kg.

These are just rough figures, read your owners manual for the bike, the japanese manufacturers have a decent section in their manuals on dirt bike suspension.

Taking some time to learn about and set up your dirt bike suspension costs nothing and can really improve your lap times.

10 Things To Do To Your Dirt Bike Right Now

By Ryan Hanna, Karel Kramer
Photography by Karel Kramer

Motorcycle Maintenance Chris Denison
Motorcycle Maintenance Bleeding Your Brakes
Motorcycle Maintenance New Grips Motorcycle Maintenance Replace Old Grips

Motorcycle Maintenance Adjust Race Sag
Motorcycle Maintenance Tools Motorcycle Maintenance Check Your Spokes
Motorcycle Maintenance Suspension Fluids
Motorcycle Maintenance Cable Breakage Motorcycle Maintenance Cable Lubricant

Motorcycle Maintenance Grease The Moving Parts Motorcycle Maintenance Grease Bearings
Motorcycle Maintenance Wash Your Bike Motorcycle Maintenance Cleaning Your Bike Motorcycle Maintenance Wash Your Bike
Motorcycle Maintenance Bleed The Air Motorcycle Maintenance Push Button Bleeder Motorcycle Maintenance Bleed The Air
Motorcycle Maintenance Protective Plates And Guards

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