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Messages - Lotus54

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TR280i / Re: Transmission Fluid
« on: November 18, 2017, 09:50:03 PM »
Be aware the oil also lubricates the main bearing.  Most 2-strokes do not do this, although I heard some other trials engines do.

 I have almost 400 hours on my Explorer.  Finally going to pull the head/cylinder and see how the piston is doing. lat I checked (head only) cylinder looked like new and what I could see of piston through exhaust looked really good.

General Discussion / Re: Ossa still in business?
« on: August 06, 2017, 04:49:52 PM »
Currently not producing any motorycles.
  They are attempting to start producing again- but who knows if that will ever happen.

They are making electric Bicycles now.

Explorer / Re: Clake II
« on: December 05, 2016, 03:37:25 AM »
Yes, the master cylinder is a bit difficult to bleed.
  Watch the videos a few times and try it.

I had sort of a system now- and also got a spare master cover that I will install a fitting to pressure bleed. I think that will be better.

Where are you located?

Explorer / Re: reed valve intake system
« on: August 03, 2016, 04:16:27 AM »
I've only used the Boyesen

TR280i / Re: 2011 tr280 i wont start
« on: May 01, 2016, 04:14:09 PM »
I'm thinking the 9v won't power the fuel pump.

  If I have a suspected issue, I'll run 12v in the appropriate  diagnostics port, then you can hear the fuel pump prime.

If it runs out of fuel it is a bear to start without priming. (At least for me)

Explorer / fuel Filter
« on: March 25, 2016, 06:14:50 PM »
A week or so ago I popped the computer onto the bike ( someone else wanted a 'How to)
  I saw a 'high current to fuel pump'

Well, I used to check fuel filters on my old Ducatis by measuring the fuel pump pressure- current goes up means the filter is starting to get clogged.

The filter is not available separately- so since I plan on keeping this bike a long time I bought the whole pump assembly.
  I believe it is the same setup used on a few of the KTM models (pics and filter are the same)

The filter is a Mahle KL 97
  It uses the crimp style  full circle clamps.

Unfortunately, the engine must come out to change.
 But I have some 280 hours so it would be good to really check everything anyway.
(Bike still runs great)

I'll replace the filter (and maybe pump) on my original setup and have it for a spare.
OR just fix up the original and keep the new one as spare.

I'll post up some pics.

I did buy a tool from NAPA auto parts to remove the connectors, I slight modification and it worked great. About $8

TR280i / Re: Transmission Fluid
« on: February 22, 2016, 05:45:13 AM »
I've only used the full synth maxima that Adrian mentioned.

270 hours and going strong.

TR280i / Re: TR280i gearbox problem
« on: February 15, 2016, 05:02:24 PM »
The early gearboxes had an issue or two- but I can't remeber exactly what.

Pop the gearbox out and take a look- could be a shift fork, shift drum or selector shaft.
  Sometimes they can get bent with a hit to the shift lever.

When pulling the gearbox, make sure to heat the tiny little screws to break loose the locktite.
Take your time and carefully work them out. Don't use an impact- or you could break the tip off in the screw.

It is pretty easy once you get past that.
  (Also make sure to undo the 'clutch fixer nut')

I think there are some pics/tips here.


Explorer / Re: Fork Servicing
« on: February 06, 2016, 06:51:14 PM »
I replaced mine with Marzocchi trials
   Much better. (I also replaced the rear with the Ohlins)

TR280i / Re: Ossa problems
« on: February 05, 2016, 04:37:06 AM »
It could be the starter gear- possibly something in the transmission.

The gearbox is easly to pull- BUT there are a few tricks (heat on the tiny screws is the main one)

Where are you located?

Explorer / Re: Engine Temperature Readings - Seizure
« on: October 30, 2015, 03:05:50 AM »
I do have a wiring diagram.
 PM me and I'll send it to you.

How where you running it?
   Idling around, high rpm, road?


Explorer / Re: Engine Temperature Readings - Seizure
« on: October 29, 2015, 01:15:18 AM »
My temp gauge never worked either.
  I don't think it is wired up.

The fan on mine comes on when it is warm.
  I can try to take some readings.

I've heard of one other Explorer seizing when new.
I think it was from running too hard when new.
They require a long break in.

Check the hoses and see if they get hot.

(What is your location?)

Explorer / Re: Tranny Oil and Amount
« on: October 24, 2015, 01:18:42 AM »
There was a service bulletin about lengthening  the breather tube.
   I used some clear tubing, and can see oil in it after long hills at higher rpm/speed.

Explorer / Explorer with TR plastics
« on: August 24, 2015, 12:41:18 AM »
Pretty quick change.
 The only part is figuring out where to put the 'Easy Start' box.

Explorer / Transmission pics
« on: August 07, 2015, 11:10:32 PM »
I had a broken shift return spring.
Once I learned some of the tricks to remove (thanks Big Don).
1. heat those 5 tiny 3mm allen head bolts that hold the gearbox cassette in. Take your time!
3. Hold the little shaft (remove the breather- or later bikes the small bolt) in front of the countershaft. What fooled me is there is not a 'nut' shape inside or anything, just smooth. Jam a small Torx wrench in there and take the 'Clutch Fixer Nut' off the other side. IT IS LEFT HANDED!
Touque is only something like 5nm back on.

of course it is supposed to be in gear.
The side cover is a bit fiddly to get back in- just make sure to look at the Guide from OSSA Canada (I'll try to attatche it for future reference).

I adjusted the spring stop eccentric with the shift forks off- making sure the shift drum 'roller' snapped into each place best possible. If it is wrong it won't snap in and you will have to jiggle the shifter to make it work.
It is pretty easy- just take your time. What I did worked quite well. (they also have a 'cutaway' case the the gearbox can mount in and reach that adjustment with everything in place- but this works fine.)

on the weekend, near the end of the ride, I noticed the shifter not returning from being pushed down (worked fine after pulled up).
 So I figured a shifter return spring.

So a $5 spring and good inspection (replaced the countershaft bearing and seal while in there) and all back together working great.
There is an adjustment that needs to be made on the spring stop- but a bit of looking and I found out how- shifts great.

I thought some of you may like to see the gearbox- it is a pretty cool little setup (sorry for the dirt, I hadn't really cleaned things up yet)

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