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Topics - Lotus54

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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

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)

Explorer / Diagnostic cables/software
« on: April 17, 2015, 02:51:18 PM »
I have this setup, works great!
I have not tried writing a new map yet- I'm waiting to get the map that is currently in the bike before trying out a new one. It runs darn well now. (But I like playing with stuff)

Explorer / BTWICE skid plate
« on: March 28, 2015, 02:44:42 AM »
I got one of the BTWICE skid plates.
  It fit perfectly and has much better coverage than stock.
Looks to be just as thick, but protects the rear of the frame and better side protection.

Works well.

Explorer / Fork Servicing
« on: January 15, 2015, 12:53:40 AM »
I'm working on servicing gone forks my Explorer.

  Even with the usual tricks the bottom om bolt just spins- before I try anything lose I'd lie, to get an. Exploded diagram or something of how the forks work.

I have not found Anything at addresses the Oll

Explorer / Side body panel
« on: November 02, 2014, 01:49:32 AM »
A tip.
   I lost a side panel (the ones that press and clip in).
I had one fall off once before, but didn't get around to doing a permanent fix.

So- notwthat I have a new panel, a small tie-wrap around the press-in part anchors it so the panel can't be lost.
A quick clip and the tie-wrap is cut, but the panel won't be lost by accident.

I have some. 120 hours before I lost one, but I would recomend doing the fix.


Explorer / 1974 Explorer and 2014 Explorer
« on: September 24, 2014, 12:40:31 AM »
Here is my latest project.
  From the original owner, nothing rusted solid (just some surface rust)- runs pretty well, 190psi cranking compression.

What do you guys think?

Explorer / Explorer 'main' tank vent leaking
« on: August 09, 2014, 08:06:03 PM »
Quite recently the little vent out of the 'main' tank (in the frame) started leaking.
The hose was too loose and leaked originally, but a bit of safety wire fixed it.
But now the little 90degree metal fitting that goes I or the dummy cap is loose and leaking Badly.
Perhaps it won't leak much when the tank is bolted down and holding it- but I'm not counting on that.

Anyone come up with a good solution?

The only one I can think of is to tap the dummy cap and thread a fitting in- or come up with on that has an O ring on it.

 Any ideas?


Explorer / Update on an Explorer after 14 months and 145 hours
« on: July 20, 2014, 12:26:01 AM »
Thought I'd put up an update on the bike so far.

Overall, I love it! Fantastic bike for how I use it. Mostly trail riding, best on the hardest trails. Not so hot on really fast trails. It will do it- but really always looking for tight stuff!


1. Broken chain tensioner spring.
2. Flakey fuel cap
3. Broken wire to speed sensor
4. Broken suspension Link (my fault)
5. Bent rear brake mount (my fault- but I don't like the setup)
6. Crappy stock brake pedal- ditched it for TR pedal- perfect!
7. Failed front wheel bearings at 88 hours (common on my KTM where I ride also)
8. Wore hole in seat before I started riding properly (was gripping with legs)
9. Plugged aftermarket Spark Arrestor (fixed with little mudflap)
10. Stock chain is crap- replaced with DID Narrow, great now.
11. Biggest issue- not enough time to ride!!!

As you can see, all are pretty minimal items or my fault. Things like wheel bearings are disposable around here with all the water and mud.

No failed plastics or broken tabs/mounts. Hard to start twice- both times due to my giving throttle without thinking and an older sparking plug.
Has not lost any coolant, ever. No leaks (except crappy fuel cap)- runs perfectly all the time (except when I plugged the non-stock spark arrestor).
The bike has been a delight- the light weight is fantastic, it is teaching better riding habits and I'm having a blast with it. Never once have I wished I didn't get it,more had gotten something else. My old KTM 300'XCW was fantastic, but I enjoy this much more (except for really fast-'rough stuff).

I'm learning loads on how to ride 'with' the bike, allowing it to do the work. I'm still learning to trust it.

I highly recommend the bike to someone that wants a super  light bike  that is very responsive. It Definately wants to be ridden standing- but I do all day rides with no problem at all, almost never sitting. Learn to rest standing, use your legs and not your arms, ride very loose and relaxed.


Explorer / Clake II
« on: May 24, 2014, 02:40:40 AM »
I installed my Clake II.
left hand rear brake, spring assisted clutch and keeping the footbrake.

I've only used it a bit so,far, but I think it will be great.

The brake can can operate the clutch also if you want, to a varying amount.
I really like a LHRB, since I can keep my feet where I want them and my hips straight with the bike.

TR280i / Rear brake caliper
« on: May 17, 2014, 12:00:35 AM »
Does anyone have a picture of the TR rear brake caliper and mount?

It seems it is different than the Explorer, and I'm looking into alternatives since the mount on mine is bent and I can see the caliper flex. The explorer came with a 4 piston caliper- appears the same as the front.


Explorer / Poor running from plugged spark arrestor
« on: April 20, 2014, 11:55:21 PM »
Just in case...

I'm running a spark arrestor on my Explorer (since most places require one).
While I've run it quite some time- yesterday it got plugged- perhaps a combo of of mud and carbon.

The bike would barely rev at all- acted like a bad plug.
Removing the arrestor totally fixed it.

I plan on a diverter to keep mud out of it.


Explorer / Engine temp sensor
« on: March 29, 2014, 02:15:04 PM »
I'm trying to figure how to. Fit an engine temp sensor.
The Vapor computer is set up foe one- I know. The speed sensor wire broke on mine so I sent it in to TrialTech (just a few hours away ) to have it repaired and they tested it. I couldn't find the connectors locally.

The only issue, there is already one wire going into the temp sensor connector from the bike.
The temp sensor has two wires, so no clue what this one does.
It is a brown wire, I have not traced it yet to see where the heck it goes.
Still no wiring schematic seems to exist.

Anyone done this?

Plus I recommend putting a tie-wrap on the bike side of the speed sensor- it moves around a lot with the wheel going up and down- maybe what broke mine. 


Explorer / Converting to TR
« on: March 04, 2014, 02:12:27 AM »
After doing a couple of trials and seeing how someone has done it- PLUS
I just pulled the subframe/tank in less than 10 minutes.

So I'm on the search for the connectors to the easy start (to make an extension cable and relocate) and the fuel quick connect. So I can make a 'plugged off one' to pop in when removing the aux tank

Anyone know?


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