Rally Raid | Moto-Abruzzo

25/09/201426/05/2016

Way too close for comfort …..

Yes, I put my hand up; I screwed up on this one! I’m normally pretty good at keeping on top of the Capo maintenance, but this time I let the brake pad checks slip by while doing a full service a few weeks ago. So the other day I decided to drop the front calipers (Brembo P4/34 triple-bridge), took one look at the pads, swallowed … and squeaked a silent ‘bugger!’ Thankfully I could engage smug-mode as I already had a new set of pads (front & rear) hidden away in the parts-pantry after stocking up on all sorts of Capo-consumables at the back end of last year. The new pads are 7.5mm thick; with approx. 4.5mm of material ……. the best of the old ones was about 1mm on its tippy-toes. 😯 Way too close for comfort, so I took myself around the back of the barn and gave myself a jolly good talking too! 😳

Anyway that’s another job out of the way. Total mileage on the old pads worked out at 18,150, not too shabby really. And the rear? Doing fine, thanks for asking …. although by the time it’s pads are ready for a change, my guess is the disk will be as well. It measures a hairs width over the 4.5mm limit, so time to look for a replacement I think.

17/09/201428/04/2019

TuneECU for Android is now out

On the 15th September 2014 the eagerly awaited TuneECU for Android app was rolled out on Google Play Store priced at €9.99. It doesn’t currently support reading or reprogramming of maps through Bluetooth only via cable, but it is version 1 so this may be added at a later date. Either way, it’ll make a handy pocket diagnostics tool and save luggage space leaving the notebook at home! Here’s a link to the TuneECU webpage where you can read more about what’s needed to get it working on your Caponord.

It might be nice to look at putting together a fully waterproof Bluetooth module/cable that can be left permanently attached to the ECU, maybe with a remote switch in the luggage tray to power it on/off ….. another winter project! 😀

03/09/201426/05/2016

Front fork service …… better late than never!

The dodgy wrist and Dog awful weather here in Italy at the moment have both contrived to keep the Capo tucked up in the barn, a hairs breadth from the magic 100,000Km. So while the rain poured its heart out, I decided to have a look through the Excel spreadsheet of service/repairs/upgrades for the Capo ……… and realised that the front forks hadn’t had an oil change for over two years!

Well I must admit to being pleasantly surprised. The oil that came out was pretty clear and a flush with a dash of 5w oil soon removed the small amount of sludgy dregs from the bottom of the legs. A refill with blended Motul 8.5w oil and a reduced air-gap of 115mm (Std 130mm) works well, so I see no reason to fiddle with settings that suit my riding style. Overall the job took about an hour a leg taking it slowly, sipping tea and watching the clouds drift down the valley!

At this point, a gentle reminder for RR owners. Please remember that the Rally-Raid supplement is WRONG regarding oil volume! The forks take approx. 580cc each for the standard 130mm±2mm air-gap – NOT 680cc as specified ….. Unless you want a mess on the garage floor when it pours over the top of the tube!

And another point that it may well be worth mentioning ….. the fork recall that Aprilia issued in 2004 – has yours been done and what exactly IS done? As far as I can gather, it was simply a new spacer below the spring as the original was the wrong size and could, under harsh riding conditions, collapse and lock the forks solid. Not my idea of a bucket load of giggles that’s for sure. Aprilia say that mine was done in 2006 (thanks Tom at Moto Forza Italia – Silverstone, UK for helping) and Marzocchi say that the current Aprilia part number AP8163475 IS the upgraded part.

The spacer in mine looks fine although definitely showing signs of compression where it sits on top of the cartridge. This time I’ve flipped them over to even out the wear, maybe next time I’ll look into adding aluminium caps to the spacers to spread the load more evenly.

Anyway, that’s all done and dusted for now …… next stop, some new brake pads I think. The fronts look like the remaining material has about the same thickness of a well sucked After Eight mint! 😳

10/08/201426/05/2016

Where the hell did July go!

Crikey time flies. It seems an age since ACIM and all the stuff that happened before and after that great weekend, so I’ll start off the week before ACIM – the great cruise control saga. On the 3rd July TNT delivered the package to customs in Ciampino (Rome) Airport – a full week before ACIM, unfortunately it was from here on I became embroiled in a constant round of emails and phone calls in an effort to get the kit cleared to complete its journey. On the Thursday 10th (day before) ACIM it looked like I might be able to collect it from the local TNT depot on the way up …. ‘call us after 9am’ I did ….. Customs still had issues, call again on Monday. So that was that, no kit fitted or available to show. Frankly I was fed up to the back teeth with the whole thing and looked forward to a stress free weekend to unwind!

ACIM 2014 San Marino 11th-13th July

What a great weekend, new faces, names to faces and names who’s threads/posts I’ve read for years – a bit of hero worship going on here! A 560 mile round trip that shook the Capo down nicely for the big trip a few days later – with a very enjoyable spirited ride back to the hotel on Saturday evening with two Capo riders across some stunning scenery……we had a blast, thanks guys!

Other than that, I’ll let Jan fill you in with more details and pics from her website – Janet’s Edublog and end by saying a big thanks to the organisers for a fantastic weekend and we look forward to meeting up with you all again soon.

MCCruise control

After ACIM, with the Capo tucked up in the barn on Sunday night, I could focus back on the cruise control and my impending trip. Time was short … too short. Either the cruise control had to be cleared by customs on Monday/Tuesday or sent back to Australia – it was that simple. If the window of opportunity was missed, then frankly the cruise control was a waste of time, effort and money as I’d have to travel and hope my wrist held out. Not only that but I’d be away for the next 14 days!

In the end, at 10am on Tuesday, I stood at the TNT depot (Chieti Scallo) and marvelled as the sun glinted off the packing tape of a big brown box full of goodies! We whizzed home in double-time and the spannering started in earnest ……

….. by Wednesday afternoon the kit was fitted, calibrated and given its first brief test – and worked like a charm! Now I was out of time, bags were packed, Capo loaded and refuelled and at midnight I dropped onto the A14 North and the cruise was engaged for the first mile of many – and it performed faultlessly throughout.

Transcontinental run

Aprilia Caponord ETV1000 Rally-Raid - 60,000 miles and counting The next 25hrs took me door-to-door and the Capo gained another 1,350 miles under its belt. The cruise had been engaged for well over a 1,000 of those miles (night-time motorways) and the odometer slid over to 60,000 miles on the M25/M40 slip road, a half hour short of Oxford. The next 13 days were a blur of activity with the Capo grabbing an MOT somewhere along the way ….. And before I knew it, the Capo and I were heading back to Dover again with panniers groaning with tea-bags, cheddar cheese and bacon!

The return run was a real mix of (summer?) weather, dense fog in France, rain and sleet in Switzerland and 36C sunshine in Italy! Once again the Capo did what it does best, kept on running faultlessly mile after mile and so finally, at 1am on Monday 4th August we rolled into the barn with the odometer now at 61,860 – just 277 miles short of the magic 62,137 ………. Or 100,000Km to be precise!

As the sidestand took the weight from my aching knees and I eventually convinced my right leg to ease its way over the saddle for the last time, I saw Jan in the red glow of the tail-light all warm smile and a cold beer! Now that’s a way to be welcomed home …….. 😀

09/08/201426/05/2016

Oil pressure switch

Over the past few months I’ve noticed the oil pressure LED getting dimmer after the initial dashboard power-on-self-test has finished. Then a couple of weeks ago, no oil light at all. If I pulled the electrical connector off the switch and shorted it to the crankcase, the lamp worked fine, so the oil pressure switch was u/s, fubar, stuffed ……….

I bought a new one from Ultimate Parts in the UK that came in a plain zip bag, not an Aprilia one and isn’t the same as the original – requiring a 24mm socket instead of the original 21mm. As such I have a sneaking feeling this is an aftermarket part and not genuine – but sold at a genuine price! Either way, both new and old are marked as 0.3-0.6bar (4.35-8.7psi).

Swapping it out on the Rally-Raid was a simple 5 minute job – remove the aluminium sump plate, disconnect the electrical connector and use a deep 21mm socket on a short extension to clear the sump guard frame and unscrew the old unit. You’ll lose a couple of tea-spoons of oil but that’s all. Simply swap to the 24mm socket to fit the new one, reattach the connector and refit the sump plate – job done. The job’s made all the easier if you do it on the side-stand rather that the main stand as the switch is mounted on the right hand side of the engine!

28/06/201426/05/2016

Ruba-dub-dub …… one Capo to scrub!

As we fast approach the fun and games of ACIM, I figured it was time to reintroduce the Capo to two things frequently lacking in its life ……. washing and polishing. Yes, the hose pipe, chamois leather and Salvol autosol have been dragged out, dusted off and liberally applied to said Capo. My how she twinkles now, well as much as matt paint can ever twinkle that is!

Unfortunately for the Capo, there has been one cleaning job on the list that I’ve been putting off, and I have to admit that the list was written several years ago – the rear wheel refurb! After a couple of cold ones, I finally mustered up the courage to tackle the gunked on grease, the lashings of welded road crud and the inevitable rusty nipples. It nearly had the better of me once or twice, but tenacity and sheer bloody-mindedness (plus a couple more cold ones!) saw the job through to the bitter end. And here’s the finished article, not too shabby if I do say so myself ….. and that chain/sprocket have now got a whopping 38,730 miles on them!!!

Before it all went back together, the Scottoiler dual-injector was checked over as were all the bearings, seals and cush-drive rubbers – and of course it would have been remiss of me to have not taken the front sprocket cover off and give it a Mk1 eyeball check – looks OK for now, but I’ll get one on order! 😉

24/06/201426/05/2016

mccruise ……. active electronic motorcycle cruise control Pt1.

Let me start by saying that as of now, the cruise control project I’ve been working on has been put on hold indefinitely ………. why?

A couple of weeks ago I contacted MCCruise in Australia about buying a couple of parts to make my own cruise control install go a little easier – off the shelf stuff, not impossible to do myself, but just easier to purchase rather than make. After a lengthy phone call with Tony Guymer, I was convinced to take an in-depth look at the new electric servo kit* with the view to fitting it to the Capo. Unfortunately, of the current 120+ kits they make, none are for Aprilia. I’d have to start with a universal kit.

Now I’ll say loud and clear, here and now …… I’m not keen on the word ‘universal’. So the idea of a universal kit just doesn’t do it for me at all and that goes for a cruise control. Maybe it’s just me, but I hate the one-size-fits-all approach to anything, they never quite look right, not factory-fit enough for me I guess. No, it has to be a bespoke kit to fit the Capo and this is where Tony eventually sold me on the idea.

Tony suggested that if I were to get some data from the Capo – measurements, connector types and locations, wiring routes and mounting places for the main units, then between us we could map out a bespoke fitment kit, a kit as close to plug’n play as is possible. Now I like that idea and being able to get involved is the icing on the techie cake for me!

So last week the Capo was stripped …… dozens of photographs, pages of notes and CAD plans for mounting brackets were compiled and sent to the MCCruise in-tray. After a few quick techie emails back and forth, Tony gave the green light on the kit and as you read this it should be working its way across the planet to little old me! 😀

I just hope that after all this time, effort and expense my wobbly-wrist appreciates it! 😉

At the end of the day, they need to sell 10+ kits for it to be viable for them, so to offer a helping hand I’m hoping to have something to show at ACIM in a few weeks time and I’ll also stick a few flyers on the bike when its parked up to nudge a bit of interest.

*Tech details in Pt2. / **Fitment details in Pt2. as well, kind of a Pt2+ I suppose!

10/06/2014

TuneECU Andoid app in the pipeline!

I just popped over to the TuneECU website and saw a ‘NEW’ one-liner tucked away below the latest TuneLibrary.dll download link on the front page ……. I almost missed it, did a double take and followed the link in a flash ….. and I’m glad I did! It certainly looks like those clever folks have been busy, three nice screenshots of an Android TuneECU app. Shown below courtesy of Tom.

So I fired off an email asking for permission to use the screenshots and to enquire if the software would work with the Caponord and although not 100% sure at the moment, Tom’s pretty sure it will …. he just needs more information back from the programmer. So bookmark tuneecu.com and keep watching!

08/06/201426/05/2016

New fault code

Aprilia Caponord ETV1000 Rally-Raid. A tacho .... but not just any old tacho, oh no. In fact if Carlsberg and M&S made tacho's...... A few days ago while doing a bit of investigating for an AF1 forum member regarding the tachometer signal from the ECU, more specifically what would he observe on a multimeter instead of an oscilloscope, I momentarily shorted the tacho line against the chassis with the bike running. The tacho shut down and the bike just kept chugging along quite happily – no EFI light, no tacho. Recycling the ignition bought the tacho back to life and it’s been fine ever since ……… but two points came out of this that may be of use to other owners.

Check for a fault code with TuneECU – ‘P1386 Tachometer, open circuit or short to ground’
When the ignition switch is first turned on the Tacho line should show a solid DC battery voltage – if you don’t see this the ECU may well have shut down the output to protect it. Only once the engine starts will you see this signal:-

Aprilia Caponord ETV1000 Rally-Raid tachometer signal

Anyway, just a quick observation, a new (to me) fault code …. one to file away in the compendium of Capo facts. It certainly proves that the tacho signal isn’t just a ‘dumb’ signal, it’s one the ECU monitors and protects as neccessary by shutting it down.

07/06/2014

That’ll teach me!

Hi all ….. a quick post about the cruise control and a word of caution!

I finally got the cruise control servo unit mounted into the tool-tray of the Capo today. A relatively straight forward job, requiring only a minor rework of one of the mounting lugs, a new bracket fabricating and a couple of holes drilled in the under-tray.

The old throttle cable was removed from the unit and a new 6mm Teflon lined sheath fitted ready to run forward to the throttle bodies. It fits a treat down the side of the two 30A fuses and there’s already a cut-out in the undertray for it to run through, talk about made for the job! I’ll refit the old in-line adjuster and look at routing it along the engine/throttle bodies next week. So far so good!!! 😀

And so everything had gone beautifully, with a final firm slap the rear seat was locked in place …………. Only to realise that the key would no longer release it! Yes the dreaded can’t-remove-the-rear-seat syndrome. My fault entirely, as I should have checked the cable-outer was secure at the latch when I put the luggage rack/deck back in place. So here for your info is how to sort out what seems a very daunting situation to be in. Others may have a different technique, but this one worked for me.

Firstly stop twisting the key harder and harder, while bashing the seat in a vein hope it will pop off ….. it won’t ….. The noise you can hear when you turn the key is simply the cable outer and spring moving – NOT the latch.

Secondly, remove the rear deck bolts (x4). Of course you may have to remove a topbox and associated mounting plate first – no one said it was going to be easy! Now grip the deck just above the rear light and lift, at the same time slide something like a ½” drive 12” extension into the gap to hold the deck up. You’ll need to get the extension right the way in, enough to expose the latch mechanism. With the mechanism visible, slide a flat bar or long screwdriver in and gently push on the tab where the cable end is visible – from the rear of the bike, push to the left. And you should hear a satisfying click as the seat pops up. Reseat the cable-outer, reassemble the bike and sink a cold beer, you’ve earned it!

What a muppet …. anyway, I hope you’ve learned a little something from my foolishness and don’t make the same mistake!

……. now to connect the servo unit to the throttles.