Author Archives: Manolo al Sol

New clutch and basket springs by EBC; 2008 KTM 530 EXC-R

New clutch parts: EBC kit (p/n DRC252) consists of fiber plates and metal friction plates, and stiffer clutch basket springs. Fits: 08-10 ’08-’10 2008-2010 KTM 530 EXC-R The clutch was grabbing unpredictably, particularly bad off the line in 1st gear. The KTM uses a flat, then beveled washer, to start the clutch pack. Helps toContinue reading “New clutch and basket springs by EBC; 2008 KTM 530 EXC-R”

Upgrading 2008 KTM 530 EXC XC-4 motor’s oil pump to 2011 parts

KTM came out with the XC-4 500cc motor in 2008, characterized by separating the engine and gearbox oiling chambers. There were a lot of running changes to the motor in the subsequent years, thus 2011 parts for the same XC-4 motor are desirable improvements on a 2008. The oil pump shaft, gears, and main oilingContinue reading “Upgrading 2008 KTM 530 EXC XC-4 motor’s oil pump to 2011 parts”

Resolving motor oil migration | 2008 KTM 530 EXC with XC-4 motor

Finally resolved the oil migration issue on the 2008 KTM 530 EXC, the first year of the XC-4 motor that contained separate motor oil and gearbox oil compartments. The bike’s factory breathers is a closed system connecting the crankcase from the valve cover, the gearbox, and the air intake after the filter. In other words,Continue reading “Resolving motor oil migration | 2008 KTM 530 EXC with XC-4 motor”

Modifying GM Hummer H2 factory 17″ wheels to fit over hubs on a 2nd gen Dodge Cummins

General Motors built the Hummer H2 generation with cast aluminum, 17×8.5 factory wheels. With an 8×6.5″ bolt pattern, the rims are compatible with OBS Ford and early 8 lug 3/4 and 1 ton American trucks. However, the center bore does not fit over the 2nd gen Dodge unit bearing hub flange without modification. To modifyContinue reading “Modifying GM Hummer H2 factory 17″ wheels to fit over hubs on a 2nd gen Dodge Cummins”

Refreshing 2nd gen Dodge 4×4 steering and suspension trackbar

The inverted-y steering and front end of the 2nd gen Dodge 4×4 truck, tasked with suspending the heavy duty Cummins motor, needed a major refreshing. Even with a solid front Dana 60 axle and stock ride height, the tie rod ends and trackbar in the suspension were clearly tired. Took the opportunity to replace allContinue reading “Refreshing 2nd gen Dodge 4×4 steering and suspension trackbar”

Dodge CAD Dana 60 conversion to manual cable actuation

1994-2002 Dodge 4×4 trucks with the front Dana 60 use a vacuum actuated CAD: center axle disconnect. The system relies on a gear driven vacuum pump off the Cummins motor and plastic tubing leading to the external diaphragm and actuator in the passenger side axle tube, next to the low pinion differential. Inside the CADContinue reading “Dodge CAD Dana 60 conversion to manual cable actuation”

Resolving overheating 12 valve Cummins turbo diesel

Truck overheated on a cool winter, late afternoon, while crawling up a hill in snarling Los Angeles traffic. Was slowly inching alongside a highway detour to bypass a wreck as it poured cats and dogs from the atmospheric river before Christmas 2021. As I crested the hilltop, noticed a late model Dodge truck pulled overContinue reading “Resolving overheating 12 valve Cummins turbo diesel”

Cummins 12valve turbo diesel joins the fleet – April 2021

::Welcome to the Fleet::: 1997 Dodge Ram 2500 4×4 5.9L 12 valve Cummins intercooled turbo diesel, 2-door extended cab long bed, 47RE 4spd automatic transmission, ball joint Dana 60 front axle, NP241 t-case, Dana 70 rear axle and 3.55 gears. Fleet truck white with a lined long box interior. Drove this 2nd gen Cummins homeContinue reading “Cummins 12valve turbo diesel joins the fleet – April 2021”