Managing IT in the wild

If you want to stay in touch with your family and friends and share your adventures during a rally there is quite a bit of IT involved. In Morocco, where I'm going now, the cellular networks are pretty good and there is actually some WIFI available too at one of the base camps.
I am combining texting, a smartphone and a mini-PC to cover my information needs. Posting updates to various sites, uploading pictures, calling home, etc. Apart from that I also bring two GPS's, one for backup, and they need to be connected to the mini-PC for uploading routes and waypoints used for navigating the stages. The mini-PC also serves as a storage for unloading images and videos from cameras and helmet cams that we bring with us.

Of course all these units needs to be recharged every night. In the past I've been running around with a bunch of cables that connects everything and then plugging in the whole mess in a power socket. It works but it's messy and it leaves all the units visible to anyone who might be interested in stealing them. So this year I put together an "IT-case". It's a small tool case that I've fitted with various velcro straps that secures all units and everything is neatly connected in the case. I placed a power socket on the side of the case so when I need to charge everything I just place the case near a power source and I plug the case in with a power cord. No more messy cables and a lot more easy to handle and less eye catching.

Enough space for GPS's, a camera, a smartphone and
a mini-PC. 

On the picture you can see the mini-PC and the two GPS units. After the pic was taken a I also fitted connectors for my camera and smartphone. And anything that uses an USB plug can be connected as well.
Hopefully this solution will be a lot easier to handle than having everything in a mess with loose cords.

The rally bike of 2011

I thought I would try to sum up what I have done to the bike to prepare it for the rally this year and also to take the opportunity to show it off for all you petrol heads out there.

KTM 530 EXC SixDays Rally Lite Edition

The bike is a KTM 530 EXC SixDays 2010 with about 55hrs on it. My goal has been to build a "rally lite" bike just as I did last year. That is, I try to do as little modifications as possible and I try to keep the bike as light and slim as I can by not putting on to much stuff on it. Rather taking things away to keep the weight down. The reasons for building a lite version are mainly these:

140/80 Michelin Desert is
one wide tire...

• Keep everything you do as simple as possible. The less complicated the less chance it will break and the easier it will be to repair in the field.
• Every custom part you put on must be field tested before the rally. And by field testing I mean a lot of tough riding not just riding down a dirt road for a while. Preferably you should do a race with the part on your bike before you can trust it.
• If you build your own parts instead of buying parts of a well known brand you need to test it even more.
• The more stuff you put on, the more stuff that can break. And things do break. The most effective way to prevent something from breaking is not to put it on.

The non-standard components on chassis and engine are:

• Rebuilt front suspension (springs, shims)
• Rebuilt rear suspension (springs, bladder)
• Cylinder head ported
• Carburator (jets, etc) adjusted on bench
• Akrapovic exhaust

A degreased chain will last longer in the desert

All these mods were made by the previous owner and since the bike has done one previous rally I consider these mods to be well tested.

Here is a list of the preparations I have done to the bike just before this rally:

New plastic and decals just
for good looks

• New wheel bearings
• New grips (soft to reduce vibrations)
• New motor oil and oil filter
• New gear box oil
• New fork oil (thicker)
• Checked and greased steering head bearings
• New brake fluid
• Checked all electric wiring for wear and function
• Mounted electric wiring for the roadbook holder
• Mounted navigaton tower
• Mounted roadbook holder (MD with backlight and remote)
• Mounted GPS mount (I'm using a Garmin Foretrex 201)
• Mounted remote control for the trip computer
• New (dry) chain and sprockets
• New Michelin Desert tires and Michelin Desert mousse (front, rear and second rear wheel)
• Cleaned the carburetor
• Changed cooling fluid to Engine Ice
• Mounted large 13L tank
• Mounted rear fender bag
• Put thread lock on pretty much every single bolt on the bike
• Checked brake pads (they were almost new so I didn't change them)
• New plastic and new decals (absolutely no function, just for good looks :)
• Charged the battery
• Mounted custom skidplate with water tank

Aluminum skidplate with water tank

Apart from that I have pretty much checked everything else on the bike for wear and function. Spokes, handlebar controls, gas wire etc. Every part of the bike needs to be in mint condition if  you want it to run smoothly through an eight day race without any major problems.

Roadbook holder, GPS, trip computer and remote controls

As per usual when preparing a bike for a race, most of the work is not visible so you will not get any credit for it from someone who doesn't understand how much work that goes into something like this. But thats just how it is. :)

Now its only two days left before I'm leaving for Spain and I can't wait to get on the bike and head out to the dunes!

Spare levers strapped to the skidplate

Both front and rear suspension has been modified

Ready to jump over those Sahara dunes!

The bikes are ready to go

So it's finally time for the bikes to start their journey through Europe down to Almeria in southern Spain where the Tuareg Rally starts. That means no more time for fiddling with my bike. And I just finished everything on it. The night before the bikes are to be loaded on the truck.

It is kind of funny that no matter how far in advance you start planning a race it always comes down to the last minute. And it's not just me you know. Everyone is doing the same thing and it doesn't matter if it's a small race or the Dakar. You're always going to do last minute changes and be deprived of sleep when the deadline is getting closer. If you got more time you will just do more stuff but you will keep going until there is no more time. That's just the way it is I guess.

Tomorrow we are heading down to the city of Örebro, in Sweden, where we will meet up with the rest of the guys and load the bikes and all the gear on the service truck. I'll be sure to get some pics of all the bikes and the truck.

Carburetor cleaning

One of the less exiting but absolutely necessary bike prep you need to do before going on a desert race is cleaning your carburetor. Even if you don't do races you should clean it once every year anyway just to save you trouble. A carburetor is an ancient piece of technology for combustion engines as compared to injection. But it has its pros and cons. On the plus side is that since the construction of a carburetor is so simple it is mostly possible to fix it, should a problem occur, when you are out in the middle of nowhere far away from your sterilized garage. You basically cannot fix an injection. Most people will carry an entire injection kit (or several) as a spare when doing rallies.

Removing and cleaning jets

My cleaning procedure consists of taking apart most of the carburetor. Cleaning each part and checking for wear and tear. All jets, the mixture screw, needle, float, float needle, the throttle valve, the accelerator pump etc etc. And when everything is nice and clean I put it back together again.

When I put it together again I usually put just a little bit of thread lock on the screws to make sure the stay fastened. I also put some thread lock on the mixture screw so it won't come lose. (I actually lost my mixture screw in a rally in 2008)

As I said, not the most exiting bike prep but a carburetor problem can possibly ruin an entire race so it is definitely a must.

Revamping my skid plate

I have a skid plate made out of aluminum that also holds 2 liters of water. Those two liters are the emergency water that every rider must carry and having them in the skid plate rather than in your backpack or somewhere else on your bike has its advantages. First off I would really recommend trying to put as much stuff as possible on your bike instead of carrying them on yourself. Having extra weight to carry will be tiresome when riding long days. The skid plate is about as low as you can get on your bike and it is good to try to put any extra weight on your bike as low as possible to keep the center of gravitation low. So having those 2 extra kilograms on the skid plate is perfect.

Johan doing his TIG magic

I was down at my friend Johan at Pro2 and his shop the other day to get some help to modify my skid plate since I can not weld aluminum myself. I drilled a hole through the water tank and put in a tube that I can use to get better access to the bolts when mounting and demounting the plate when servicing the bike. Everything to save a couple of minutes each day when servicing is worth doing.

Johan did a superb job and all it cost me was a couple of brews. Since Johan is also going to the Tuareg rally I will repay him in the Sahara. :)

Wheel bearings

So, it's about three weeks until the bikes are loaded on the service truck and begins the journey down to Spain so its time to start doing bike preps. I've mentioned the steering dampers I will be using in an earlier post and today I  want to say a word about wheel bearings. Or actually two words: Change Them!

During the years I have made it a habit of changing the wheel bearings every year on all my bikes no matter if I got them brand new or used. I have had a rear wheel bearing fail on me once and it totally destroyed the entire hub. Costing me several hours of work to replace the hub. When it happened I had checked the bearings when I changed tires just a couple of riding hours before it happened and they all seemed fine. So I learned the hard way that when bearings fail they can fail so fast that you will not notice it until it's too late. And I might add that that particular bike was less than a year old and with me as the first and only owner.

Fill the gap with grease and your bearings will live longer

While I'm at it I might as well share a tip about wheel bearings. Once you fit the new ones on there will be a gap between the bearing and the sealing. Make sure you fill that gap up entirely with grease (also do this if your bike is brand new from the factory). The bearings themselves are sealed so the grease will not lube the bearings but it will act as a barrier and prevent water and dirt to get in and reach the bearings. And water and dirt is what will kill your wheel bearings. I've done this for a couple of years and it really does make a huge difference.

If we go back to fact that bearings can fail fast it should be obvious that I will never go to a rally without having brand new wheel bearings on. Most manufacturers have wheel repair kits that contains all bearings, seals and spacers that you'll need and they are relatively cheap and it's quite an easy operation to change them. So changing my wheel bearings is an easy insurance that my bike will take me through deserts and rivers for thousands of kilometers without any troubles.

Steering damper or big biceps?

One bike modification that I will be doing differently this year compared to my earlier desert races is the use of a steering damper. I have never used a steering damper on any of my bikes before. Not at home when riding enduro or offroad and not in the two previous desert rallies either. Mostly because I have never really felt the need for it.
In 2008 in Morocco I rode a KTM 625 which is a pretty heavy bike that more or less behaves like a freight train plowing through any obstacles and sandy courses so I didn't have any problems with driving without a steering damper. And when I'm at home I usually never ride for long enough periods of time that I will feel any fatigue caused by a nervous front wheel. But in 2010 I rode a KTM 400 during the Tuareg rally. The 400 is a much lighter bike that becomes quite nervous when riding at high speed in tough terrains. For the first time I actually noticed how much the front wheel was bouncing back and forth and during some stages when I was going flat out on loose sand roads I actually had to slow down because I simply couldn't hold on to the handle bars anymore. A friend of mine who was riding with me later described the situation as: "Ronnie has a steering damper, Danny has arms the size of my thighs, and I have nothing but pain". Ok, granted that I'm in fairly good physical shape but I was also getting tired at that stage so after last year's rally I promised myself that I would never race again without a steering damper.

Öhlins steering damper

So, said and done. My new KTM 530 has been equipped with a Öhlins steering damper. For you who don't know, a steering damper works by dampening the movements of the handlebars. But it does so in a way that it only dampens fast movements. This means that when you are turning the handlebars during normal riding no dampening takes place and you will not notice it at all. But when fast and sudden movements occur, say for example when you hit a rock with your front wheel, the movement is heavily dampened. So instead of sending the front wheel, and you, off in a random direction the front wheel will keep straight and you can continue riding in the direction you intended.

Now this will of course help you avoid some situations that might otherwise lead to a crash, but it will also save you a lot of energy since you don't have to do all the dampening yourself as you otherwise would when you are using your arms as steering dampers.

So this year I am not going to slow down on those loose fast tracks or in those tricky dried out river beds. I'm going flat out all the way... ;) And hopefully I can avoid crashes like the one last year when I hit a rock in the middle of a curve that lead to a face plant and a sprained ankle.

Or if nothing else, it will at least be a cool looking piece of gear on my bike.

'Twas the winter before the rally

So, its been exactly two months since my last update here. That means I've been busy with life I guess. You know, all the stuff that we need to do in order to be able to go riding in the desert. Unless you are working as a tour guide in the desert that is. :)

Even though I haven't posted anything here lately I still have been busy preparing myself for the next rally physically. Endurance and strength is important in any race and the same goes for rallies. If you don't get tired physically, you will be able to stay mentally fresh longer. And that means safer and faster riding. I usually try to train about 5 days a week. Divided 50/50 between strength and cardio/metcons. Now I'm gradually starting to switch over to more cardio/metcons to focus on endurance and when the race gets closer I will be doing mostly endurance training.

The new weapon of choice. KTM 530 Sixdays

I also picked up my new bike today. Sort of like a late christmas gift for myself. It's a KTM 530 EXC Sixdays with about 50 hours on it. I think the 530 will be a perfect bike for the Tuareg Rally. This year I rode a KTM 400 EXC and it was great because of its low weight and easy handling. The only thing it lacked was some power and top speed. It wasn't a big issue but since I'm aiming at improving my results next year every little advantage I can get is needed so the extra power from the 530 will be most welcome in the dunes.

I will be posting updates on the work I'll be doing on the bike to prepare it for the race. Some things I know I will be doing are navigation tower, larger gas tank, water tanks and checking and replacing all the bearings and wires. I guess I will be spending a lot of hours in the garage in the nearby future…

Happy New Year to all of you!