Fitting the TM40 from XRs Only - Calling BuRP!!

Need help please
For a start the throttle cables are way too short - My bars are raised about an inch so I have the option of routing the cables below the bars and above the top triple clamp and the cables are still way short or, if I route them the correct way the push cable is about 11.5 cm short and the pull cable about 13.5 cm short.
Is there somewhere I can order longer cables or must I have them made up?

What needle and needle jet are used on the XR? So far from what I have read it looks like the following works
AJ 1.2 (1.1 in the carb)
NJ Y-4 (Y-6 in the carb)
Needle 9DJY01 (9DJY04 in the carb)
IJ 22.5 - 25
MJ around 145

BuRP - Where did you get your cables and carb tuning parts? In South Africa or USA? What needle jet and needle are you using at our altitude?

"Is there somewhere I can order longer cables or must I have them made up?"

Same thing, MotionPro in the US, I got mine some 3" longer I think - my bars are also raised by quite a bit.
Get their cable-lubing tool & lube at the same time, you'll thank me later.


Jetswise (any), mail Andrew from Motorcycle Components on mcomp@mweb.co.za
No stock, costly, you have to wait for him to import also but I got what I wanted. I've tried bypassing them but some overseas agents will refer back to them, so so much for trying.... in vain.


No idea what JN & NJ I have, I think there's a '6' in somewhere.
But anyway, you'll need to tune your own bike, and tuning-wise this is where all our bikes will differ, not so much on the IJ or MJ's, which is simple enough anyway.
Google for the numbers of the various JN's (& NJ's) to find what's leaner and what's richer, and where (slidewise) that is - this info I found and is useful but don't have it anymore.
The good news though is that your bike - once equipped with the correct idle jetting and a main somewhere ballpark (145?) - will start, and then you can take it from there by determining first if the main is fine (WO runs), then finetune the mids by means of the JN&NJ combo.


To all, if you'll order a TM40 from XRsOnly (I did) do yourself a favor and specify the complete jetting you want it to come with, for they invariably supply 'some' jetting which is never even close - like mine!
I like this company (a lot actually) but for this single thing, it's atrocious what they supply jetting-wise. Oh, no, I'm not alone in thinking this, search the net for same opinion of others.

Put the idle combo 25 & 1.2 in - if you don't then you'll have problems, I've spent DAYS on only this bit.
I actually advertised to put a 27.5 in (works quite well) to keep the low-down temp's down, but this does not make a big-enough difference to justify the minor surging (at very low speeds) the bike does with the 27.5 which completely disappear when the 25 is mounted.
Put the 22.5 in and you're back to surging, PLUS your low-down temps will go up.
Trust me for this, for once?

Hey BuRP

You are correct regarding buying jets and needles from Sudco, they refer me back to Motocomp who take 4 weeks to get it (and at least another week to post it to me). That sucks I could probably get them in 7 days if Sudco would ship direct.

I will let you know how I do with getting cables made up. As far as I can tell I need them 5" longer if I stick to the original cable routing. Maybe 4" if I take a shortcut below the bars but over the top triple clamp.

I doubt the XR's Only cables could work on a standard handlebar setup. Has anyone tried?

Lengthened my cables by 130mm - Got them back same day - Ordering some jets on Monday and will have them Tuesday - I will start with same jetting as Burp and go from there.

Unfortunately 1.2AJ as well as other NJ and JN I will have to wait 3 - 4 weeks for

Don't know if they still exist but there was a place in city deep called anropa, where end street heads south out of jhb City towards Alberton just off Heidelberg road that did custom cables.

appleseed wrote:Don't know if they still exist but there was a place in city deep called anropa, where end street heads south out of jhb City towards Alberton just off Heidelberg road that did custom cables.

Yes, that is where I took my cables

cool, last time i used them was 99 ish to get cables made for my yz490. goo to know I haven't managed to kill all my brain cells yet

So I learn, didn't know about the place

Cables working - Carb fitted - Piggy started

It was almost 9pm so I didn't start fiddling with jetting/tuning

Dead spot just off closed throttle and popping on over run? I assume that means too lean on the pilot jet?

Ordered the wrong type of Mikuni pilot jets so will get the right ones on Thursday.

Throttle sucks a bit, you really need to grab a big handfull to open completely - A quick action throttle would be nice

Getting my pilot jets tomorrow

2x AJ, 1x NJ and 3x needle will be here end of the month - With my assortment of PJ and MJ I should be able to dyno and jet properly

You sure about that 25 pilot jet? My piggy didn't like it, she is much happier with a 15

Not sure how the rest of my jetting is but even sitting right forward with my weight over the bars in 1st the front end comes up quick if I roll on and then grab a handful

with leovince full exhaust and stock motor I use a pilot jet #30
but I have some pops after gas closing, I'll try with #32,5

Did a WOT test today - Was a bit lean with the 145 so trying a 150

150 instead of 145 is an increase of 7%.... that's a big jump Chris, I thought you had a 147.5?
Anyway, easy to try too

BuRP wrote:150 instead of 145 is an increase of 7%.... that's a big jump Chris, I thought you had a 147.5?
Anyway, easy to try too

On WOT test today it was still just a bit grey - Went to 152.5 and is pulling my arms out their sockets - Will do another WOT sometime soon

Remember, I have
Cam
Pipe
Cutout airbox
Ported head
11:1 piston

WOT being 150 - 160km/h up a long hill and clutch in and kill engine

Uphill ain't a good idea, keep it level matey
Sounds like I'll have to bring my helmet for that braai ....

BuRP wrote:Uphill ain't a good idea, keep it level matey
Sounds like I'll have to bring my helmet for that braai ....

My piggy is not under any load on a flat, hence the uphill

At 100+ km/h it de-fi-ni-te-ly is under quite a bit of load already, and quicker means exponentially so!
You hang on for dear life on that 'naked' then don't you?
QED!
As said, keep it level, it's best

BuRP wrote:At 100+ km/h it de-fi-ni-te-ly is under quite a bit of load already, and quicker means exponentially so!
You hang on for dear life on that 'naked' then don't you?
QED!
As said, keep it level, it's best

The front end goes through a bit of a wiggly (and sometimes scary) stage around 130 but at 160 she is fine

How's your suspension-setup height-wise?
Smaller wheels need to be compensated for somewhere, I'd hate to 'wiggle' at those speeds

BuRP wrote:How's your suspension-setup height-wise?
Smaller wheels need to be compensated for somewhere, I'd hate to 'wiggle' at those speeds

I wonder is shane3 has a wiggle on his motard? I will PM him.

That XR650L had the same wiggle, I thought it was just the long forks flexing