99' KTM LC4 640 Rocker Cover Repair & Pics

[overlandr]

Originally Posted by fujian

Thanks for the tips, I agree that the thread title needs to be changed, Could you change it for me? " LC4 640 Enduro - Rocker Cover Leak " that would be a more fitting title.

This may help.

http://www.advrider.com/forums/showthread.php?t=741009

Also, learning how to search for stuff on ADV using google is very useful as there is a wealth of collective wisdom on here. One just has to know how to locate it.

[laramie LC4]

Originally Posted by fujian

Thanks for the positive comment Laramie, Where did you get the idea that I'll not be returning anything to the knowledge pool ?

sorry dude, sounded like you were going to fly in and fly out. we get lot's of guys that just expect help, then do very little to return the favor. did i rush to judgement?

laramie

[fujian]

Originally Posted by laramie LC4

sorry dude, sounded like you were going to fly in and fly out. we get lot's of guys that just expect help, then do very little to return the favor. did i rush to judgement?
laramie

No drama's, I'll try and return the favor by uploading original material in the form of photos.

[makazica]

Man.....rocker covers on these bikes usually leak from the exhaust side of the engine.....in your case I think you could fix the leak without taking the cover off....tip: try changing the o-rings on rocker shafts....

BTW Have you managed to take the cover off? If not, the water pump shaft is holding it in place, turn the engine slowly to free it up!

[wrk2surf]

Originally Posted by fujian

Thanks for the tips, I agree that the thread title needs to be changed, Could you change it for me? " LC4 640 Enduro - Rocker Cover Leak " that would be a more fitting title.

ask a moderator in a PM they are listed at the bottom of each main page..

[fujian]

Originally Posted by wrk2surf

ask a moderator in a PM they are listed at the bottom of each main page..

Perfect I'll do that! Need to get the title changed, it's inaccurate!

[fujian]

Originally Posted by makazica

Man.....rocker covers on these bikes usually leak from the exhaust side of the engine.....in your case I think you could fix the leak without taking the cover off....tip: try changing the o-rings on rocker shafts....

BTW Have you managed to take the cover off? If not, the water pump shaft is holding it in place, turn the engine slowly to free it up!

Managed to take it off, that's exactly what I did, just slowly kicked the kick start over to pop it free from the sealant.

I'm just now worried about a few of my own screw ups, mainly clearance issues with the Allan bolts and the decompresson cable attachment...

[fujian]

Having a hard time tightening up the last bolt on the rocker cover ( the very forward, right 5mm Allen bolt ) How do you torque it I know it needs 8 NM of torque just can't get the Allen socket bit to fit ( the inspection cover / Decompression attachment point ) is in the way...



Perhaps this will do the trick....it did, found one ( used the hack saw ) and made my own 5mm hex socket !

[fujian]

Originally Posted by overlandr

If you want to show what steps you're taking, why not personalise the thread title to describe what the thread is about - something like "Fixing the rocker cover leak on my 640"? BTW its not an adventure you have there more like the enduro - still a very nice setup with that 18l tank. A line or two under each photo describing keys events would also help.

Finally the thread title has been changed, I'm removing the old silicone sealant now for the second time...first time I applied the sealant ( and rushed the job ) made a mistake with the bolts and just let it go, doing the job now for a second time, going to check the valves and replace the inspection cover gaskets.

[fujian]

I had been putting the job on hold until getting the proper bolt lengths & proper, I never did so I just went ahead anyway,



58 = AH SCREW DIN0912-M 6X40 A2
I installed one with 35 millimeters length and without the self locking nut
59 = SELF LOCKING NUT M6 10.9

My question is: Is this " Self locking nut " critical or can you do without?

On above diagram 55 = AH SCREW DIN0912-M 6X55 12.9
Part Number: 0912060551

I replaced this bolt because it isn't threading in, I removed the copper washer to get it into the receiving end a tiny bit more but doesn't tread in at all, ( the threads are stripped I'm guessing )

Has anyone been able to use a tap, to create new threads for a cylinder bolt ? Can this be done with the rocker cover on? It's a small thing but without this bolt in use the rocker cover is probably going to leak again, bolt # 55 needs to get 15 NM.

Anyone with previous Tapping experience would be great to hear from, it would be nice to hear from anyone actually.

[fujian]

Went out and found what kit to get in order to repair the threads and got this! Thanks to an inmate " Gunnerbuck " for the suggestion of using a Helicoil type repair.



38$ for the kit in Perth, Australia



Good to see that it will be stronger,



Perfect fit ! 6mm bolt size with a 5 mm head/hex key

Bolt is 55mm long and is torqued to 15NM

[fujian]

Worked on the first try, didn't need to drill,the tap tool dug into the old treads making room for the coil to be twisted in.



Can't tell by the photo but the Coil has been inserted! Success



Radiator Right side



Left Side






Night time operation

[fujian]

Bike was stolen October 2012 from the house I was staying in Morley, just outside of Perth, Western Australia. NO insurance ( was going to update my policy and get more coverage after going these repairs...oh well..back in Canada now.

[joe cool]

That really sucks! Very sorry to hear.

[bmwktmbill]

Fujian,
I can't think of too much worse in motorcycledom.

There is a special hell for whomever took your machine.
bill