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View Results: What is the horrible noise?
Cam chain tensioner 2 5.13%
Camshaft rockers / bearings 10 25.64%
Big end 10 25.64%
Gearbox main shaft bearing 3 7.69%
Crankshaft bearings 8 20.51%
Other? 6 15.38%
Voters: 39. You may not vote on this poll

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Old 03-17-2013, 06:45 AM   #106
overlandr
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Quote:
Originally Posted by moto_psycho View Post
Oil pumps are fine, they turn smoothly, no visible damage.
What's the mileage on this engine again? Regardless, I would be looking for any signs of internal wear/damage on those two pumps. A feeler gauge is handy. Also a search engine should quickly reveal 'adv wisdom' on related subjects, eg try this as a search filter!

"oil pump" feeler gauge 640 ktm site:www.advrider.com

PS IIRC, buried somewhere on this forum are details of a rebuild of 640 following some sort of major failure. Anyway, immediately, following the rebuild, the engine failed again!! The owner this time went through everything and found an issue with the oil supply, did the 2nd rebuild and all was ok. I think,.....Others will correct me if I'm mistaken, I hope.

overlandr screwed with this post 03-17-2013 at 06:53 AM
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Old 03-17-2013, 06:55 AM   #107
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Quote:
Originally Posted by overlandr View Post
What's the mileage on this engine again? Regardless, I would be looking for any signs of internal wear/damage on those two pumps. A feeler gauge is handy. Also a search engine should quickly reveal 'adv wisdom' on related subjects, eg try this as a search filter!

"oil pump" feeler gauge 640 ktm site:www.advrider.com

PS IIRC, buried somewhere on this forum are details of a rebuild of 640 following some sort of major failure. Anyway, immediately, following the rebuild, the engine failed again!! The owner this time went through everything and found an issue with the oil supply, did the 2nd rebuild and all was ok. I think,.....Others will correct me if I'm mistaken, I hope.
Was that some sort of stuck check valve in the oil supply lines?
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Old 03-17-2013, 07:47 AM   #108
overlandr
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Originally Posted by Boon Booni View Post
Was that some sort of stuck check valve in the oil supply lines?
As some peeps say: BINGO! 'cos I found the bugger that I was rambling on about in my post above; quoted below from Mr. Gaspipe's thread:

"Quote:
[Originally Posted by creeper
So... did I miss something or what was the cause(s) of the failure?]
Bad oil passage, then oil pump failure, followed by motor death [x 2].
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Was post #21 in this ol' thread 'ere. May help you.

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Old 03-17-2013, 08:48 AM   #109
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Quote:
Originally Posted by overlandr View Post
As some peeps say: BINGO! 'cos I found the bugger that I was rambling on about in my post above; quoted below from Mr. Gaspipe's thread:

"Quote:
[Originally Posted by creeper
So... did I miss something or what was the cause(s) of the failure?]
Bad oil passage, then oil pump failure, followed by motor death [x 2].
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gaspipe [the original]"


Was post #21 in this ol' thread 'ere. May help you.
Checking all oil passages is a mandatory step in rebuilding an engine.........a little trick for oil passages or fuel passages in carbs is to blow a little smoke through them to make sure they are not clogged.

Cheers
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Old 03-29-2013, 07:37 AM   #110
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I've lapped all the valves etc. Crank is being pressed at the engineer's atm
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Old 03-29-2013, 07:42 AM   #111
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Originally Posted by moto_psycho View Post
I've lapped all the valves etc. Crank is being pressed at the engineer's atm
Please make sure you video a wiggle/play test like you did the first time for the bad unit. I have little to no experience with a roller/needle bearing style con rod and am curious what a good bearing looks like.
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Old 03-29-2013, 09:48 AM   #112
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Originally Posted by Boon Booni View Post
Please make sure you video a wiggle/play test like you did the first time for the bad unit. I have little to no experience with a roller/needle bearing style con rod and am curious what a good bearing looks like.

If you had seen the crank/lower con rod bearing on my Hodaka, that would have made most people tear it apart...........but the wobble/side to side play it had is just the way it is..........but no radial movement at all....so it was installed that way......and the little Wombat runs fine.

If you send me a pm with your email address I might be able to send you the video of the Hodaka.

Cheers
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Old 03-29-2013, 05:48 PM   #113
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Quote:
Originally Posted by Boon Booni View Post
Please make sure you video a wiggle/play test like you did the first time for the bad unit. I have little to no experience with a roller/needle bearing style con rod and am curious what a good bearing looks like.
I have a pair of new cranks and a serviceable old one sitting here.. The new ones have never been used and there is very little side {or any} play at all.... The old one has more side to side movement and you can cant the rod a minimal amount, but there is no detectable bearing lift and fall {rock} as you do this... The side play is well within spec... The next time I go through my parts boxes I'll try to remember to shoot a bit of video of my old unit to add as a reference...
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Old 03-30-2013, 07:49 PM   #114
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Originally Posted by Droptarotter View Post
If you had seen the crank/lower con rod bearing on my Hodaka, that would have made most people tear it apart...........but the wobble/side to side play it had is just the way it is..........but no radial movement at all....so it was installed that way......and the little Wombat runs fine.

If you send me a pm with your email address I might be able to send you the video of the Hodaka.

Cheers


Quote:
Originally Posted by gunnerbuck View Post
I have a pair of new cranks and a serviceable old one sitting here.. The new ones have never been used and there is very little side {or any} play at all.... The old one has more side to side movement and you can cant the rod a minimal amount, but there is no detectable bearing lift and fall {rock} as you do this... The side play is well within spec... The next time I go through my parts boxes I'll try to remember to shoot a bit of video of my old unit to add as a reference...


Hey that'd be great. I really want to get a data point for future reference.
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Old 04-26-2013, 05:35 AM   #115
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How is your rebuild going.

My mechanic finally put the engine back in mine as of this morning so should be able to collect it this evening all going well.

Would have loved to have been able to do the rebuild myself as you are. Hope your getting it sort with out to many issues.
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Old 04-26-2013, 02:43 PM   #116
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Interesting that you posted today! Just got my crank back at 3:30!

Needless to say, the old one was ****ed!!!



Engine is about half assembled atm. In the meantime I have stripped everything on the frame, the head bearings were destroyed, I've sprayed the frame orange (cheap rattle can job, there was a lot of rust) and will be waxing it on Monday. Still got to rebuild the forks, then it is just a case of re-assemble. If something goes wrong then, there will be numerous dead Austrians popping up near Ipswich...
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Old 04-27-2013, 01:35 AM   #117
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Getting there! Spare bedroom stinks of oil n grease n ****, mmmmmmm
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Old 04-27-2013, 01:38 AM   #118
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The eagle eyed among you will notice the lack of balance shaft in the last picture, in which, I present:



My blank, for I really cannot be bothered to remove the bearings! (that is a cat hair, not an albino pube...)

Will get more done later, but I'm off kickboxing in a min!
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Old 04-27-2013, 02:49 AM   #119
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Great job so far. Mine has the engine back in the frame now. But the lad got call to a break down and did get it finished yesterday so won't have mine back until Wednesday due to been away from work.


Great to even see the engine back together. My failures where a mirror image of yours except for the crank bearing. Mine was fine but my main had been distroied. I used all original KTM parts and a mechanic to put mine right. Cann't wait to have it back.
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Old 04-27-2013, 02:52 AM   #120
ericGSsti
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Quote:
Originally Posted by moto_psycho View Post
Interesting that you posted today! Just got my crank back at 3:30
I saw this thread go up the day my engine failed so following a similar path.

Even needing fork seals done.

Best of luck with the rest of the work on yours.
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