ADVrider

Go Back   ADVrider > Bikes > Orange Crush
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 07-30-2011, 04:47 AM   #1591
zedtours
Gnarly Adventurer
 
zedtours's Avatar
 
Joined: Jan 2006
Location: Surrey
Oddometer: 354
balancer shaft seal

Thanks for reply on oil breather/balancer shaft seal.Seal did not look too bad [a la severino's] but it is a weird set up as shaft acts as the breather thru it's centre and with inertia it does seem that any oil getting up to airbox must come past that seal. Am I right?
zedtours is offline   Reply With Quote
Old 07-30-2011, 12:59 PM   #1592
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by zedtours View Post
Thanks for reply on oil breather/balancer shaft seal.Seal did not look too bad [a la severino's] but it is a weird set up as shaft acts as the breather thru it's centre and with inertia it does seem that any oil getting up to airbox must come past that seal. Am I right?
Generally yes, unless you have bigger issues causing the engine to breath REALLY heavily, and then it blow it out anyway!

I put a one way valve in my breather pipe too, like the later 950's and 990's have. That and the seal did the trick!
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 07-31-2011, 03:22 AM   #1593
StevenD
Hmmmm, dirt!
 
StevenD's Avatar
 
Joined: Aug 2005
Location: Holland, Amserdammed
Oddometer: 1,108
Later models really dont have a one way valve. Just a aluminium block with a narrower channel in it. I think the one way valve was tried and gotten rid of really soon after that.
Do you have a picture of the valve you have installed?
__________________
999 LC8 Rat-Rally custom - 500 EXC - XR666R '85
StevenD is offline   Reply With Quote
Old 07-31-2011, 03:45 AM   #1594
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by StevenD View Post
Later models really dont have a one way valve. Just a aluminium block with a narrower channel in it. I think the one way valve was tried and gotten rid of really soon after that.
Do you have a picture of the valve you have installed?
No, it's the latest one though according to KTM.
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 08-04-2011, 05:52 PM   #1595
ciedema
мотоциклист
 
ciedema's Avatar
 
Joined: Oct 2007
Location: On the road! Finally!
Oddometer: 1,909
Hi Lyndon,

Thanks for providing such a very detailed thread. It is huge to credit to you and a benefit to all others.

I am about to embark on preparation of 04 for a 2 year RTW trip. I was originally consisting replacing my old girl but like an old pair of jeans I know how she'll feel every time I go for a ride.

I plan strip the motor down for inspection as part of prep and replace bearings and like, she has a bit of a gearbox rumble in neutral with the clutch out plus the gear shift becomes very frim, loosens up and becomes firm after a big hit on my last trip so something may have come adrift somewhere in gear box.

Anyway to get to the point. From reading your post when you pulled your engine down much of wearable items were well within spec. Obviously to measure much of this requires some specialist equipment. Could you please provide a list of what special tools you think would be required? (dial indicators etc)

Also how well do you find that GPR exhaust holds to damage from rocks, logs etc up being swung down like that? I am thinking that is that way to go and adding rear tanks both sides.

Thanks heaps

Craig
__________________
Stories from the Seat Facebook My Photos Cannonball Charity Ride
Personal Attacks - the last refuge of the intellectually impaired.

Quote:
Originally Posted by XR650L_Dave View Post
The only guaranteed route to failure is the attempted solution of problems through the application of ideology.
ciedema is offline   Reply With Quote
Old 08-05-2011, 12:28 AM   #1596
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by ciedema View Post
Hi Lyndon,

Thanks for providing such a very detailed thread. It is huge to credit to you and a benefit to all others.

I am about to embark on preparation of 04 for a 2 year RTW trip. I was originally consisting replacing my old girl but like an old pair of jeans I know how she'll feel every time I go for a ride.

I plan strip the motor down for inspection as part of prep and replace bearings and like, she has a bit of a gearbox rumble in neutral with the clutch out plus the gear shift becomes very frim, loosens up and becomes firm after a big hit on my last trip so something may have come adrift somewhere in gear box.

Anyway to get to the point. From reading your post when you pulled your engine down much of wearable items were well within spec. Obviously to measure much of this requires some specialist equipment. Could you please provide a list of what special tools you think would be required? (dial indicators etc)

Also how well do you find that GPR exhaust holds to damage from rocks, logs etc up being swung down like that? I am thinking that is that way to go and adding rear tanks both sides.

Thanks heaps

Craig
Hi there, way to go......I would take my old girl around the world tomorrow, no worries! Well done having a go yourself. Be really meticulous though, you don't want to do a Steverino and have to do it four times before getting it right While your in there do everything that needs doing if you can afford it, it'll save you in the long run.

I can tell you straight away what the intermittent stiff gearshift is, it will be the small roller bushes on the shift fork that locates into the shift drum. One of these will be getting elongated, I've had to replace them before on other bikes that had the exact same symptoms. It'll only be one of them but get yourself three new ones regardless. While you are in there, replace the shift drum too, I've replaced a few broken ones from the earlier bikes, KTM replaced them with a stronger part, details are in here somewhere.

As for the tools, get yourself an engine repair manual, it tells you everything you need and you will need this to know all the specifications and wear limits etc. If you PM me your email address I will send you one, use the 990 engine repair manual as you will also them discover the other little bits and pieces that have changes over the years and you can decide if you want to upgrade those parts too. I'll send you both if you like.

You'll need KTM bearing presses to replace the white metal bearings (if you need to, although my guess is that they will be in spec). Also, if you have the older 04' engine and cases, you should check your base gasket surfaces for corrosion. Again, I have seen a few with this problem now. Again, details are in this thread. Get yourself a clutch holding tool too, it helps a lot.

Other than this you just need a good set of micrometers, dial bore gauges, feeler gauges (for ring gaps and valve clearances) and some plastigauge to check the rod bearing clearances.

It really does depend how many miles she's done how far you need to go into her. Dig out a list of all the tech service bulletins and double check that they are all done too, i.e. clutch bolts, boosters plate bolts, replacement of clutch push rod, flywheel bolts, flywheel lapping to crankshaft etc etc.

As for the GPR, I've had mine on for about 30,000 miles now and had no issues with rocks damaging it, or flattening it or anything. If you get it from www.adventure-spec.com they do a G-It bash plate to go with it (this is what I use) and it has an extra bit to protect the GPR. The silencer needed re-packing and re-riveting after 25K but I chose to replace it with an Akra and the collector pipe cracked so I had to get that welded. This is nothing worse than the standard system though, I had to get the rear header welded a couple of time on the standard system. I'm happy with it, it works and it looks good and best of all, it's gets all the heat away from under the seat!

Hope this helps, good luck with it and if your in the UK look me up!

Pyn
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 08-05-2011, 03:24 AM   #1597
ciedema
мотоциклист
 
ciedema's Avatar
 
Joined: Oct 2007
Location: On the road! Finally!
Oddometer: 1,909
Quote:
Originally Posted by Pyndon View Post
Hi there, way to go......I would take my old girl around the world tomorrow, no worries! Well done having a go yourself.
Your pics show that it not that much harder that my 450 motor - just more bits.

Quote:
While your in there do everything that needs doing if you can afford it, it'll save you in the long run.
Yeah definitely going to do that. It will need need do 100,000km on our trip and I hope to keep the motor more or less in one piece over this time.

Quote:
I can tell you straight away what the intermittent stiff gearshift is, it will be the small roller bushes on the shift fork that locates into the shift drum. One of these will be getting elongated, I've had to replace them before on other bikes that had the exact same symptoms. It'll only be one of them but get yourself three new ones regardless. While you are in there, replace the shift drum too, I've replaced a few broken ones from the earlier bikes, KTM replaced them with a stronger part, details are in here somewhere.
Yeah will be replacing the lot no point scrimping on such a small part. I saw the pics of the upgraded drum seems also see no point in scrimping on this - especially since I am serial gearbox abuser.

Quote:
As for the tools, get yourself an engine repair manual, it tells you everything you need and you will need this to know all the specifications and wear limits etc. If you PM me your email address I will send you one, use the 990 engine repair manual as you will also them discover the other little bits and pieces that have changes over the years and you can decide if you want to upgrade those parts too. I'll send you both if you like.
That would be beaut.

Quote:
You'll need KTM bearing presses to replace the white metal bearings (if you need to, although my guess is that they will be in spec). Also, if you have the older 04' engine and cases, you should check your base gasket surfaces for corrosion. Again, I have seen a few with this problem now. Again, details are in this thread. Get yourself a clutch holding tool too, it helps a lot.
Yep I saw those. Cool didn't of the clutch holder (generally use a rattle gun )

Quote:
Other than this you just need a good set of micrometers, dial bore gauges, feeler gauges (for ring gaps and valve clearances) and some plastigauge to check the rod bearing clearances.
Quote:
It really does depend how many miles she's done how far you need to go into her. Dig out a list of all the tech service bulletins and double check that they are all done too, i.e. clutch bolts, boosters plate bolts, replacement of clutch push rod, flywheel bolts, flywheel lapping to crankshaft etc etc.
Probably a long way as per above I want to her to go a long way with out having to pull her to bits.

Quote:
The silencer needed re-packing and re-riveting after 25K but I chose to replace it with an Akra and the collector pipe cracked so I had to get that welded. This is nothing worse than the standard system though, I had to get the rear header welded a couple of time on the standard system. I'm happy with it, it works and it looks good and best of all, it's gets all the heat away from under the seat!
Will the Akra (or Wings) cans bolt straight up? That way I would only need the system and use one the wings pipes. I was looking at using the down swept as I want to have a fuel cell on each side. I have will have to see if Neduro will make me one for the RHS. I could put the Safari tanks on but I ride a KTM not a UTB.

Quote:
Hope this helps, good luck with it and if your in the UK look me up!

Pyn
It does heaps, and April next year I will be in the UK for the start of the trip.
__________________
Stories from the Seat Facebook My Photos Cannonball Charity Ride
Personal Attacks - the last refuge of the intellectually impaired.

Quote:
Originally Posted by XR650L_Dave View Post
The only guaranteed route to failure is the attempted solution of problems through the application of ideology.
ciedema is offline   Reply With Quote
Old 08-05-2011, 02:39 PM   #1598
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by ciedema View Post
Will the Akra (or Wings) cans bolt straight up?
No, you have to use a custom silencer as it used a 54mm slip-on, not a bolt on.
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 08-08-2011, 06:21 AM   #1599
neduro
Addict
 
neduro's Avatar
 
Joined: Jul 2003
Location: Colorado Springs, CO
Oddometer: 11,763
Quote:
Originally Posted by Pyndon View Post
No, you have to use a custom silencer as it used a 54mm slip-on, not a bolt on.
That's a standard size for many manufacturers, though, so I think you can find a replacement pipe if you need one.
__________________
Doubletake Mirrors- Folding D/S mirror that is both useful and indestructible.

Dual Sport Riding Techniques DVDs: Clear instructional DVDs to improve off-road skills.
neduro is offline   Reply With Quote
Old 08-08-2011, 07:03 AM   #1600
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by neduro View Post
That's a standard size for many manufacturers, though, so I think you can find a replacement pipe if you need one.
Oh yeah, forgot about you guys. Most European manufacturers use 52mm and 60mm inlet size, manufacturers such as Akrapovic for example. Hence why you will not find an off the shelf Akrapovic to fit the GPR 54mm (or I could not anyway) hence a modification was required.

Only 54mm silencers I could find to slide straight on the GPR just did not cut the mustard in either the Pyndon aesthetics or durability departments "and for that reason.......I'm out" sprung to mind.

Ned you set the ball rolling with the injuries......did my Medial Collateral Ligament on my left knee on the CRF yesterday. Not good at all but at least I have some time of work to get some maintenance done of the bikes, having no knee does not stop the wrenches turning

Pyn
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 08-08-2011, 08:32 AM   #1601
6USMC6
R.I.P. Party Boss
 
6USMC6's Avatar
 
Joined: Jan 2009
Location: The "Upper" Valley of the Shenandoah.
Oddometer: 4,295
Pyn -
I don't know about the Medial, but I tore both of my Anterior Collateral Ligaments years ago and I've been able to function just fine without them. The doc said that he couldn't repair mine due to my age but that if I kept myself in shape that the muscles in my legs would easily compensate for the missing (torn) Anterior Ligaments.

Good luck with it.
__________________
Mike -

"For those who fight for it life has a flavor the protected never know."
USMC 65-68 RVN 66-67
6USMC6 is offline   Reply With Quote
Old 08-09-2011, 04:35 AM   #1602
ciedema
мотоциклист
 
ciedema's Avatar
 
Joined: Oct 2007
Location: On the road! Finally!
Oddometer: 1,909
Knees - the one injury that I constantly live in fear of, the recuperation is way to long.

Pyn,

For the case bearings that are standard sizes do you get them from KTM or buy them from a bearing supplier?

Cheers,

Craig
__________________
Stories from the Seat Facebook My Photos Cannonball Charity Ride
Personal Attacks - the last refuge of the intellectually impaired.

Quote:
Originally Posted by XR650L_Dave View Post
The only guaranteed route to failure is the attempted solution of problems through the application of ideology.
ciedema is offline   Reply With Quote
Old 08-09-2011, 08:49 AM   #1603
neduro
Addict
 
neduro's Avatar
 
Joined: Jul 2003
Location: Colorado Springs, CO
Oddometer: 11,763
Quote:
Originally Posted by Pyndon View Post
Ned you set the ball rolling with the injuries......did my Medial Collateral Ligament on my left knee on the CRF yesterday.
Bad news! Sorry, mate, heal fast.

FWIW, I have no idea what I'd be doing if I were still fully functioning, been working dawn to dark everyday without the distraction of riding, probably a good thing the option was removed for a few weeks.
__________________
Doubletake Mirrors- Folding D/S mirror that is both useful and indestructible.

Dual Sport Riding Techniques DVDs: Clear instructional DVDs to improve off-road skills.
neduro is offline   Reply With Quote
Old 08-09-2011, 10:32 AM   #1604
Pyndon OP
Beastly Adventurer
 
Pyndon's Avatar
 
Joined: Feb 2006
Location: Somewhere on two wheels!!
Oddometer: 2,400
Quote:
Originally Posted by ciedema View Post
Knees - the one injury that I constantly live in fear of, the recuperation is way to long.

Pyn,

For the case bearings that are standard sizes do you get them from KTM or buy them from a bearing supplier?

Cheers,

Craig
Generally KTM but it really does not matter. If I want them quickly, bearing supplier works best.
__________________
Pyn
Currently on www.racestoplaces.com
www.lyndonposkittracing.com or you can also look me up on Facebook or Twitter.
My Dakar Rally Experience
My KTM 950 Story
Pyndon is offline   Reply With Quote
Old 08-11-2011, 11:51 AM   #1605
CodyY
ADVenture Capitalist
 
CodyY's Avatar
 
Joined: Jun 2006
Location: Fort Worth, TX
Oddometer: 9,481
My MCL is wonky, its loose but has tightened up on its own over the last few years. But still loose.
__________________
Not an ACTUAL motorcyclist
CodyY is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 11:44 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014