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Old 12-12-2006, 04:08 AM   #241
nevgriff64
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Thanks for that detailed description Pyndon..

I noticed that mine has just started to leak around the pipe o ring so with this help it has just saved me some heart ache..

Cheers mate..

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Old 12-12-2006, 04:31 AM   #242
uk_mouse
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On my bike the O rings on the pipe going to the water pump (as seen in the picture above) are installed one either side of the flange on the pipe. Rather than both on the inside of the flange as in Pyndon's pics. I think this is how it was from the factory.

Any comment as to which way is correct? Having two O rings together seems unusual.
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Old 12-12-2006, 05:19 AM   #243
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Excellent. Thanks very much.
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Old 12-12-2006, 06:27 AM   #244
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Quote:
Originally Posted by cpmodem
Excellent step by step Pyndon. Butt, did you double photos 5/6? Thanks for taking the time to put this together. Adds greatly to the knowledge base.
-cp
cpmodem,

Photo's 5 and 6 are different, I removed the bolts from the retaining flange . I know, an insignificant change but some people may forget to loosen the one under the pipe as you cannot see it from the normal working position.

Pyn
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Old 12-12-2006, 06:30 AM   #245
Pyndon OP
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Quote:
Originally Posted by scottr
How do you like the new lid?
It's ok, not as impressed with the XD as I was with my Arai Quantum F though. I really need a large, the XL is a little too big even with the thicker liner but the L has pressure spots and is plain unconfortable. It's a little noisy and a little heavy but no buffet problems noted with the beak.

It'll doooo!
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Old 12-12-2006, 06:32 AM   #246
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Quote:
Originally Posted by LiveInTheOutdoors
Pyndon, nice write up, lots of effort there, thanks.

Question: what did you use to clean the water pump housing etal. I see a scotch brite pad there, but did you use a solvent too?

Tx
Hey LiveIn,

I just used a light Scotchbrite pad as you so noted and a little WD40 as a lubricant, this works great. They do tend to break up a little if you rub them over sharp edges though so you have to be carefull not to get any in the engine . Clean everything thoroughly afterwards too.

Thanks, Pyn
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Old 12-12-2006, 06:41 AM   #247
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Quote:
Originally Posted by gefr
Some questions arose from your post!!
1) You didn't use the new item 60035054044 for the shaft, replacing both items 6003505400 and 0760123072 ! Don't know if it is a vast improvement but would be good to use the latest spare parts. Any particular reason not doing so??
2) You seem to buy 11 items, but you throw away 15!! What were the extra parts you felt like replacing once opening the side engine covers??
3) What is the circular washer you are throwing away!! the bigger one??

Thanx for your effort and presentation!!

George
George,

1) I don't know the difference between part numbers but my early 04' model had a way old shaft in and it lasted 12,000 miles. It's just what the dealer had in stock, thats all. So long as its good for 10,000 miles then I will be doing it again anyway. It's good to try and get the latest though, yes, I agree.

2) Wow, you really are observant, good on ya . The additional four parts are, two small pressure rings from the old seal (small springs that keeps the seal tight on the shaft) that came off when removing the seal. The other two parts are the lower screen cover gasket and the oil filter cover o-ring. I changes the oil at the same time and it still has the originals so I replaced them all this time.

3) The said large washer is the oil filter cover o-ring.

I shoud of known better and kept these seperate for this purpose .

Thanks, Pyn
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Old 12-12-2006, 06:46 AM   #248
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Quote:
Originally Posted by uk_mouse
On my bike the O rings on the pipe going to the water pump (as seen in the picture above) are installed one either side of the flange on the pipe. Rather than both on the inside of the flange as in Pyndon's pics. I think this is how it was from the factory.

Any comment as to which way is correct? Having two O rings together seems unusual.
I think it would work either way but I believe it works much better with them both on the inside so that they are on a good portion of the machined bore. When you tighten the flange up, the lip on the pipe squashes them together and seals any gaps. They need to be squashed to seal tightly as the bore in the water pump housing is not that thight a fit for the o-rings.

It never leaks this way (as shown in the pictures).

Pyn
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Old 12-12-2006, 07:24 AM   #249
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Nice job Pyn.

Your tool for holding the impeller was nice. I was in a super rush doing mine and didn't have time to make a tool so I used a large pair of needlenose pliers in the two holes in the impeller, works like a charm.

I have torque wrench envy.
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Old 12-12-2006, 09:39 AM   #250
Stephen
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Very nicely done, sir.

Thank you.

You're just not gonna let any mysteries remain, are ya?
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Old 12-12-2006, 11:52 AM   #251
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another job that I am now no longer worried about doing! Thanks Pyn, as was said before, I will just put the laptop on the airbox, make sure the wife is out and away I go!!!

D
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Old 12-12-2006, 02:10 PM   #252
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Very nice! I am in for that exercise this winter so it really came with good timing.

Jens
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Old 12-12-2006, 02:41 PM   #253
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Thumb

It's been well said already but thanks for taking the time in giving a very detailed guide...i hope i don't need it (wheres some wood...) but it's good to know stuff like this is available. Of all the sites i darken this is easily the BEST out there due to people like you and of course the excellent ride reports that people take the time to create....time to donate some cash i think!!...............Cheers Chris.
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Old 12-12-2006, 05:52 PM   #254
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I think your neighbors property value just went up!!!
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Old 12-12-2006, 05:54 PM   #255
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Great job, thank you!!! I'm doing my 12K bike this winter in prep. for a 9K mile round trip ride to the Arctic Circle this summer. Do you have any other "how-to's that I can search? One question, it seems that I've read that circlips often (always?) have two sides and there is a correct and incorrect way to install them. If memory serves, the beveled or chamfered side always faces out. Is this true with KTM spec. circlips? Thanks.
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