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Old 09-10-2006, 11:56 PM   #1
firerigger OP
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Joined: Jan 2006
Location: Durango CO
Oddometer: 810
Check those sprockets!

Okay, I am usually pretty meticulous in my maintainence of my motorcycles. But apparently I overlooked one tiny little detail on my KTM. Today, while descending Ophir Pass, I downshifted from 3rd to 2nd and all heck broke loose. Actually, it was my rear tire that broke loose. The rear wheel locked up, and I had a few stressful seconds bringing my ride to a stop without dumping it over the edge. I inspected the bike and found that the counter sprocket had come off, then lodged between the frame and swingarm. So, I broke the chain, wrapped it up out of the way, then coasted down to the highway to wait for a ride home. SUCK! So check those bolts!
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'07 Triumph Tiger 1050
'07 Triumph Daytona 675

Gone but not forgotten:
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firerigger screwed with this post 09-11-2006 at 10:03 PM
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Old 09-11-2006, 12:11 AM   #2
firerigger OP
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Photo evidence



Once I got home, it took about an hour to get the sprocket free of the frame. I had to remove the swingarm to do it. Luckily the sproket is fine. The chain is done, and the chain slider looks like a victim of Freddy Krueger.
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Current rides:
'04 KTM 450 EXC
'07 Triumph Tiger 1050
'07 Triumph Daytona 675

Gone but not forgotten:
'00 KTM LC4-E Sixdays
'06 KLR 650
'06 DL-1000

Save yourself (and me!) money at SmugMug: Coupon code YE2eMDKcBDhGY
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Old 09-11-2006, 07:11 AM   #3
kellyk7
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OK enlighten us, how do you break the chain with field tools, Just interested because I am thinking of my tool set and that might be a tough job with what I carry.
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Old 09-11-2006, 06:08 PM   #4
katbeanz
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Location: Kansas City
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WTF is the deal with Ophir, I lost my toolbag on it a couple weeks ago. My buddy had a pretty spectacular over the bars getoff on it too. It's one of the easier ones out there as far as passes go.

It's jinxed I tell ya.

http://www.advrider.com/forums/showthread.php?t=163625
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Old 09-11-2006, 06:30 PM   #5
enduro-ince
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Location: Placerville Co.
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Yikes!!, Could a been a nasty one. I'll be checking mine here in a few minutes.
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Old 09-11-2006, 07:08 PM   #6
creeper
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Quote:
Originally Posted by firerigger
I inspected the bike and found that the counter sprocket had come off, then lodged between the frame and swingarm.
Not to be a dick about it... but a dab of paint and a hole in the cover to check alignment goes a long way.



Quote:
Originally Posted by kellyk7
OK enlighten us, how do you break the chain with field tools, Just interested because I am thinking of my tool set and that might be a tough job with what I carry.
With a Motion Pro M-6 kit... they pack small and light. Without it... a rock.
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Old 09-11-2006, 07:17 PM   #7
creeper
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Ooops... almost forgot. Don't reuse that bolt and washer if you can help it firerigger. Get a new bolt, which comes with a new cup washer.
The new bolt will have dry Loctite on it, so between that, a new washer and the correct torque value (and a little dab of paint) you shouldn't ever loose another one.

Very good to hear that you didn't go down and didn't crack the cases.
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Old 09-11-2006, 08:16 PM   #8
firerigger OP
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Location: Durango CO
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Yeah, I have a new bolt on order, and I drilled the inspection hole in the plastic cover, and I will use that dab of paint. Thanks for the well wishes.
__________________
"The eyes are the groin of the head.."
"I never fail...sometimes I succeed in finding out what doesn't work."

Current rides:
'04 KTM 450 EXC
'07 Triumph Tiger 1050
'07 Triumph Daytona 675

Gone but not forgotten:
'00 KTM LC4-E Sixdays
'06 KLR 650
'06 DL-1000

Save yourself (and me!) money at SmugMug: Coupon code YE2eMDKcBDhGY
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Old 09-11-2006, 08:17 PM   #9
firerigger OP
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Joined: Jan 2006
Location: Durango CO
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Quote:
Originally Posted by kellyk7
OK enlighten us, how do you break the chain with field tools, Just interested because I am thinking of my tool set and that might be a tough job with what I carry.
I just undid the master-link. Fortunately, it was accessable. I don't know what I would have done if it had been jammed under the sprocket.
__________________
"The eyes are the groin of the head.."
"I never fail...sometimes I succeed in finding out what doesn't work."

Current rides:
'04 KTM 450 EXC
'07 Triumph Tiger 1050
'07 Triumph Daytona 675

Gone but not forgotten:
'00 KTM LC4-E Sixdays
'06 KLR 650
'06 DL-1000

Save yourself (and me!) money at SmugMug: Coupon code YE2eMDKcBDhGY
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Old 09-11-2006, 08:24 PM   #10
R_W
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Quote:
Originally Posted by creeper
Not to be a dick about it... but a dab of paint and a hole in the cover to check alignment goes a long way.
Were you an airplane mechanic in one of your previous lives?

People are always getting on my case for the alignment dots and lines on my stuff.
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Old 09-11-2006, 08:34 PM   #11
creeper
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Quote:
Originally Posted by R_W
Were you an airplane mechanic in one of your previous lives?

People are always getting on my case for the alignment dots and lines on my stuff.
Nope... Raced bikes for a decade or two and built several for others. When you're in a big hurry, witness marks can really come in handy to avoid wasted time.
A 30 second walk-around beats the shit out of grabbing handfuls of tools, wasting time checking the torque on perfectly torqued fasteners.
Not as bad as I used to be... now I just do driveline, brakes, oil lines... stuff that will ruin your day if it lets go.

I got all the time in the world these days, but I still like me witness marks.
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Old 09-11-2006, 09:01 PM   #12
sas
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Quote:
Originally Posted by creeper
Not as bad as I used to be... now I just do driveline, brakes, oil lines... stuff that will ruin your day if it lets go.

I got all the time in the world these days, but I still like me witness marks.
Hey Creeper, this sounds like a really good idea to me. If you don't mind, could you detail out all the marks you used, where you put them, what you checked for? I'm a total noob, so simple is good.

Thanks!
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Old 09-11-2006, 09:24 PM   #13
creeper
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Quote:
Originally Posted by sas
Hey Creeper, this sounds like a really good idea to me. If you don't mind, could you detail out all the marks you used, where you put them, what you checked for? I'm a total noob, so simple is good.

Thanks!
All you need to do is verify the correct torque value and put a set (or a blob) of bright color paint mark(s) on the fastener and the corresponding surface.
Wipe off any excess dirt or oil first so the paint sticks. Bottles of "touch-up" paint work well for this type of thing... at least that's what I like to use.
I'm sure there are other ways you can do it that would work just as well.
  1. Front and rear sprocket bolts. (the nuts on the rear sprocket actually)
  2. Shift lever bolt.
  3. Rear brake link rod jam nut.
  4. All the external oil line banjo bolts.
  5. Rear brake lever adjuster eccentric screw.
  6. Front brake caliper extension bolts. (320mm 640 Adventure brake has an intermediate "extender" mount bolted to the forks)
  7. Both brake caliper banjo bolts.
  8. Spin-on filter.
  9. Starter motor bolts.
  10. The two inner exhaust support bracket to subframe bolts.
  11. Anything that has come loose or fallen out completely in the past. (see #10)

There's lots of others you could do... just about anything you want. I tend to do fasteners that don't get a wrench on them under normal circumstances or, like I said, things that could really ruin your day if they came loose.
I tend to be a bit of a fanatic with maintenance, so many fasteners you might consider critical actually see a wrench on a regular basis.

C
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Old 09-11-2006, 09:25 PM   #14
ChrisC
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Quote:
Originally Posted by sas
Hey Creeper, this sounds like a really good idea to me. If you don't mind, could you detail out all the marks you used, where you put them, what you checked for? I'm a total noob, so simple is good.

Thanks!
A dab on the bolt head and a corresponding dab on the sprocket. Don't mark the washer as it spins independently of the bolt/sprocket assembly...
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Old 09-11-2006, 09:30 PM   #15
creeper
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Quote:
Originally Posted by ChrisC
A dab on the bolt head and a corresponding dab on the sprocket. Don't mark the washer as it spins independently of the bolt/sprocket assembly...
Chris is referring to the sprocket washer on a KTM LC4. Once I had paint on the bolt, the washer and the sprocket... considering the washer has a tendency to turn under normal circumstances, Chris has been pulling my Johnson about it ever since he saw a picture of my "three dots".
Had to wipe the paint off the washer so he'd leave me alone... but he has the memory of an elephant and unlimited need to poke fun at me.

He's also very big on speeling and gramur.
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