Completed 600 mile service myself

Wayne Weber · 09-14-2003, 08:35 PM

I finished the service today, as well as removing all the EPC/speed limiting/carbon canitser stuff. Here's what I found:

Wayne Weber · 09-14-2003, 08:37 PM

Sorry for the small pics but I haven't figured out the hosting thing yet.

The glovebox/tanks/fairings come off easily, except for the hose clamps which aren't always positioned the best.

Wayne Weber · 09-14-2003, 08:43 PM

The oil change is easy once everything is off. The lower oil screen takes a little tug to get out. The oil filter is a pain, I punched a hole in it and took it out with a hook tool. The airbox and carbs took a beer and a little studying of the shop manual, but were not bad either. It's nice since you don't have to disconnect the throttle/choke/TPS cables. I used a bungee to keep them up by the handlebar. The rear valve cover is very accessible. Here is a pic of the front: It looks like you have to remove the oil tank vent hoses, but it's not needed; just pull it out of the way and you can get the feeler gauges in. You would have to remove the hoses if you need new shims. All of my valves were in spec, so I was happy (less work!). That's a brake cleaner spray can lid covering the intake port.

Wayne Weber · 09-14-2003, 08:46 PM

As I mentioned I removed all unneccessary equipment, including the EPC stuff, the speed limiting hoses/solenoids for 2/3 gear, and the charcoal canister (in the left side fairing). 3 lbs of stuff total, but more importantly it's much easier to work on now. Here is the plug/cap combo I used for the EPC valves on the heads.

Wayne Weber · 09-14-2003, 08:49 PM

I checked the synchronization of the carbs. Since I removed the hoses for the noise reducing equipment, I attached permanent synch hoses to the intakes, so I don't have to remove ANYthing to check the synch in the future! I connected the new tubes with a piece of 1/8" TIG wire (see next post). Fortunately the synch was also very close, at both idle and 3500 rpm or so. Good deal, lets go ride!

Wayne Weber · 09-14-2003, 08:52 PM

Here is a close up of how I ran the synch hoses on the right side of the bike. I'll just leave these here and simplify future synch testing.

2 and 3 gears do seem faster! nothing earth shattering, but better. I can't wait to get these CAT's off!

I'll probably check everything again around 5000 miles to see how it's going, then let it run till 15000 or so.

Gerg · 09-14-2003, 09:02 PM

Wayne, How much was the shop manual?

Greg

Wayne Weber · 09-14-2003, 09:05 PM

Summing up: The bike isn't hard to work on, but it does require way to much disassembly for routine work such as oil/filter/air filter replacement. In my mind the air filter should not require ONE tool to replace, and the oil change should not require removing any extraneous parts. The plastic "skid" plate sides are a pain to install, crappy captured nuts. To many fastener heads - 6-8-10mm hex plus 5 and 6 allen.

The only odd tool you might need is a 14mm allen hex attachment for a 3/8" ratchet for removing the cover and turning the motor to find TDC.

Good stuff: 75 degree V is easy to push carbs back on. Only 3 bolts on tanks. Wires for blinkers/fuel light are long enough to disconnect in a reasonable way. Emmisions junk is easy to remove. All fastenters are accessable and don't require contortions to reach. A 1/4" wobble extention is still nice though.

The engineers did get a little fastener happy - 8 bolts on the air filter, 10 on the glove box, 5 on each side plate and fairing, 3 on each pastic skid plate side cover etc.

I only attached the fairing with the upper two bolts, I'm going to use tapered rubber plugs in the 3 that connect to the tank - so if, I mean WHEN I crash, the fairing won't tear out any thing on that $1192 tank.

Next project: REAL tank protection. I spent the afternoon designing it, I'll start fabricating tomorrow.

If you've done oil/valves on any bike before, you can do it on this one. Here's the tools I used to complete this maintenance.

Gerg · 09-14-2003, 09:10 PM

External Circlip pliers do remove the filter quite easily. I think thats what's called for in the manual (owners).

Greg

Wayne Weber · 09-14-2003, 09:13 PM

Quote:

Said Gerg:
External Circlip pliers do remove the filter quite easily. I think thats what's called for in the manual (owners).

Greg

and I even have a set. Next time! thanks...

Goss · 09-15-2003, 06:22 AM

So you plugged and capped the connections at the head? Insurance I assume so that the plug would not come out? What about the connection at the carbs ?

Great write up.

Goss

Renazco · 09-15-2003, 06:29 AM

Great write up Wayne

Grover · 09-15-2003, 12:02 PM

Good stuff :):

Wayne Weber · 09-15-2003, 06:53 PM

Quote:

Said Goss:
So you plugged and capped the connections at the head? Insurance I assume so that the plug would not come out? What about the connection at the carbs ?

Great write up.

Goss

Yeah, just insurance. I don't trust the caps to seal good when hot, and don't trust the plugs to stay.

The carbs have two connections each. I capped the ones on the top of the carb. The other one isn't really the carb, but on the intake port of the motor. That's what I ran the "synchro-tubes" to.

Toolman · 09-16-2003, 07:00 AM

Wayne, good job! Glad to see some Snap-On tools in the photo! Thanks, we appreciate the business!

Toolman

09-14-2003, 08:35 PM	#1
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	KTM950-Completed 600 mile service myself I finished the service today, as well as removing all the EPC/speed limiting/carbon canitser stuff. Here's what I found: Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!) Wayne Weber screwed with this post 09-14-2003 at 09:15 PM

09-14-2003, 08:37 PM	#2
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	600 miles service Sorry for the small pics but I haven't figured out the hosting thing yet. The glovebox/tanks/fairings come off easily, except for the hose clamps which aren't always positioned the best. Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!)

09-14-2003, 08:43 PM	#3
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	service The oil change is easy once everything is off. The lower oil screen takes a little tug to get out. The oil filter is a pain, I punched a hole in it and took it out with a hook tool. The airbox and carbs took a beer and a little studying of the shop manual, but were not bad either. It's nice since you don't have to disconnect the throttle/choke/TPS cables. I used a bungee to keep them up by the handlebar. The rear valve cover is very accessible. Here is a pic of the front: It looks like you have to remove the oil tank vent hoses, but it's not needed; just pull it out of the way and you can get the feeler gauges in. You would have to remove the hoses if you need new shims. All of my valves were in spec, so I was happy (less work!). That's a brake cleaner spray can lid covering the intake port. Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!) Wayne Weber screwed with this post 09-14-2003 at 09:06 PM

09-14-2003, 08:46 PM	#4
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	service As I mentioned I removed all unneccessary equipment, including the EPC stuff, the speed limiting hoses/solenoids for 2/3 gear, and the charcoal canister (in the left side fairing). 3 lbs of stuff total, but more importantly it's much easier to work on now. Here is the plug/cap combo I used for the EPC valves on the heads. Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!)

09-14-2003, 08:49 PM	#5
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	synching I checked the synchronization of the carbs. Since I removed the hoses for the noise reducing equipment, I attached permanent synch hoses to the intakes, so I don't have to remove ANYthing to check the synch in the future! I connected the new tubes with a piece of 1/8" TIG wire (see next post). Fortunately the synch was also very close, at both idle and 3500 rpm or so. Good deal, lets go ride! Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!)

09-14-2003, 08:52 PM	#6
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	synch mod Here is a close up of how I ran the synch hoses on the right side of the bike. I'll just leave these here and simplify future synch testing. 2 and 3 gears do seem faster! nothing earth shattering, but better. I can't wait to get these CAT's off! I'll probably check everything again around 5000 miles to see how it's going, then let it run till 15000 or so. Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!)

09-14-2003, 09:02 PM	#7
Gerg Cupcake Joined: Dec 2001 Location: Left Coast Oddometer: 7,905	Wayne, How much was the shop manual? Greg

09-14-2003, 09:05 PM	#8
Wayne Weber ^OP why are we stopping? Joined: Aug 2003 Location: Golden CO Oddometer: 3,854	600 mile service summary Summing up: The bike isn't hard to work on, but it does require way to much disassembly for routine work such as oil/filter/air filter replacement. In my mind the air filter should not require ONE tool to replace, and the oil change should not require removing any extraneous parts. The plastic "skid" plate sides are a pain to install, crappy captured nuts. To many fastener heads - 6-8-10mm hex plus 5 and 6 allen. The only odd tool you might need is a 14mm allen hex attachment for a 3/8" ratchet for removing the cover and turning the motor to find TDC. Good stuff: 75 degree V is easy to push carbs back on. Only 3 bolts on tanks. Wires for blinkers/fuel light are long enough to disconnect in a reasonable way. Emmisions junk is easy to remove. All fastenters are accessable and don't require contortions to reach. A 1/4" wobble extention is still nice though. The engineers did get a little fastener happy - 8 bolts on the air filter, 10 on the glove box, 5 on each side plate and fairing, 3 on each pastic skid plate side cover etc. I only attached the fairing with the upper two bolts, I'm going to use tapered rubber plugs in the 3 that connect to the tank - so if, I mean WHEN I crash, the fairing won't tear out any thing on that $1192 tank. Next project: REAL tank protection. I spent the afternoon designing it, I'll start fabricating tomorrow. If you've done oil/valves on any bike before, you can do it on this one. Here's the tools I used to complete this maintenance. Attached Images __________________ Wayne 04 KTM 950 S 93 KTM 550 93 XT225 Adventure Serow! 00 Weber Rally Twin (www.rallytwin.com) Gas Gas 270 2 Waterbuffalo's (Sold!)

09-14-2003, 09:10 PM	#9
Gerg Cupcake Joined: Dec 2001 Location: Left Coast Oddometer: 7,905	External Circlip pliers do remove the filter quite easily. I think thats what's called for in the manual (owners). Greg

09-15-2003, 06:22 AM	#11
Goss LC8 Adventurer Joined: Sep 2002 Location: North Texas Oddometer: 1,315	So you plugged and capped the connections at the head? Insurance I assume so that the plug would not come out? What about the connection at the carbs ? Great write up. Goss __________________ 2004 KTM 950 Adventure S 2012 Ducati Multistrada 1200 Pikes Peak

09-15-2003, 06:29 AM	#12
Renazco Formerly AKA Boejangles Joined: Apr 2003 Location: Santa Rosa, Ca. Oddometer: 4,695	Great write up Wayne

09-15-2003, 12:02 PM	#13
Grover Blinkenlights Adventurer Joined: Jun 2002 Location: So. Cal, USA Oddometer: 1,691	Good stuff :):

09-16-2003, 07:00 AM	#15
Toolman toolman Joined: Oct 2002 Location: Loganville, GA Oddometer: 120	Wayne, good job! Glad to see some Snap-On tools in the photo! Thanks, we appreciate the business! Toolman __________________ Toolman KTM 530 exc KTM 950 Adventure S KTM 250xcfw Husaberg 501 Husqvarna 430WR

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