|09-28-2007, 06:44 PM||#1|
Joined: Oct 2001
boyscouts 3 week LC4 refresh
Just got back from a 6 week trip to Alaska which nearly doubled the mileage on my 2002 LC4 Adventure. It now sits at just under 25,000 miles and I have 3 weeks to prep it to head for South America. I'm going to use this thread to both plan and document the work on the bike.
Before leaving for Alaska I did the following maintenance and upgrades:
I'm trying to decide whether it is worth it to reseal the rocker cover. With the tools I had, I couldn't get the torque wrench on some of the bolts, maybe just torque things down and see if it still seeps.
I've been told I can remove the seals on my wheel bearings and replace the grease. I'll need a special circlip tool to get the seals out. Worth it? Any lines on where to get pliers that can both expand and compress a circlip, haven't found them locally?
Here's the strange carb behavior. Any time the bike would be on it's side for any length of time, it would start up just fine. A couple miles down the road it would start to stall as if flooded. I could work through it by pulling in the clutch and tickling the throttle for 15 -30 seconds. It would then run fine for awhile but eventually start to stall again and in general run crappy at low revs. I could force a stall by accelerating hard and then snapping the throttle closed. Draining the float bowl would set things right until the next time the bike ended up on its side. Sound like a float height issue? Crap in the carb? Float bowl overflow clogged? I suppose I'll pull the carb, give it a good cleaning and check the float height but any suggestions would be welcome.
Any suggestions on how to seal the oil sight glass. Not a big deal but I'd like to keep as much of the oil inside the motor as possible?
That's it for now. Questions, comments, suggestions welcome. I'll update the thread as I get things done. I'll be up at the Redwood Rendevous this weekend so won't be able to get started on this till next week.
|10-02-2007, 10:09 AM||#2|
I dont want a pickle
Joined: Oct 2005
Location: Cotati Ca. USA
May be we should roll south together.
I just got done preppin my bike 03 640 adv. going to MEX for a few months. Just been prerunning around the north bay,to make shure everything is rite-on.
When is your departure date? Are you gonna pound the freeway to the border? Are you on a tight time frame to get to S.A.?
Are you running solo?
On the oil sight glass. Mine started weaping a few months back. Packed the outer cravass with high temp clear rtv. Seemed to work. Will replace before I leave.
Circlip Pliers I got mine at the local bearing house. Seen them a NAPA auto
What kind of spares are you hauling?
Me: CDI,coil and wire,levers,various gaskets and seals,bulbs,tubes,fuses,spark plugs.ect.
|10-02-2007, 10:33 AM||#3|
Joined: Sep 2001
Location: Santa Cruz, Calif
|10-04-2007, 12:25 AM||#4|
Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
If you are going to reseal the rocker cover get some of that Hondabond HT - supposed to be the cat's meow.
Motion Pro is just down the peninsula from ya, and they have a bunch of tools, like snap ring pliers. If they don't sell it I bet they will direct you where to go.
Kronreif Trunkenpolz Mattighofen LC4 640
Its not so much staying alive; its staying human that counts.
|10-04-2007, 12:44 AM||#5|
Joined: Jun 2006
Location: Dunedin. New Zealand
I used it and it works. Make sure you put sealant over the NEW O-Rings around the waterpump housing.
2012 KTM 690 R
2010 KTM 990 R (Sold)
2008 N.Z.Yamaha Safari: http://www.advrider.com/forums/showthread.php?t=306905
2007 N.Z.Adventures Safari: http://www.advrider.com/forums/showthread.php?t=201557
|10-04-2007, 10:55 PM||#6|
Joined: Jul 2005
I've been to South America....
Random thoughts and ideas in no particular order based on my SA trip and my recent trip in Asia....
I would reseal the rocker cover now, think about the problems of doing it outside the USA.
Get the bike running right before you leave.
Keep in mind there are probably no KTM parts for the duration of your trip.
My ideas focused on personal safety for me and for the bike.
I always wanted to keep us both cool, calm and safe.
It's a team effort in a weird sort of way.
I always had more parts than other travelers and worked on everyone's bike.
For the carb issue, I would say the float needle (rubber tipped) is shot. Vibration can kill then in 10k miles. Buy two, one for a spare. If you don't have the carb rebuild kit buy two of those, one to rebuild and one for a spare.
I would carry rebuild kits for the front and rear brake master cylinders and the calipers but then I don't like to ride without both brakes.
Regrease the steering head bearings.
New brake pads front and rear.
New chain and sprockets.
New battery unless it was new for Alaska.
Buy a grease needle and do the wheel bearings and the sprocket carrier bearing(no need to remove the bearings or seals-slip it in).
New countershaft seal and bushing and a set for spares.
Replace fork seals and carry old seals for a backup, install neoprene fork boots.
Motion pro spoke wrench(better than KTM's), torque all the spokes. On the road check them once a week if on rough roads.
Zip tie the spokes.
Front, rear new tubes as spares, new tires before you cross the border.
I would not carry spare tires, it's the best way to wreck the rear shock.
Throttle and clutch cable spares plus levers.
Water pump rebuild seals bearings and o-rings, carry as spares.
Nuts and bolts in a handy place including a seat bolt, faring bolts and KTM's locking nuts in both sizes.
Gaskets including a head gasket, valve cover gaskets, oil filter gasket(small).
Loop of gasline.
Travel tiedown straps.
Spring puller tool. KTM makes a nice one.
Spare fan thermoswitch and temp indicator thermoswitch.
2x's more fuses than you think you will need.
Old innertube rubberbands.
Sealants including Aquaseal or seamseal, epoxy, Hondabond 4.
Boot and glove waterproofing.
Get the Aerostitch catalogue and replace any gear that is worn out.
Consider a new tankbag if yours is old.
Zippers love to fail on everything.
Spare helmet shield.
Buy whatever you think you will need to be comfortable.
Tape $100-500 dollars in an envelope(what makes you comfortable) to the seat base and forget it.
Hacksaw blade, small files-flat and round, piece of innertube for a bottom on your parts bag(tire boot).
You won't need many clothes, especially cotton-go synthetic, you will need parts and tools.
I rode in a Aerostitch Darien light jacket and pants and Sidi On Road boots for both my trips.
My second pair of shoes were Crocks, jammed between the hard bags and the frame.
I carried a Crazy Creek chair on both trips under my back bag.
I use straps , bungees and a Aerostitch HD cargo net over everything, hard bags and a tank bag.
On the last trip I wore a back protector.
I always take my electric vest and a on/off switch cord. I am skinny and hate to be cold.
All the borders in Central America are a 3 ring circus so check the steering head lock for smooth operation.
Have a document pouch and a money pouch.
Strip the bike before you hit the borders and put everything that can be removed under lock and key for safety and peace of mind.
Buy help at the borders.
I always take my electric vest and a on/off switch cord.
I use heated grips.
Sorry for the long list....
In the end the good feeling is worth a thousand dollars...so spend it.
If you don't like any of this just forget it, get on the bike and go.
'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing
The faster it goes the faster it breaks.
And high performance=high maintenance.
bmwktmbill screwed with this post 10-05-2007 at 08:14 AM
|Thread Tools||Search this Thread|