KTM LC4 metal shavings...any ideas? - Page 2

mada · 12-30-2012, 12:05 PM

I removed the sprint on the pushrod before removing the preassure plate, maybe you are not supposed to but thats how i did it and i guess thats why they did not come out together.

Why the lock washer broke yes thats a good question, no idea...

gunnerbuck · 12-30-2012, 12:41 PM

It is not uncommon for those lock washer tabs to break off if they have been reused and bent over a couple of times... When doing a big engine rebuild project those little parts often fly under the radar... It is only upon reassembly where you end up saying "why didn't I order a new one of these?" And rather than face a delay, end up reusing the old part...

bmwktmbill · 12-30-2012, 10:34 PM

Mada,
You work fast...be sure to read the workshop manual on clutch reassembly.

There is a correct orientation of the plates and pressure plate that is specified, also replace the seal on the crankshaft in the clutch case for safety.

Workshop manual is here in pdf.:

http://www.horizonsunlimited.com/hub...ual-98-a-35025
bill

Steveman · 12-31-2012, 08:52 AM

Quote:

Originally Posted by gunnerbuck

It is not uncommon for those lock washer tabs to break off if they have been reused and bent over a couple of times... When doing a big engine rebuild project those little parts often fly under the radar... It is only upon reassembly where you end up saying "why didn't I order a new one of these?" And rather than face a delay, end up reusing the old part...

+1 , I've seen that broken tabs more than once...

mada · 01-02-2013, 12:57 PM

Removed the clutch hub today and main bearings looked fine and were also of the newer type.
Noticed some cracks in one of the oil pump gears so that will be replaced as well. Luckily most parts cost less than $10 each so this time i'll get away with $50 in parts only.
Many thanks for all replies!

MORT666 · 01-02-2013, 01:48 PM

Well done.

12-30-2012, 12:41 PM	#17
gunnerbuck I.Hopp. Joined: Nov 2005 Location: N.V.I, B.C. Oddometer: 3,074	It is not uncommon for those lock washer tabs to break off if they have been reused and bent over a couple of times... When doing a big engine rebuild project those little parts often fly under the radar... It is only upon reassembly where you end up saying "why didn't I order a new one of these?" And rather than face a delay, end up reusing the old part... __________________ 640 A x 2

12-30-2012, 10:34 PM	#18
bmwktmbill Traveler Joined: Jul 2005 Location: Traveler Oddometer: 3,998	Mada, You work fast...be sure to read the workshop manual on clutch reassembly. There is a correct orientation of the plates and pressure plate that is specified, also replace the seal on the crankshaft in the clutch case for safety. Workshop manual is here in pdf.: http://www.horizonsunlimited.com/hub...ual-98-a-35025 bill __________________ '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. Bill Shockley

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12-30-2012, 12:05 PM	#16
mada ^OP Adventurer Joined: Apr 2007 Location: Sweden Oddometer: 70	I removed the sprint on the pushrod before removing the preassure plate, maybe you are not supposed to but thats how i did it and i guess thats why they did not come out together. Why the lock washer broke yes thats a good question, no idea...

01-02-2013, 12:57 PM	#20
mada ^OP Adventurer Joined: Apr 2007 Location: Sweden Oddometer: 70	Removed the clutch hub today and main bearings looked fine and were also of the newer type. Noticed some cracks in one of the oil pump gears so that will be replaced as well. Luckily most parts cost less than $10 each so this time i'll get away with $50 in parts only. Many thanks for all replies!

01-02-2013, 01:48 PM	#21
MORT666 Gnarly Adventurer Joined: Aug 2009 Location: U.K Oddometer: 199	Well done.