KTM 640 Horrible engine noise!!!! - Page 3

moto_psycho · 02-12-2013, 11:28 AM

I must admit, the video makes the bike sound like its going to explode. It is no way near as bad as that, I've just put it back together sans counter balance shaft. It sounds better, but not completely. My guess is rod bearings.

So, who's done this job before? What are the main things to look out for? Which rebuild kit is better? Am I better off buying a full crankshaft assembly pre made instead of getting an engineer to press out the webbs? Or is it easy enough to do yourself?

Foot dragger · 02-12-2013, 11:43 AM

That vid does make it sound like a threshing machine eating a box of rocks. Sounds like having an experienced mechanic look at it might be a good idea.

moto_psycho · 02-12-2013, 12:55 PM

I am a qualified mechanic, and in 3 months a qualified mechanical engineer. It's not that. It's the fact I may need to buy special tools etc to complete certain jobs. I was considering just replacing the main bearing for a phosphor bronze shell bearing (the company I work for supplies aluminium / phosphor bronzes to the aerospace industry).

So yeah, I'm happy to strip the engine down. Just buying certain tools etc may eventually cost more. Plus there is the effort involved... but then there is the piece of mind that I know everything about the engine inside and out. Regardless it is going to cost me a bomb and I am very pissed off as I only bought the bike a few months ago (I researched the bike before and everyone goes on about how they are noisy, so the slightly off noise I heard then I didn't acknowledge.

But, I suppose I will just have to take my time, strip and rebuild everything, and have the best 640 enduro THAR EVER BE! (within reason :p). It's just gonna take some time, moving house, holiday etc... funds be low.

*sigh*

Btw, I bought a strap wrench for getting the clutch apart, it broke. So I thought, what is a modern world use for karate?

wrk2surf · 02-12-2013, 12:57 PM

an impact should do the job

moto_psycho · 02-12-2013, 01:00 PM

Another tool I didn't have to hand! Hence the belt. Worked perfect off and on

. Torqued to 90nm + loctite 243. It's gotta ride to the new house, then it'll be in bits for months. Powder coat the frame, rebuild the forks... it will be mint. And I will document it on here... no doubt nothing will possibly go wrong :p.

gunnerbuck · 02-12-2013, 06:32 PM

Put the transmission in 5th gear and have someone step on the brake while you loosen the clutch nut... Do the same thing when the time comes to torque it back up...

ericGSsti · 02-14-2013, 02:19 PM

Hope you get yours sorted. My machanic changes the gear and ring bearing on mine. Did all the filters and topped up the oil.

I was delighted until he started it. No difference at all.

Dropped it in to KTM this evening.

moto_psycho · 02-16-2013, 01:23 AM

Is that on the starter motor?

I'd be grateful if anyone could give me a hand just describing what order is best to strip the engine in. I have a copy of the manual but experience suggests there are always better ways, especially when considering all the special tools are not to hand! So obv clutch, crank nut and stator loosened in frame, anything else?

gunnerbuck · 02-16-2013, 01:35 AM

Quote:

Originally Posted by moto_psycho

Is that on the starter motor?

I'd be grateful if anyone could give me a hand just describing what order is best to strip the engine in. I have a copy of the manual but experience suggests there are always better ways, especially when considering all the special tools are not to hand! So obv clutch, crank nut and stator loosened in frame, anything else?

The one tool you will really need is a fly wheel puller...
Here are some threads that may be helpful:

http://advrider.com/forums/showthread.php?t=632893

http://advrider.com/forums/showthread.php?t=633753

http://advrider.com/forums/showthread.php?t=628511

moto_psycho · 02-17-2013, 07:11 AM

Cheers for that!

Does the full gasket set have the seals for the water pump?

gunnerbuck · 02-17-2013, 10:13 AM

Quote:

Originally Posted by moto_psycho

Cheers for that!

Does the full gasket set have the seals for the water pump?

Yes the seals are there, but you may have to replace the shaft if it shows a wear ring on the sealing surface...

ericGSsti · 02-20-2013, 10:07 AM

Just to let you know my finding. The head Mechanic from KTM here in Dublin rang me to call into him today so he could show me the damage and wear that had caused my noise and metal that was found on the sump magnets. He was concerned when I had dropped it in and I had told him it had broken the teeth on the starter gear so that where he headed for first to investigate. Turns out all my noise is caused by the starter clutch assemble and fly wheel. There is a lot of wear on the starter clutch and it's relivent components. The clutch itself should only spin one direction but turned both ways and there was wear on every thing else so he's replacing the whole starter clutch assembly and I'll have it back Friday.

Hope your finding aren't to bad.

wrk2surf · 02-20-2013, 03:54 PM

It will probably now need a flywheel or some machining on it to get the gouges out.. surpised the sprague would not have disintegrated

ericGSsti · 02-20-2013, 11:09 PM

Quote:

Originally Posted by wrk2surf

It will probably now need a flywheel or some machining on it to get the gouges out.. surpised the sprague would not have disintegrated

Fly wheel is been replaced with a new one.

moto_psycho · 02-25-2013, 09:26 AM

Probably gonna ditch the starter motor on mine, so no worries if it is the cause

View Results: What is the horrible noise?
Cam chain tensioner	2	5.13%
Camshaft rockers / bearings	10	25.64%
Big end	10	25.64%
Gearbox main shaft bearing	3	7.69%
Crankshaft bearings	8	20.51%
Other?	6	15.38%
Voters: 39. You may not vote on this poll

02-12-2013, 11:28 AM	#31
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	I must admit, the video makes the bike sound like its going to explode. It is no way near as bad as that, I've just put it back together sans counter balance shaft. It sounds better, but not completely. My guess is rod bearings. So, who's done this job before? What are the main things to look out for? Which rebuild kit is better? Am I better off buying a full crankshaft assembly pre made instead of getting an engineer to press out the webbs? Or is it easy enough to do yourself? __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-12-2013, 11:43 AM	#32
Foot dragger beat up ex flat tracker Joined: Dec 2006 Location: chico,just below rag dump(nor-cal) Oddometer: 6,753	That vid does make it sound like a threshing machine eating a box of rocks. Sounds like having an experienced mechanic look at it might be a good idea. __________________ 2003 DR 650.(1976 Montesa 250 Enduro-nice!) - - 1990 MASI TEAM-3V.- 1976 Motobecane, Super-Mirage.- Kona, HumuHumuNukuNukuApua'a. Single Speed ThRaShEr BiKe. 1968 360 Greeves challenger MXer. 1999 Triumph Trophy 1200. 2011 KTM530 EXC. 2012 KONA Hei Hei Deluxe (ongoing bike issues) -2009 KTM 200XC-W.

02-12-2013, 12:55 PM	#33
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	I am a qualified mechanic, and in 3 months a qualified mechanical engineer. It's not that. It's the fact I may need to buy special tools etc to complete certain jobs. I was considering just replacing the main bearing for a phosphor bronze shell bearing (the company I work for supplies aluminium / phosphor bronzes to the aerospace industry). So yeah, I'm happy to strip the engine down. Just buying certain tools etc may eventually cost more. Plus there is the effort involved... but then there is the piece of mind that I know everything about the engine inside and out. Regardless it is going to cost me a bomb and I am very pissed off as I only bought the bike a few months ago (I researched the bike before and everyone goes on about how they are noisy, so the slightly off noise I heard then I didn't acknowledge. But, I suppose I will just have to take my time, strip and rebuild everything, and have the best 640 enduro THAR EVER BE! (within reason :p). It's just gonna take some time, moving house, holiday etc... funds be low. sigh Btw, I bought a strap wrench for getting the clutch apart, it broke. So I thought, what is a modern world use for karate? __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-12-2013, 12:57 PM	#34
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,305	an impact should do the job __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

02-12-2013, 01:00 PM	#35
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Another tool I didn't have to hand! Hence the belt. Worked perfect off and on . Torqued to 90nm + loctite 243. It's gotta ride to the new house, then it'll be in bits for months. Powder coat the frame, rebuild the forks... it will be mint. And I will document it on here... no doubt nothing will possibly go wrong :p. __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-12-2013, 06:32 PM	#36
gunnerbuck I.Hopp. Joined: Nov 2005 Location: N.V.I, B.C. Oddometer: 3,075	Put the transmission in 5th gear and have someone step on the brake while you loosen the clutch nut... Do the same thing when the time comes to torque it back up... __________________ 640 A x 2

02-14-2013, 02:19 PM	#37
ericGSsti Gnarly Adventurer Joined: Oct 2009 Location: Dublin, Ireland Oddometer: 252	Hope you get yours sorted. My machanic changes the gear and ring bearing on mine. Did all the filters and topped up the oil. I was delighted until he started it. No difference at all. Dropped it in to KTM this evening. __________________ 2008 KTM 640 adventure. Africa Twin XRV750 RD04 IBA membership no.35934 "In the spirit of adventure, open to all riders and carrying a message of friendship between all men"- Thierry Sabine 1977 founder of the Paris Dakar -

02-16-2013, 01:23 AM	#38
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Is that on the starter motor? I'd be grateful if anyone could give me a hand just describing what order is best to strip the engine in. I have a copy of the manual but experience suggests there are always better ways, especially when considering all the special tools are not to hand! So obv clutch, crank nut and stator loosened in frame, anything else? __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-17-2013, 07:11 AM	#40
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Cheers for that! Does the full gasket set have the seals for the water pump? __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-20-2013, 10:07 AM	#42
ericGSsti Gnarly Adventurer Joined: Oct 2009 Location: Dublin, Ireland Oddometer: 252	Just to let you know my finding. The head Mechanic from KTM here in Dublin rang me to call into him today so he could show me the damage and wear that had caused my noise and metal that was found on the sump magnets. He was concerned when I had dropped it in and I had told him it had broken the teeth on the starter gear so that where he headed for first to investigate. Turns out all my noise is caused by the starter clutch assemble and fly wheel. There is a lot of wear on the starter clutch and it's relivent components. The clutch itself should only spin one direction but turned both ways and there was wear on every thing else so he's replacing the whole starter clutch assembly and I'll have it back Friday. Hope your finding aren't to bad. __________________ 2008 KTM 640 adventure. Africa Twin XRV750 RD04 IBA membership no.35934 "In the spirit of adventure, open to all riders and carrying a message of friendship between all men"- Thierry Sabine 1977 founder of the Paris Dakar -

02-20-2013, 03:54 PM	#43
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,305	It will probably now need a flywheel or some machining on it to get the gouges out.. surpised the sprague would not have disintegrated __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

02-25-2013, 09:26 AM	#45
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Probably gonna ditch the starter motor on mine, so no worries if it is the cause __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

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