ADVrider

Go Back   ADVrider > Bikes > Orange Crush
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 03-12-2013, 04:35 AM   #46
RedRupert
Brit in the Soviet Union
 
RedRupert's Avatar
 
Joined: Jun 2006
Location: Riga, Latvia / Bergerac, France / Colchester, UK
Oddometer: 571
Quote:
Originally Posted by Vicks View Post
but on a low mileage '08 990, it might be worth the risk not taking every thing off - if you don't need to ?
I agree, but it only amounts to two piston circlips extra.

As Peanuts mentioned, you can get the cylinders off without removing the pistons from the cylinders - in fact, according to the manual, you are not supposed to remove the pistons from the bottom of the cylinders, but only from the top. I don't know why they say this, and I'm not convinced that it needs to be so.

Also, you can keep the head attached to the cylinder, so as not to disturb the expensive head gasket.

So, by removing the cylinder and the head as one, you'll only need to buy two piston circlips (about £10). Then you'll have the option of replacing the base gasket, which I think should be done.
__________________
KTM 970 Adventure (2004 with carbed 2008 SD 990)
Honda 650 Dominator (1988)
Kawasaki KLR 650 (1988)
Yamaha RD 350 LC (1984)
RedRupert is offline   Reply With Quote
Old 03-12-2013, 06:17 AM   #47
Vicks
I love sand !!!
 
Vicks's Avatar
 
Joined: Oct 2006
Location: Abu Dhabi, UAE
Oddometer: 2,959
Quote:
Originally Posted by RedRupert View Post
I agree, but it only amounts to two piston circlips extra.

As Peanuts mentioned, you can get the cylinders off without removing the pistons from the cylinders - in fact, according to the manual, you are not supposed to remove the pistons from the bottom of the cylinders, but only from the top. I don't know why they say this, and I'm not convinced that it needs to be so.

Also, you can keep the head attached to the cylinder, so as not to disturb the expensive head gasket.

So, by removing the cylinder and the head as one, you'll only need to buy two piston circlips (about £10). Then you'll have the option of replacing the base gasket, which I think should be done.
All good points and thanks for that. Learn something everyday.
__________________
'07 KTM Adv990S - Gone to a good home
'10 KTM 530Exc-Rally, some items for sale
No myriad hues of laser lights, no bottles that are oozing with nectars from heaven
No beautiful body soft and warm to the touch but, i have a very small desire
Give me a dark... long... winding road, three gears to go and my Hellas on fire !!
Vicks is offline   Reply With Quote
Old 03-12-2013, 02:59 PM   #48
JLC640 OP
Adventurer
 
Joined: Oct 2012
Oddometer: 27
Good information guys Keep it coming. Plan to have motor sitting on work bench by this weekend and start digging into it.
Is there any issue with just using a long 8mm bolt to lock the crank instead of having to order and wait for the tool?
If I'm understanding you guys correct? You recommend removing cylinder and head as one pull cylinder up until I can remove circlip leaving pistons in bottom of cyl. and replacing base gasket.Not removing head from cylinder.
The bike only has just over 12k.
JLC640 is offline   Reply With Quote
Old 03-12-2013, 03:11 PM   #49
DirtyADV
Beastly Adventurer
 
DirtyADV's Avatar
 
Joined: Jan 2007
Location: SWEDEN, Skellefteå
Oddometer: 1,929
Quote:
Originally Posted by JLC640 View Post
Good information guys Keep it coming. Plan to have motor sitting on work bench by this weekend and start digging into it.
Is there any issue with just using a long 8mm bolt to lock the crank instead of having to order and wait for the tool?
If I'm understanding you guys correct? You recommend removing cylinder and head as one pull cylinder up until I can remove circlip leaving pistons in bottom of cyl. and replacing base gasket.Not removing head from cylinder.
The bike only has just over 12k.
I lifted the cylinders and heads as a unit when replacing the base gaskets.

Did the rear last autumn and was able to get 250 kms before winter hit and it seemed to hold up fine.

/Johan
__________________
Have changed name, was previously Dirty950

www.dirtyadv.com (under construction)
DirtyADV is offline   Reply With Quote
Old 03-12-2013, 03:48 PM   #50
Peanuts
Beastly Adventurer
 
Peanuts's Avatar
 
Joined: Sep 2009
Location: UK
Oddometer: 1,437
Quote:
Originally Posted by JLC640 View Post
Is there any issue with just using a long 8mm bolt to lock the crank instead of having to order and wait for the tool?
A fully threaded set screw or length of threaded bar with two nuts locked together. Grind it to a shallow (45 degrees) point at the end.
Peanuts is offline   Reply With Quote
Old 03-14-2013, 04:37 AM   #51
RedRupert
Brit in the Soviet Union
 
RedRupert's Avatar
 
Joined: Jun 2006
Location: Riga, Latvia / Bergerac, France / Colchester, UK
Oddometer: 571
Quote:
Originally Posted by JLC640 View Post
If I'm understanding you guys correct? You recommend removing cylinder and head as one pull cylinder up until I can remove circlip leaving pistons in bottom of cyl. and replacing base gasket.Not removing head from cylinder.
The bike only has just over 12k.
Yes. But be very careful - just move the piston down enough to expose the circlip/gudgeon pin fully. It's too easy to go a little too far, and have the rings out of the bore - it's not the end of the world if this happens, but it's worth the effort to prevent it happening.

No need to remove the head from the cylinder.

Replace the base gasket - there's no reason to risk reusing. Some owners have experienced weeping base gaskets.
__________________
KTM 970 Adventure (2004 with carbed 2008 SD 990)
Honda 650 Dominator (1988)
Kawasaki KLR 650 (1988)
Yamaha RD 350 LC (1984)
RedRupert is offline   Reply With Quote
Old 03-14-2013, 04:57 AM   #52
RedRupert
Brit in the Soviet Union
 
RedRupert's Avatar
 
Joined: Jun 2006
Location: Riga, Latvia / Bergerac, France / Colchester, UK
Oddometer: 571
Special Tools

Quote:
Originally Posted by JLC640 View Post
Good information guys Keep it coming. Plan to have motor sitting on work bench by this weekend and start digging into it.
Is there any issue with just using a long 8mm bolt to lock the crank instead of having to order and wait for the tool?
Are you aware of the special tools that you'll need? For example:

* Ignition rotor puller (an M16 x 1.5 mm grub-screw + an M20 x 1.5 mm screw or bolt).

* A 46 mm socket for the big nut on the crank-shaft.

* A means of getting to, and correctly torquing, the 13 mm cylinder nut that's obstructed by the cam-casing while assembling. You can use the KTM bottle opener along with a 1/2" torque wrench.

* A gear puller.

* Clutch tool.

* Sparkplug spanner (not many fit - needs very thin walls).

Photos of my engine locking tool:

It needs to be 100 mm or longer.

The tip:



The head - I cut a slot with a hacksaw for a screwdriver:

__________________
KTM 970 Adventure (2004 with carbed 2008 SD 990)
Honda 650 Dominator (1988)
Kawasaki KLR 650 (1988)
Yamaha RD 350 LC (1984)

RedRupert screwed with this post 03-20-2013 at 04:06 AM
RedRupert is offline   Reply With Quote
Old 03-14-2013, 05:07 AM   #53
RedRupert
Brit in the Soviet Union
 
RedRupert's Avatar
 
Joined: Jun 2006
Location: Riga, Latvia / Bergerac, France / Colchester, UK
Oddometer: 571
Engine Stand

I made an engine stand from plywood scrap (I didn't have the material, tools or skill to make a metal one). I hate struggling with the motor, while trying to torque tight nuts etc.

It makes working on the engine a pleasure, rather than a struggle. It was well worth the effort to make.

It's only necessary to remove the motor from the stand just before splitting the crank-case. By then it's pretty light anyway.

__________________
KTM 970 Adventure (2004 with carbed 2008 SD 990)
Honda 650 Dominator (1988)
Kawasaki KLR 650 (1988)
Yamaha RD 350 LC (1984)

RedRupert screwed with this post 03-20-2013 at 04:02 AM
RedRupert is offline   Reply With Quote
Old 03-14-2013, 06:15 AM   #54
Peanuts
Beastly Adventurer
 
Peanuts's Avatar
 
Joined: Sep 2009
Location: UK
Oddometer: 1,437
Quote:
Originally Posted by RedRupert View Post

That would look sweet on my dining table :)
Peanuts is offline   Reply With Quote
Old 03-19-2013, 02:29 PM   #55
JLC640 OP
Adventurer
 
Joined: Oct 2012
Oddometer: 27
Got her split open this is pics of damage.
http://tinypic.com/r/262lkpf/6
http://tinypic.com/r/2r3kx8g/6
http://tinypic.com/r/16jg08o/6
http://tinypic.com/r/2lc9y7r/6
Still have no idea what caused it but it sure made a mess.
JLC640 is offline   Reply With Quote
Old 03-19-2013, 02:45 PM   #56
Boon Booni
Red Clay Halo
 
Boon Booni's Avatar
 
Joined: Aug 2003
Location: Richmond, Va
Oddometer: 12,986
Quote:
Originally Posted by JLC640 View Post
Got her split open this is pics of damage.
http://tinypic.com/r/262lkpf/6
http://tinypic.com/r/2r3kx8g/6
http://tinypic.com/r/16jg08o/6
http://tinypic.com/r/2lc9y7r/6
Still have no idea what caused it but it sure made a mess.
That totally blows, but I'm sticking with my story.


Quote:
Originally Posted by Boon Booni View Post
Looking at the damage to the gear tooth, I'd surmise that there is another chunk of something floating around in the sump of his bike, probably from the factory. when he layed it over the something moved around and got caught up in his first gear and then tried to go through it breaking off the tooth.

I don't think he's got bent shift forks or anything else beyond a broken first gear.

.02c
__________________
A little nonsense now and then is relished by the wisest men.

You can be Han Solo, and I can be another Han Solo...
Boon Booni is online now   Reply With Quote
Old 03-19-2013, 03:47 PM   #57
JLC640 OP
Adventurer
 
Joined: Oct 2012
Oddometer: 27
That is the only thing that really makes since to me.
The only other thing that might have happened. If you notice the pin on oil injection tube is bent. I laid the bike down on the left hand side. If the tube shifted slightly to the left and the pin came out off the groove in the case it would have hit the teeth on first gear. Even if it just broke one tooth the rest could have been caused by that tooth.That is unlikely but my only other idea.
Just glad I have it torn down, ready to order parts, and get it back together.
May have some questions for you guys during reassembly. Appreciate your help!
JLC640 is offline   Reply With Quote
Old 03-20-2013, 02:24 PM   #58
Peanuts
Beastly Adventurer
 
Peanuts's Avatar
 
Joined: Sep 2009
Location: UK
Oddometer: 1,437
Peanuts is offline   Reply With Quote
Old 03-20-2013, 08:12 PM   #59
Vicks
I love sand !!!
 
Vicks's Avatar
 
Joined: Oct 2006
Location: Abu Dhabi, UAE
Oddometer: 2,959
crap !!! thats MAJOR damage and i'm sure not many LC8 engines have suffered. I'm simply unable to think of the reasons that led to teeth shearing off a gear wheel in this manner. What are the chances of taking this up with KTM ? A simple drop should not cause such damage !!!

If KTM doesn't cover it, i would defn. keep the parts as a (dark) memorabilia.

hope you get her running back soon.
__________________
'07 KTM Adv990S - Gone to a good home
'10 KTM 530Exc-Rally, some items for sale
No myriad hues of laser lights, no bottles that are oozing with nectars from heaven
No beautiful body soft and warm to the touch but, i have a very small desire
Give me a dark... long... winding road, three gears to go and my Hellas on fire !!
Vicks is offline   Reply With Quote
Old 03-20-2013, 08:25 PM   #60
Boon Booni
Red Clay Halo
 
Boon Booni's Avatar
 
Joined: Aug 2003
Location: Richmond, Va
Oddometer: 12,986
Quote:
Originally Posted by JLC640 View Post
That is the only thing that really makes since to me.
The only other thing that might have happened. If you notice the pin on oil injection tube is bent. I laid the bike down on the left hand side. If the tube shifted slightly to the left and the pin came out off the groove in the case it would have hit the teeth on first gear. Even if it just broke one tooth the rest could have been caused by that tooth.That is unlikely but my only other idea.
Just glad I have it torn down, ready to order parts, and get it back together.
May have some questions for you guys during reassembly. Appreciate your help!
Make sure you collect the broken bits. Count them and see if you come up with 1 more than you have teeth missing.


...and for those of us that seem to have some problem with your photo hosting site..













__________________
A little nonsense now and then is relished by the wisest men.

You can be Han Solo, and I can be another Han Solo...

Boon Booni screwed with this post 03-20-2013 at 08:31 PM
Boon Booni is online now   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 05:11 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014