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Old 03-02-2013, 07:31 PM   #16
gravityisnotmyfriend OP
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Location: ((kg*m)/s^2), IA, USA
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Here's a pic of my slap hammer concoction:




It aint' pretty. And it don't work real well. But it worked and it was pretty much free. I got the old seal out without damaging the case.

So, on to the electrical. I hooked up 12V DC to the bike to simulate it running and tore the front end apart to diagnose why the lights don't work in the instrument panel:





Turns out that 3 light bulbs were burned out, one had fallen out of its socket and one was missing. That left two bulbs that weren't burnt out. I plugged them into various sockets and whaddya know? The electrical is fine! I just gotta order some new bulbs.

And, I figured out the turnsignals. The flasher relay is physically crushed. The outer case is broken. If you hold it just right it'll work, but sometimes it doesn't. It just needs replaced.


So, here's the real exciting part. The bike is as dismantled as it's going to get. As soon as my parts get here, I can start putting her back together! Up until this point, I've left the bike in worse shape than she was before I started - every night. Now, it's going to look like I'm making progress!

I really wish it were warm enough to take this carcass to a car wash. She's sorely in need of a pressure washing!
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Old 03-03-2013, 10:32 PM   #17
bmwktmbill
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Grav,
Nice work. Nice tool.

I think there is a silicone O-ring that works with the spacer/seal surface.
Be sure to replace that.

At least there is on the '02 Adventure.
bill
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'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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Old 03-04-2013, 05:40 AM   #18
gravityisnotmyfriend OP
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Thanks!

Yeah, I've got the O-Ring coming with the rest of the KTM-parts.com order. Creeper's write up covered that in detail.

It looks to me that the chain was set way too tight and that's why this seal was leaking. I just hope it didn't do any real damage to the bike.
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Old 03-04-2013, 09:30 PM   #19
bmwktmbill
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That's so common. If there's no play in the shaft things should be good.

You can keep n eye on it.
Do you have a cush hub?

That might help.
b
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'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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Old 03-05-2013, 05:37 AM   #20
gravityisnotmyfriend OP
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I didn't notice any play - but didn't look for it either. I'll give it a good look tonight.

The shop manual sure makes it look like I have a cush hub. The Austrian translation of dämpfergummi is "drive rubber". Close enough!

Most of my parts came in yesterday. Hopefully I can get some time in the garage tonight to start putting her back together. The only thing I don't have are the bulbs for the instrument cluster. I've found them in a few places - but I can't get my 4 itty bitty 1000 hr incandescent bulbs for less than about $30.

I can either order them from China in packs of 10 for $.50/piece and pay $30 shipping or I can order them from Cheap Cycle parts for $4/piece and pay $10 shipping. Either way feels like a rip off! The same bulb is used in some Yamahas. I'll see if I can find them that way. Maybe there's a dealership that carries them around here.

I'm really considering converting the whole mess to LEDs. It wouldn't be any cheaper - but at least I'd never have to replace burnt out bulbs.

gravityisnotmyfriend screwed with this post 03-05-2013 at 05:44 AM
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Old 03-05-2013, 06:12 AM   #21
gravityisnotmyfriend OP
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Of all places - Boats.net has them for $2.04/piece with $1.75 shipping. I can live with that!
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Old 03-05-2013, 09:26 AM   #22
bmwktmbill
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When I was in Bolivia I crashed hard and tore the instruments off my BMW.

I used my GPS for the rest of the trip south then back to the USA.

Speed and total miles plus gas reset miles, no problem

Never missed the instruments and ran the machine another 100K miles.

Got to like the clean look. Utilitarian.
bill
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'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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Old 03-05-2013, 10:14 AM   #23
gravityisnotmyfriend OP
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I did the same thing to my '71 350. Except, I used wrenches to take them off!




Most of the time, I just guess at my speed. But, if I want to know I'll put my GPS on. You can see the handlebar mount in that pic.

I'm not too concerned about most of the lights. But, if my low oil or over temp lights aren't working, I fear cooking my engine. I can live without the rest.

gravityisnotmyfriend screwed with this post 03-05-2013 at 10:19 AM
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Old 03-05-2013, 10:29 AM   #24
gravityisnotmyfriend OP
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I don't know what's going on with photobucket. Thumbnail images are tiny and direct you to a photobucket page with a small version of the picture. Direct [img]file address[/img] makes them show up huge. Weird. So, bear with me while I struggle through figuring it out.

I got my parts in the mail yesterday. Had to spend all night on homework and not fixing my bike. If any of you are considering your master's in engineering I would strongly advice against it. It really gets in the way of wrenching time!


Anyway, here's all the parts ready to go together:



After smearing a bunch of loctite on my fingers - and a little on the seal, I was able to get that seated:



Then, the bearing went on the shaft easily - with a little help from an arbor press:


Bearings and shaft ready to go in. I smeared some grease in the recess of the seal to help get the shaft to slide through and maybe help keep the oil out of the coolant and the coolant out of the oil:


Bearings and shaft went in easily. New clips and o-rings installed


Slid the impellor back on and put on a new washer with the old bolt. She's ready to go back on the bike!



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Old 03-08-2013, 05:21 AM   #25
gravityisnotmyfriend OP
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New project for the night. Install the sprocket shaft seal. I have a look at what I'm working with. Too much grease and gunk built up:


After a little cleaning:


Find the new parts:



Line up the seal....




Huh. I guess I didn't need that driver after all. There's a good 1/8" all around the outside of the seal. The weird thing is that the spacer is a perfect fit. Huh. I guess I gotta call the folks at KTM-Parts and find out what their exchange policy is. Crap.


The night wasn't lost. I did get my water pump installed and my valve cover back on and sealed. Apparently, I didn't take any pictures though.

gravityisnotmyfriend screwed with this post 09-10-2013 at 04:29 PM
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Old 03-08-2013, 05:47 AM   #26
gravityisnotmyfriend OP
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So, I double checked my invoice. I ordered a 0760324771 and that's what the package that it came is says as well. It also says 32X47X7

Which I interpret as 32mm ID, 47mm OD, and 7mm thick. Let's see:

Thickness? Check.


ID? Check.


OD? Hmmm....


Its actually about 42.2mm. Hopefully I can get a new part coming soon. I had hopes of having this bike back together this weekend.
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Old 03-08-2013, 06:17 AM   #27
johnno950
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if you could do time for "crimes against motorcycle maintence" i think you would get about 5yrs
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Old 03-08-2013, 06:30 AM   #28
gravityisnotmyfriend OP
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Quote:
Originally Posted by johnno950 View Post
if you could do time for "crimes against motorcycle maintence" i think you would get about 5yrs
Thanks for your insightful post... I guess.

Maintence? Maintence? Is that the act of mainting your bike? How do you maint?




















Oh, you mean maintenance. Yes, this bike is in a sorry state - but if anyone deserves time, it's the PO.

gravityisnotmyfriend screwed with this post 03-08-2013 at 11:37 AM
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Old 03-13-2013, 05:43 AM   #29
gravityisnotmyfriend OP
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I got a little bit of quality time with the bike last night. I tried to get some pics - but nothing really turned out. But, I got the water pump back together. Got the new jets installed and the carb back together. And, I got all the dash lights in and the front end back together. So, I'm making forward progress and actually putting stuff back together.


Here's the list. Plain black is yet to be addressed. Green is repairs in progress. Yellow is done.

Valves - need to check lash.

Front shocks – leak

Clutch – slips

Plastics – plain white

Spark plug – New one will go in after checking valve lash.

Turnsignals – Needs a new flasher relay

Sprocket Shaft Seal Leaks - needs a new seal. Should be here tomorrow

Instrument lights – bulbs replaced

Waterpump – rebuilt.

Headlight – flickers
Just a loose connection.


Tail light – doesn’t work
Handlebar wiring was redone - poorly


Parking light – doesn’t work
Parking light deosn't exist. Need to buy a replacement.


Rear shock – shot
Replaced


Carbs – jetted too fat
New jets ordered. 195-170MJ; 52-45 idle jet.


Seat – I hate the white seat
Painted with vinyl interior paint. Not lasting very well.


Luggage – none
Luggage rack built. Top box acquired - but I need to mount it.


Handlebars – too low
Rotated back too far. Moved them forward and I think It'll work


Steering - spooky at highway speeds.
Steering stem had too much slack. Tightened her up.

gravityisnotmyfriend screwed with this post 03-13-2013 at 05:52 AM
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Old 03-13-2013, 10:47 AM   #30
gravityisnotmyfriend OP
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Oh, and I got a package in the mail over lunch.



This one should do the trick! Hopefully I can get that put in this evening.
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