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Old 02-17-2014, 05:40 AM   #121
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Originally Posted by StevenD View Post
Correct, points to exhaust. Also visible by the size of the valve indents on most pistons.

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Thanks !!

Got the case halfs back together last night. It was kind of a bugger getting the counter shaft through the seal. I hope I did not mess up the seal I put electrical tape around the splines, but I see KTM has a special cap, similar to a fork bullet, to protect the seal.

Anyone had problems with the countershaft seal after splitting the cases?
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Old 02-17-2014, 06:59 AM   #122
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Originally Posted by COXR650L View Post
Thanks !!

Got the case halfs back together last night. It was kind of a bugger getting the counter shaft through the seal. I hope I did not mess up the seal I put electrical tape around the splines, but I see KTM has a special cap, similar to a fork bullet, to protect the seal.

Anyone had problems with the countershaft seal after splitting the cases?
I bet it's fine. Rubber is resilient, as long as you didn't cut it or stretch it too much.
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Old 02-17-2014, 07:24 PM   #123
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Good luck with the rest of the build. I finished mine up a couple days ago and did a short test ride, everything seems ok so I am taking it on a 6,000 mile test ride this Saturday.
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Old 02-17-2014, 07:29 PM   #124
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Good luck with the rest of the build. I finished mine up a couple days ago and did a short test ride, everything seems ok so I am taking it on a 6,000 mile test ride this Saturday.
Sounds like a long day.
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Old 02-18-2014, 05:36 AM   #125
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Good luck with the rest of the build. I finished mine up a couple days ago and did a short test ride, everything seems ok so I am taking it on a 6,000 mile test ride this Saturday.
Good for you!!

Well I guess I will be re-splitting the cases. I cannot get it to shift gears, so I must have got something put in the wrong way.....
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Old 02-18-2014, 11:31 AM   #126
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Good for you!!

Well I guess I will be re-splitting the cases. I cannot get it to shift gears, so I must have got something put in the wrong way.....
Check the shift mechanism is pushed all the way home and the spring roller leaver thing is properly located...
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Old 02-18-2014, 07:09 PM   #127
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Thanks, should be an interesting ride, heading to Pahrump, Nv to the ALtrider Dakar ride with Jimmy Lewis. It's in the 20's F here and a foot of snow, supposed to be in the 40's when we leave.


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Check the shift mechanism is pushed all the way home and the spring roller leaver thing is properly located...
I saw that happened on here somewhere and when I was putting mine back together, I made sure I checked that.

.
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Old 02-22-2014, 05:53 AM   #128
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Ok cases are all back together and going smooth till the inevitable......I have an extra part

This washer was in the bag of clutch stuff and it only seems to fit the transmission main shaft, but I dont see where it is supposed to go, nor find it on the laserfich.

It is a hardened washer and seems to fit perfect on the trans main shaft, it has marking NTN 204E/220.




The large washer for the clutch basket collar has a perfect mark that is the same size as this washer, but it does not seem right......




Any help or ideas??
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Old 02-22-2014, 06:43 AM   #129
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Did you disassemble the main shaft? What's the dimensions?
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Old 02-22-2014, 06:53 AM   #130
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Did you disassemble the main shaft? What's the dimensions?
No, and it will only fit over the threaded portion of the main shaft, not the splines.

Dimensions:
29.5x22.2x2.45

Its hard to see in the picture, but the inside radius of the washer is tapered on the numbered side at about a 45 deg angle, but not the other side.
Thanks for the help

Also, I am now installing the piston rings and the manuel says to install with the "mark" facing the piston head. The oil ring has a mark on it and the middle ring say "top" so that is pretty clear, however the top ring has no marks. Is the top ring installed with the shoulder face of the ring up or down?
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Old 02-22-2014, 07:06 AM   #131
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Originally Posted by COXR650L View Post
No, and it will only fit over the threaded portion of the main shaft, not the splines.

Dimensions:
29.5x22.2x2.45

Thanks for the help
You always go internal first for search reference. I can't find nothing that size in the manual. 22.2 x 30.2 x 1.5 only on the main shaft. The spacer behind the roller bearing has splines...and the other washer is for the nut on the clutch booster.
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Old 02-22-2014, 07:10 AM   #132
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Originally Posted by charlie264 View Post
You always go internal first for search reference. I can't find nothing that size in the manual. 22.2 x 30.2 x 1.5 only on the main shaft. The spacer behind the roller bearing has splines...and the other washer is for the nut on the clutch booster.

Hummmm, I wonder where it came from. I have been looking at parts diagrams and I can find anything that looks similar
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Old 02-22-2014, 07:16 AM   #133
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Does the top ring ends butt up flat? Normaly the shoulder slanting down on the top ring and up on the second.....
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Old 02-22-2014, 07:22 AM   #134
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Does the top ring ends butt up flat? Normaly the shoulder slanting down on the top ring and up on the second.....
I's assuming the shoulder has to point down on the compression ring. However on the middle ring if installed per the manuel and based on how the old piston ring is installed (top one has been removed to check end gap) the middle ring has the shoulder facing down as well.

Do you think both rings should have the shoulder facing down?


Thanks
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Old 02-22-2014, 07:30 AM   #135
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Originally Posted by COXR650L View Post
I's assuming the shoulder has to point down on the compression ring. However on the middle ring if installed per the manuel and based on how the old piston ring is installed (top one has been removed to check end gap) the middle ring has the shoulder facing down as well.

Do you think both rings should have the shoulder facing down?


Thanks
Can you see a small dot on the top ring? The dot faces up. Normally the top ring has the \| < piston. and the second ring /| < piston if that makes sense. Did the rings not come with a diagram? .
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