KTM LC4 (640) Thread Index

[Boon Booni]

Originally Posted by biensur22

Why don't you do a reverse lookup. Check the part numbers on the seals/bearings you pulled from your existing wheel and cross reference them through some michrofiche (i know you can do it through munn-racing's interface accessed through KTM-talk). That might give you an idea what wheel you're dealing with and replacement parts.

Part number for the seals and bearings match 2003 250EXC, 450/525 sx, mxc, exc. Not sure about the axle diameter for those bikes, so I can't be sure if the bushings will work.

I'll keep looking.

[gunnerbuck]

Originally Posted by Boon Booni

Need some help.

Replacing the front wheel bearings and seals on my 2002 640 Adventure. Bearings are coarse. Seals and bushing surface are shot.

This is what I've got comparing the old parts (top) to the new parts (bottom)...



The new bearings fit perfectly on the axle, the old bearings ride on a bushing which fits on the axle. New seals and bearings won't fit the hub bore.

Any ideas on what I need to order to redo the front end? Anyone want to buy spacers, seals and bearings for a 2002 640 ADV?

Thanks...

FWIW, also ordered bearings and seals for the rear wheel, and everything looks right.

Looking at your old take out units, it appears to me that your bike has the recall front wheel with the Excel rim.... When they recalled the original wheel in 03 due to spoke breakage problems they replaced it with the wheel off the RFS bikes and made the adapter spacers for it to fit the 640 A...

What you need to do is order a bearing and seal kit for a 03 KTM 450/525, even an aftermarket kit will work... You will then need to order the spacers through KTM : part #584 09 012 000... These spacers will take a couple of weeks to arrive as they are a special order item...

[juames]

My '02 has the top bearings and spacers. Just bring the old bearings to a bearing shop and they can match them up for you, and clean up the spacers and re-use them...worked for me.

[Boon Booni]

Originally Posted by gunnerbuck

Looking at your old take out units, it appears to me that your bike has the recall front wheel with the Excel rim.... When they recalled the original wheel in 03 due to spoke breakage problems they replaced it with the wheel off the RFS bikes and made the adapter spacers for it to fit the 640 A...

What you need to do is order a bearing and seal kit for a 03 KTM 450/525, even an aftermarket kit will work... You will then need to order the spacers through KTM : part #584 09 012 000... These spacers will take a couple of weeks to arrive as they are a special order item...

Yes it does have the Excel Rim.

Thanks.

Originally Posted by juames

My '02 has the top bearings and spacers. Just bring the old bearings to a bearing shop and they can match them up for you, and clean up the spacers and re-use them...worked for me.

Yep, I was thinking about cleaning up the spacers, or perhaps taking them to a machine shop and seeing what it would cost to machine them down and having a stainless slip ring made for the seal surface.

[gunnerbuck]

I had my machinist friend make me up a set of spacers for my project bike after I had the wrong parts sent from a KTM dealer as outlined in this thread:http://advrider.com/forums/showthread.php?t=839121

[HydroDog]

Originally Posted by Boon Booni

Yes it does have the Excel Rim.

Thanks.





Yep, I was thinking about cleaning up the spacers, or perhaps taking them to a machine shop and seeing what it would cost to machine them down and having a stainless slip ring made for the seal surface.

Why not just go to your favorite bearing store and get a speedy sleeve to fit the seal area?

[juames]

Anyone know if there is a water pump rebuild kit available, or do I have to order all the part separately?

Planning on doing my first water pump rebuild on my '02, and not sure of what parts I need.

[tdreyer]

Originally Posted by juames

Anyone know if there is a water pump rebuild kit available, or do I have to order all the part separately?

Planning on doing my first water pump rebuild on my '02, and not sure of what parts I need.

Did you not look at the first page of this thread? It is the index for most everything LC4. Anyway, look here. First post gives you the parts breakdown. Bearings and seals can be had cheaper if you've a supplier near by. Just order 2 of everything so you'll have a kit waiting on the shelf for any future emergency or an inmate in need.

[skibum69]

Originally Posted by juames

Anyone know if there is a water pump rebuild kit available, or do I have to order all the part separately?

Planning on doing my first water pump rebuild on my '02, and not sure of what parts I need.

have you checked your cam rollers while you're in there?

[juames]

Haven't opened it up yet, but it's around 30,000kms now so its probably ready.

Originally Posted by skibum69

have you checked your cam rollers while you're in there?

[enduro0125]

Originally Posted by juames

Haven't opened it up yet, but it's around 30,000kms now so its probably ready.

Do it.

DAMHIK

[juames]

Worth doing both intake and exhaust?

[Boon Booni]

Originally Posted by HydroDog

Why not just go to your favorite bearing store and get a speedy sleeve to fit the seal area?

I'd never heard of a speedy sleeve before. That's exactly what I'm looking for.

Good idea.

[enduro0125]

Originally Posted by juames

Worth doing both intake and exhaust?

Yes.

[skibum69]

Do it, don't end up like I did