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Old 12-10-2012, 06:37 PM   #3391
gunnerbuck
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Originally Posted by Boon Booni View Post
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...
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Old 12-10-2012, 07:35 PM   #3392
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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.
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Old 12-10-2012, 08:16 PM   #3393
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Quote:
Originally Posted by gunnerbuck View Post
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.



Quote:
Originally Posted by juames View Post
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.
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Boon Booni screwed with this post 12-10-2012 at 08:50 PM
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Old 12-10-2012, 10:41 PM   #3394
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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
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Old 12-10-2012, 11:48 PM   #3395
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Originally Posted by Boon Booni View Post
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?
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Old 12-11-2012, 05:40 AM   #3396
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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.

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Old 12-11-2012, 06:45 AM   #3397
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Originally Posted by juames View Post
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.
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Old 12-11-2012, 07:43 AM   #3398
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Originally Posted by juames View Post
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?
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Old 12-11-2012, 07:52 AM   #3399
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Haven't opened it up yet, but it's around 30,000kms now so its probably ready.

Quote:
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have you checked your cam rollers while you're in there?
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Old 12-11-2012, 07:55 AM   #3400
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Haven't opened it up yet, but it's around 30,000kms now so its probably ready.
Do it.

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Old 12-11-2012, 08:33 AM   #3401
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Worth doing both intake and exhaust?
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Old 12-11-2012, 08:35 AM   #3402
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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.
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Old 12-11-2012, 03:11 PM   #3403
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Worth doing both intake and exhaust?
Yes.
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Old 12-11-2012, 04:38 PM   #3404
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Old 12-11-2012, 04:44 PM   #3405
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Do it, don't end up like I did
Or me.
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