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Old 05-31-2011, 07:58 PM   #6361
Gerst
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Quote:
Originally Posted by mxchamp View Post
It's too bad you didn't post photos of your seal change job.

I am probably mistaken but I don't think that there is one in the index.

http://www.advrider.com/forums/showthread.php?t=102920

It's in there, actually it's how I learned


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Old 06-01-2011, 01:29 PM   #6362
WIsixfitty
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I'll just put this here cuz...i dunno I need halp.

riddle me this or I am crazy or option #3.

Ok so about 6 mounths ago I pulled my top end off for new cam follower bearings, water pump rebuild and roller bearing upgrade to my 02.

I vaguely remember at the time having a problem with my pump coming off even when I was pretty sure it was at tdcc.

Now when it is at tdcc the slot in the cam bolt is horizontal. The only way to get it verticle for pump install is at bdc.

I did not remove the cam or anything off the crank itself. Just the clutch etc for the bearing change. Since nothing was removed in the crank and valve train it should still be timmed and in synch, correct?

The clucth is a seperate system.

Did I screw up or miss something?
Am I crazy?
Should I drink more beer and just put it back together?
option#4



signed,
two strokes are simple like me in WI.
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Old 06-01-2011, 03:41 PM   #6363
gunnerbuck
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The slot in the pump often will not point upward with the engine at TDC... You need to roll the engine till the slot points up for pump removal and installation and then roll the engine back to TDC with the cams pointing down to install the rocker cover..
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Old 06-01-2011, 03:54 PM   #6364
WIsixfitty
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Quote:
Originally Posted by gunnerbuck View Post
The slot in the pump often will not point upward with the engine at TDC... You need to roll the engine till the slot points up for pump removal and installation and then roll the engine back to TDC with the cams pointing down to install the rocker cover..
ok this relieves my confusion.

Thanks!
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Old 06-01-2011, 11:34 PM   #6365
makazica
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Quote:
Originally Posted by gunnerbuck View Post
The slot in the pump often will not point upward with the engine at TDC... You need to roll the engine till the slot points up for pump removal and installation and then roll the engine back to TDC with the cams pointing down to install the rocker cover..

I don't know how it's set up on other LC4's but the slot on mine is NEVER horizontal when the piston is at TDC!

M.
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Old 06-02-2011, 02:43 AM   #6366
jonnyw
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Guess what I am riding?

The proper way to do a water crossing.
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Old 06-02-2011, 07:06 AM   #6367
mxchamp
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Talking

Quote:
Originally Posted by Gerst View Post
http://www.advrider.com/forums/showthread.php?t=102920

It's in there, actually it's how I learned


DoH!!!

I just had my entire engine rebuilt. That seal was leaky and so was the kickstart/shift shaft seal.

No leaks on my 640 no more!!!!!

Only cost me $2250 bucks!
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Old 06-02-2011, 09:29 AM   #6368
Gerst
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Quote:
Originally Posted by mxchamp View Post
DoH!!!

I just had my entire engine rebuilt. That seal was leaky and so was the kickstart/shift shaft seal.

No leaks on my 640 no more!!!!!

Only cost me $2250 bucks!

mx, mind sharing what the mileage was? Was this a preventative rebuild? If not, were there signs she was going before she went? I'm new to mechanical things and trying to learn what I can (I need a motorhead neighbor)

Got a thread?
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Old 06-03-2011, 02:12 AM   #6369
blanc
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Just bought my first ktm adv a 2001. Have a few questions

http://www.advrider.com/forums/showthread.php?t=693986
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Old 06-03-2011, 08:07 PM   #6370
mxchamp
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Talking

Quote:
Originally Posted by Gerst View Post
mx, mind sharing what the mileage was? Was this a preventative rebuild? If not, were there signs she was going before she went? I'm new to mechanical things and trying to learn what I can (I need a motorhead neighbor)

Got a thread?
Hey Gerst, here's a little story for ya.

I bought the bike used from a Marine up in Minneapolis with 24,000 miles indicated on the very inaccurate IMO. Paid too much for it seeing how much 07's are going, but was only 2 hours away, not sitting in Cali. She ran real good though coming home from Minneapolis. I just had to kick start her only.

Anywhoo, first test ride the electric starter would not work. Made one heck of a noise. This is my 3rd LC4 so I wasn't worried. I read the index and knew it was the starter clutch.

Fast forward to fixing starter clutch fixed it no problem. Except one problem was that I didn't have the proper GIANT torque wrench to torque her down properly. So I hit her 3 times with a big hammer and said hey it's all good.

Rode her around for a week or two and my conscience got to me. Opened her up again with the proper torque wrench and I should have left her alone.

Turns out this is what I think happened. While attempting to torque her properly, I removed the little allen screw in front of the engine took out the washer and put her back in to hold the connecting rod so I could torque the flywheel. This is a BIG NO NO! She was quiet before the re-torque, instant banging after the re-torque.

I damaged the connecting rod from putting that much torque on the flywheel nut. (I found this out after getting a proper owner's manual and it says it right there in black in white) So from now on put a 1 inch dowel between the spokes of the back wheel in 5th gear to hold the engine. Never use that little screw for nothing but to hold the engine in place while adjusting your valves.

The bike still ran when I rode her to the local KostsTooMuch dealership a week before West Fest in Darby MT. My mechanic told me to shut her down and not ride her again. The engine was bangin harder than a screen door in a hurricane. Thank goodness I had my trusty X challenge.

To finish up with this long drawn out story. The connecting rod was still within KTM specs. She was a little on the higher side but still good. The piston was bangin the side of the cylinder. Sooooo she needed to have the cylinder re-nickel plated. That's why the high cost. I kept everything to stock so I didn't have a hard time finding parts later in life.

I also did some other thing's to her like a new clutch cover with site glass to easily read the oil level, new oil pumps, water pump rebuild, some other little odds and ends.

But she has all new bearings, seals, gaskets and I think I even have a brand new main bearing because I replaced the main bearing before the engine rebuild.

It was all worth it because I love this bike! And the governor will never let me get another bike again.

I hope this helps and I didn't put you to sleep!
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Old 06-03-2011, 10:37 PM   #6371
johnno950
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The tdc bolt locates into the crankshaft.
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Old 06-04-2011, 12:14 AM   #6372
makazica
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Quote:
Originally Posted by mxchamp View Post

I damaged the connecting rod from putting that much torque on the flywheel nut. (I found this out after getting a proper owner's manual and it says it right there in black in white) So from now on put a 1 inch dowel between the spokes of the back wheel in 5th gear to hold the engine. Never use that little screw for nothing but to hold the engine in place while adjusting your valves.

Thank goodness I had my trusty X challenge.
Not only black in white, but I believe that info is written in BOLD letters in the manual.

Why is the X challenge so trusty? You don't mess around it without a manual?



Just messing with you.........

M.
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Old 06-04-2011, 09:08 AM   #6373
Gerst
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Thanks for the story mx,
That's a hard lesson to learn but it sounds like you took it in stride, have a practically new engine and taught a stranger on the internet something.
I should buy a service manual! Anyone know where I can get a spiral bound hardcopy?
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Old 06-04-2011, 07:32 PM   #6374
mxchamp
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Bluhduh

Quote:
Originally Posted by johnno950 View Post
The tdc bolt locates into the crankshaft.
Wherever it goes, I broke it.
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Old 06-04-2011, 07:34 PM   #6375
mxchamp
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Quote:
Originally Posted by makazica View Post
Not only black in white, but I believe that info is written in BOLD letters in the manual.

Why is the X challenge so trusty? You don't mess around it without a manual?



Just messing with you.........

M.
I don't have an owner's manual. Never got one with the bike. I saw the BOLD wording at the dealership, after the damage was already done.

The X challenge is the bike that got me to Darby Montana and back last summer. That Rotax engine is bulletproof. Never had a problem with her the entire 16,000 plus miles that I put on the girl.

She is now happy down in Dallas Texas with her new owner.

How do you do multiple "quotes"???
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