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Old 10-15-2010, 03:42 PM   #16
grimripper
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It's great to watch someone who knows what their doing
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Old 10-15-2010, 04:21 PM   #17
imaybail
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Ooh, Lc4

Yeah, I'm subscribed fershur.
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Old 10-15-2010, 07:56 PM   #18
wrk2surf
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its funny the way the 02 has the newer color bottom end .. cases etc but no high flow head.. the older black head... in between year..

we just made a stand as well.. nice one you got..

make sure when you get the gasket kit it has at least two colors case gaskets as my buddy a machinist had problems shimming the crank and his only had one black gasket ... mine had two or three thicknesses including a green one.. we have actually sent both motors to a ktm shop (malcolm smith) as the shimming is not going easy.. maybe on our 3rd motor we will understand the black magic of shimming...

always good work tseta
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Old 10-16-2010, 02:57 AM   #19
makazica
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Quote:
Originally Posted by wrk2surf
its funny the way the 02 has the newer color bottom end .. cases etc but no high flow head.. the older black head... in between year..

we just made a stand as well.. nice one you got..

always good work tseta
My friend had an '02 but his didn't have the gray engine, it was completely black, same as my '01....interesting....

Not to hijack Tseta's thread but how difficult would it be to mount a High flow head to a '01 or '02 bike?

And yes, always good work!!

M.
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Old 10-16-2010, 05:20 AM   #20
laramie LC4
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Quote:
Originally Posted by wrk2surf
.. maybe on our 3rd motor we will understand the black magic of shimming...
aint that the truth. that was the hardest part when i rebuilt mine as well. plus, unless you have the magic KTM tool, you only get one shot. if you didnt shim right the first time, getting those bearing races back off is not easy. we tried everything. i finally sent mine to Chip and had him do it for me, he had the correct tool and it took him a few secs.

love the engine frame/stand you built, that will make life a lot easier.

laters,

laramie
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Old 10-16-2010, 10:23 AM   #21
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grimripper: I don't really know what I'm doing. I just poke around with a few wrenches and hope I don't break anything in the process.

imyabail:

wrk2surf, laramie & makazica: The blue adventure is a 1998, with the gray main engine block and a black head. I will have to read up on this shimming business before the time comes to actually do it on this engine.

I have heard that there is some interest in the measurements of the engine stand I made. Seeing as KTM wants around 800 big ones for the "official" LC4 stand, I can see why people are interested. However, I must say that the stand I built is quite crude and has been "hammered" to fit in many places. However, due to popular demand, I will post some of the main dimensions later on.

-----

Today's main focus was on the swingarm and rear suspension of the blue adventure. Many of the smaller bolts holding the chain guards etc. on the swingarm were quite corroded and generally in a bad condition. So, the tools of the trade to get these bolts out were a dremel with a cutoff wheel and a portable drill with high quality drill bits.





The shafts seals on the swingarm were easy to remove with a tire spoon.



You can see that the bearings and the bushings are in a miserable condition. I will be replacing all the components here.





I then pressed out the actual needle bearings on both sides of the swingarm by using a big vise and a clever combination of sockets. They came out without a problem.



I also cleaned and lubricated the linkage piece. The bearings and bushings here were in much better condition. I only replaced the shaft seals as a few of them were quite tired looking.



The rear shock absorber was also cleaned. It will be taken to the local dealer for maintenance as the bottom adjuster seems to be somehow messed up. I'm sure fresh oil and nitrogen can't hurt it either.

Tomorrow I will be installing the new bearings onto the swingarm, and perhaps start on the engine disassembly.

Cheers,

Tseta
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Old 10-16-2010, 09:03 PM   #22
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This is way better than football!!!
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Old 10-17-2010, 10:55 AM   #23
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Another long day at the garage. Some more unpleasant surprises were found this time.

Things started off well enough. I pressed in new bearings to the swingarm, using a similar socket trick on the big vise.





Much better. The bearings were then greased well and the stop disks, bushings and seals were installed as well.

Then onto the engine itself.



When removing the cylinder head top section, I noticed that a previous owner had stripped the threads in the head for one of the mounting bolts.



I then got the cylinder head top section, waterpump and camshaft removed.





Then it was time to remove the cylinder head.





Next, the cylinder itself.









The piston skirt looks good, as does the cylinder. No scratches.

I then took out the piston pin circlips and pressed out the piston pin.



This is a neat trick I learned somewhere on the 'net for keeping the rod from knocking onto the cases:



I then started cleaning the piston and found something quite intriguing.



See it?

What about this discoloration?



Sure enough, there is a hairline crack that goes through the piston.



My guess is that the discoloration is caused by some of the combustion gases leaking through that crack onto the lower side of the piston. Not good...

-T
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Old 10-17-2010, 02:48 PM   #24
laramie LC4
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wow, good catch. that could have cause some issues in the near future.....

laramie
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Old 10-17-2010, 05:21 PM   #25
wrk2surf
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dont forget to rebuild the waterpump.. while you are waiting for a piston
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Old 10-17-2010, 07:05 PM   #26
bmwktmbill
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Tseta,
Did you test the crack with kerosene to make sure it is all the way through?

In the picture of the piston underside I have a difficult time seeing the crack.

There is quite a bit of carbon on the piston top, when you get to the carb I'd be interested to know what the jetting and needle position are?
bill
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Old 10-17-2010, 09:10 PM   #27
Tseta OP
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The crack does indeed go all the way through the piston.

I will check the jetting today.

I think I will find out how bad the damage is in the bottom end of the engine before ordering parts or rebuilding other components.

Cheers,

Tseta

Edit. Whoops, spelling is hard...

Tseta screwed with this post 10-18-2010 at 02:51 AM
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Old 10-18-2010, 02:38 AM   #28
makazica
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Quote:
Originally Posted by Tseta

The crack does indeed go all the way through the cylinder.

I will check the jetting today.

I think I will find out how bad the damage is in the bottom end of the engine before ordering parts or rebuilding other components.

Cheers,

Tseta
I know you meant "all the way through the piston".....just not to get people confused.

Why do you think there is going to be damage in the bottom end?

M.
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Old 10-18-2010, 02:52 AM   #29
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Quote:
Originally Posted by makazica
Why do you think there is going to be damage in the bottom end?
I think there is damage in the bottom end because of all the bits that came out with the oil (the bearing cage rivet piece, the corners of some gear wheels, etc.).

-T
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Old 10-18-2010, 03:50 AM   #30
makazica
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Quote:
Originally Posted by Tseta
I think there is damage in the bottom end because of all the bits that came out with the oil (the bearing cage rivet piece, the corners of some gear wheels, etc.).

-T
Right, sorry, I forgot the start of the story....
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