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Old 10-29-2010, 10:59 AM   #1
gunnerbuck OP
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Joined: Nov 2005
Location: N.V.I, B.C.
Oddometer: 3,794
640s 127,000 service


Here she is last week on her last ride for a while..

Well I started the tear down yesterday to see what the internals look like....

The top end and crank have nearly 90,000 km on them... The transmission/transmission bearings have the full 127,200 km on them....

It's been about 43,000 km since the last valve job... This stretch there has been very little adjustment required to the valves so I'm hoping to get away with just a seat regrind and not have to replace any parts... The head is in transit to the machine shop right now to see...


I noticed a pinhole in the exhaust midpipe near where it joins the muffler....



The piston still looks servicable with only slight rub spots on the front/back of the skirt... The rings are very worn showing a huge amount of ring end gap when measured in the cylinder... I measured the gap on my new set of rings and they are easily within spec...


The bore is still in very good condition and will only require a slight hone to help seat the new rings...

The cam shaft is in very good shape but due to a worn 99 cent pin on the decomp cam I have to replace it with a new unit... KTM does not offer any parts for the decomp so I'll try to find somebody with a shagged cam that I can steal parts from to make the old one serviceable..

The intake roller has near 43,000 km on it so I will change that...

The cam chain & sprockets are still in good shape but will be replaced in spite...

Now to the bottom end...

The clutch is in unbelievably good shape after all those miles with stock gearing.... All the plates and disks measure near or at the spec for new, none have more than 10% wear.... The basket has slight grooving that can be filed out... I have a used clutch with 1/4 the miles so I'll swap out whatever parts show the most wear...

The conrod bearing and crank end bearings are tight... The mainshaft bearings are good to go....


But I detect some wiggle in the countershaft...

The wiggle is in the small needle bearing on the idle end of the countershaft... These are the bearings I was worried about as they have to spin much faster than the bigger roller bearings on the other end of the shafts... I will replace the needle basket on the mainshaft as well while I have it apart...

Next step is to pull the engine and split the cases...


f

gunnerbuck screwed with this post 11-28-2010 at 07:47 PM
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Old 10-29-2010, 11:08 AM   #2
30Bones
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Not to start a debate by any means, but are all the miles put on by you and what oil did you use and how often did you change it?

Very impressive!
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Old 10-29-2010, 11:33 AM   #3
makazica
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127 000



I really wish mine's gonna look like that with 127 000 km....



Carry on....



M.
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Old 10-29-2010, 12:02 PM   #4
gunnerbuck OP
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Quote:
Originally Posted by 30Bones
Not to start a debate by any means, but are all the miles put on by you and what oil did you use and how often did you change it?

Very impressive!
Yes, all the miles are mine, bought the bike new in Aug 04...

After I replaced the top end at around 40,000 km I decided to switch to Rotella 5/40 synthetic ... I change oil every 5000-6000 KM and alternate filters changing only one per change.... I sometimes drag out the change interval a little longer if I'm on a long trip... No debate, for me Rotella is the oil of choice..
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Old 10-29-2010, 12:12 PM   #5
wallache
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I love these kind of threads!

For those of you that are not metrically inclined, 127,000 km is almost 79,000 miles. Pretty amazing.
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Old 10-29-2010, 01:50 PM   #6
Tseta
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Wow, impressive kilometers for sure, and I'm sure they haven't been "easy" either.

Are you planning to change any other bearings or components inside the cases?

http://www.kotikone.fi/smothered/mystery.jpg

http://i302.photobucket.com/albums/n...IMG_1412-1.jpg

Gunner, I now understand what you meant by the "mystery" plate being a part of the case casting on newer LC4 models.

Good pictures, please remember to take plenty more and post them up, if you have the chance.

It will be interesting to see this project and compare it with the older 1998 LC4 that I have torn apart.

Cheers,

Tseta
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Old 10-29-2010, 03:00 PM   #7
pingo
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/subscribed

Great thread, and great bike!
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Old 10-29-2010, 04:18 PM   #8
gunnerbuck OP
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The cam is in perfect shape except for this little pin that engages the decomp... It's supposed to be flat on top...


Engine out cases split...



Gearbox out case halves empty..



Measuring countershaft small end compared to mainshaft small end.... The countershaft is shot...



Failed countershaft needle bearing


Out comes the spare parts motor for it's transmission...


This is turning into a big project....


f
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Old 10-29-2010, 05:36 PM   #9
gunnerbuck OP
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Quote:
Originally Posted by Tseta
Wow, impressive kilometers for sure, and I'm sure they haven't been "easy" either.

Are you planning to change any other bearings or components inside the cases?

Tseta
I think that I am going to change all the bearings in the cases for new as they have a lot of miles on them.... The gear and shift support needle bearings out of my spare engine should be in good enough {I hope} to use as they have less than 20,000 km on them...

gunnerbuck screwed with this post 10-29-2010 at 07:29 PM
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Old 10-29-2010, 08:15 PM   #10
Luke
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Quote:
Originally Posted by gunnerbuck

... KTM does not offer any parts for the decomp so I'll try to find somebody with a shagged cam that I can steal parts from to make the old one serviceable..

I've got a junk camshaft that you're welcome to. One of the lobes is trashed and the decomp lobe is gone, but the pins look to be in good shape. I have no idea how you'd get them out of the camshaft, though. Maybe just grind away the camshaft around the pins. Then drill the pins out of your camshaft.
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Old 10-29-2010, 09:26 PM   #11
gunnerbuck OP
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Maybe heat the camshaft and press the pin out....
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Old 10-29-2010, 09:28 PM   #12
gunnerbuck OP
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Pulled my spare engine apart and its gearbox looks to be in excellent condition:Things are looking up.


Now I am working with an outfit online to get all the case bearings at reduced prices...
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Old 10-29-2010, 11:21 PM   #13
bmwktmbill
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Nice work Gunner, darn KTM and their needle bearings!!!
bill
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Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 10-30-2010, 12:45 AM   #14
Tseta
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Note to self: must acquire a spare engine...

Gunner, while you have both of your engines open, do you think you could take a look at the (clutch) main bearing retaining plates and see if they show any wear?

http://www.advrider.com/forums/showthread.php?t=617218

-T
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Old 10-30-2010, 08:11 AM   #15
gunnerbuck OP
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No wear on either retaining plate, the 127,000 motor has a bit of paint scuffed and from the other motor the part looks new...

gunnerbuck screwed with this post 10-30-2010 at 06:57 PM
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