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Old 11-28-2011, 05:45 PM   #31
gunnerbuck OP
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Quote:
Originally Posted by bmwktmbill View Post
Oh boy, David.
What a nasty job.
Now I know why I regrease everything every 10K miles as part of my usual routine.

My swing arm bolt and bearings suffered some from neglect but I got to it in time to save them.

Are yours salvagable?
bill.
As far as I can tell all the other shafts and bearings are serviceable, but you never know as this bike has not seen too much love...
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Old 11-30-2011, 06:03 AM   #32
meat popsicle
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Is this a good sign that the LC4 did not require excessive service? Since you bought another one to work on too. Or is this a sign that you luv your garage?

Real question: I didn't notice in the thread: how many miles on the bike?
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Old 11-30-2011, 07:25 AM   #33
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This bike has near 19,000 miles {28,000 KM} on it, less than 1/5 the use of my prime bike...

At times I think about going back to my original idea to use this bike as a parts platform... But it's a catch 22 as half the parts that I'll need off this thing are probably shot due to lack of lube...
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Old 11-30-2011, 04:26 PM   #34
meat popsicle
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Makes me feel better about my maintenance work - my 20,000+ mile LC4 looks much better. (but I do need to get at a few things... :)

Maybe the parts you don't think you'll need will be the expensive ones you'll be happy to scavenge off this one. But I'm thinking you like a challenge, and this one should be full of 'em.
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Old 11-30-2011, 10:20 PM   #35
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Progress or not..

This afternoons weather was favorable so I spent it outside with my container of varsol.... I cleaned up the links, shafts and swingarm as best I could, inspected all the bushing and bearings and found them to be serviceable... I repacked them with grease being very carefull not to loose the needles out of the swingarm as they are not contained... The secret is to slide the bushing out each way only enough to be able to smear grease onto the needles and still have the bushing hold the ends in place... Do one side first and then slide the bushing the opposite way to expose the other side... I have done this about every 1.5 years on my prime 640 an am still on the original swingarm bearings....


Swingarm and links back in place

The back brake line shield tube was worn through at the support clips so I trimmed out the bad spots and slid the tube down to put a fresh part on the clips... A bit of that pretty black tape holds the tube together...

The bike was missing the brake line support bracket so I made one up out of the old chainguard and used zip ties to hold the line in place...

I greased the brake slider pins and added new pads as the old ones showed some funky wear...

The old chain guard was busted up so I installed a replacement that I had kicking around...

The under fender was missing some hardware and the shock protector extension had a hole worn through it so I replaced both with some better ones that I picked up in an airbox deal...

I then installed the rear wheel and found the axle adjustment bolts to be seized up... About 20 minutes of back and forth action with a wrench along with plenty of lube freed them up good enough, on my prime bike I smear grease on the threads periodically to keep this from happening....

Once the wheel was installed I gave it a spin and noticed right off that the brake disk is bent... You can usually do a rudimentary fix by just hammering it flat... Instead I dug through my spare parts and found a solid disk that was in much better shape...

This will go on tomorrow, all for now...

f

gunnerbuck screwed with this post 12-01-2011 at 11:10 PM
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Old 12-01-2011, 08:45 PM   #36
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Swapping out the disk...


Off comes the wheel, disk and a bit of a thread cleanup..

Clean the bolt threads as well...

The 2 disks side by side are tight together on one side...

The other side shows a pretty bad warp, probably caused by contact with a boulder or stump...

A bit of thread locker...

All back together... This solid disk is a numbered part for the EXC line, but will also fit the LC 4s as KTM run a lot of the same size harware throughout their lineup...
f
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Old 12-08-2011, 12:22 AM   #37
gunnerbuck OP
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Muffler


I picked up a KTM SM muffler, looks like it will be an easy fit....

Before mounting it I decided to tear it apart and do a few mods...

The previous owner said the silencer was quite loud... The burnt out packing is partly to blame...

I assembled a few items out of my shed junk boxes {glad I never throw some stuff away} that will go into the making of my quiet core/spark arrestor :We have an outer race from a bearing which provides a friction fit in the silencer end cap...

Then a chunk of 1 1/8" ID pipe with a friction fit expansion collar to weld to the bearing race...

This unit will then slide into the endcap and restrict the flow {and hopefully cut noise} from 1 3/8" down to 1 1\8"... A spark arresting screen will be fitted into the end cap before sliding the reducing tube in place... I'll trim back the pipe so there is about 4" of exposure out of the end cap and into the silencer body... I'll try to get some pictures of the final product...

All for now....

f
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Old 12-24-2011, 08:07 PM   #38
gunnerbuck OP
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Merry Christmas All...

I managed to find a bit of spare time today to finish my muffler project...


Here is the quiet core after some welding and cutting...

My welds are ugly but it doesn't matter as they will be hidden away...

Here is the final product ready to install after welding the noise deflector cone and a bit more grinding...

I came up with a friction fit tube that slides in the end to hold the sparky screen in place...



Packing the muffler and end cap...

The secret is not to jam this stuff in too tight as the packing needs a bit of air pockets to more effectively absorb the sound...

Here is what it looks like in place after riveting...

As most of the area I ride in is forested land having a spark arresting screen in place is an important measure, especially during the dry summer season...

All for now....

f

gunnerbuck screwed with this post 12-24-2011 at 08:13 PM
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Old 12-25-2011, 05:41 AM   #39
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Old 12-25-2011, 11:37 PM   #40
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I managed to sneak in a bit more bike time after tonights turkey dinner...


I wanted to fix a few wiring issues on the back end before mounting the racks..I scrounged up a working OEM turn signal to match up to the other side...

A bit of solder to ensure good contact...

Fixed a few issues between the fenders and managed to get the plate lamp working...

With the fender work done it was onto mounting the racks...

With quite a bit of fiddling and tweaking I managed to get the racks bolted in, having a bent up sub frame didn't help the alignment process....

Before I quit for the night I decided to see how the bike looked in black...

With some fresh paint on the fairing and a bit of polish on the old plastics I don't think it will look too bad...

I have a six days front fender in black with green metal flake to try yet...

All for now...
f
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Old 12-27-2011, 04:15 AM   #41
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Nice work mate,I agree black looks cool


Keep up the good work,an interesting rescue of a classic bike!
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Old 12-27-2011, 08:17 AM   #42
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Quote:
Originally Posted by gunnerbuck View Post
Before I quit for the night I decided to see how the bike looked in black...
With some fresh paint on the fairing and a bit of polish on the old plastics I don't think it will look too bad...

I have a six days front fender in black with green metal flake to try yet...

All for now...
f
Great job!!! Ya once the other plastics are waxed and buffed, it will look like new. These 640's are still one of my favourite bikes!!

Cheers,

Cumbacheech
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Old 12-27-2011, 07:47 PM   #43
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Once the front fairing is repainted ,an some good ol' shiny dressing on the side plates an rear fender ....BAM,,it will look super sharp...NICE !!!!
Paul.S
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Old 12-27-2011, 07:51 PM   #44
gunnerbuck OP
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Quote:
Originally Posted by shevthump914 View Post
Once the front fairing is repainted ,an some good ol' shiny dressing on the side plates an rear fender ....BAM,,it will look super sharp...NICE !!!!
Paul.S
I'll try to get the fairing over to you soon for paint, I like the job you did on the tank...

David...
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Old 12-28-2011, 12:27 AM   #45
izom
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..yeah now GB got a spare bike !!! ;-))

thanx dude for the good pics reworking the linkage a.s.o.!

- im always shocked how some guys messed up there "beloved" bikes!?

greetz
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