Generator cover

[Lil' Irv]

Should I consider updating with torque limiter or is it even applicable to the '04's? What is the torque limiter intended to protect in the motor? And what is the nasty snap sound I've been hearing on startup if not the torque limiter?

Full of questions this morning...

[MortimerSickle]

Originally Posted by Lil' Irv

Should I consider updating with torque limiter or is it even applicable to the '04's? What is the torque limiter intended to protect in the motor? And what is the nasty snap sound I've been hearing on startup if not the torque limiter?

Full of questions this morning...

FWIW, I know one guy (who worked for the dealer) who fixed (backdated?) his torque limiter by replacing it with the early setup, rather than with the updated model.

A guess on the sound: Those bolts hold the freewheel. They would have been loose for a while before breaking, and might have allowed some slack, to be taken up when the starter engaged the freewheel.

[thumpingaway]

Think I've got the same problem. The stator bolts backed out, shredded into peices and took parts of the starter and flywheel with it. At least that's what I've been told. It's gonna cost about 1200bucks to fix, unfortunatley I'm not that mechanically inclined so I've got to pay the mechanic. Thought about selling the bike before I comitted to fixing it. Hope it's worth it.

[Sadlsor]

Holy crap.
$300 - MAX - for a new alternator, less than $20 for your LocTite or equivalent.
You got the interweb, ya got OC, buy a couple of wrenches and the satisfaction comes free.
NOBODY was a born mechanic... we all learned somewhere, and we all learned by doing.
I actually learned here...on Orange Crush. My trials and travails are documented on this website.


Face your fear... live your dream.

[geometrician]

We should all have our VIN's checked by your dealer- you can call one & we are required to provide you with any & all motorcycle history details & any outstanding recalls or technical bulletins for your bike.

All we need are the last 6 digits of your VIN to check the bike out. Here's the TB0410 that covers your bike

Many long-time owners have been riding through town & visit the shop; when I check their VIN's there are often open bulletins for their bikes. They thought everything had been taken care of until I did a check on the bike.

KTM dealers are also to enter service history when they work on a bike so the repairs/updates can be seen by any dealer (and KTM) anywhere. When you get your bike serviced (valve adjustment, technical bulletin work) make sure to ask the dealer if they updated the motorcycle's service history- which is not the same as a warranty claim process, if applicable

Hate to hear of your problem, I guess you're doubly kicking your own ass now for not replacing those bolts...

[sstewart]

When mine came apart,it ruined the bolt holes in the rotor itself. I had to purchase the whole assembly. I have done 5 oil changes,now we are good.

[Uller]

I just changed a balancer shaft seal (06' 950AdvS w/ 35k mi.) and decided to take a look at the flywheel bolts in the process due to the info provided here. THANKS!!!!

I had 2 of 6 bolts loose and backing out. There was still some thread locker on the bolts that were loose so they weren't all the way out and no damage yet. It was close though.

[v8toilet]

Originally Posted by Uller

I just changed a balancer shaft seal (06' 950AdvS w/ 35k mi.) and decided to take a look at the flywheel bolts in the process due to the info provided here. THANKS!!!!

I had 2 of 6 bolts loose and backing out. There was still some thread locker on the bolts that were loose so they weren't all the way out and no damage yet. It was close though.

On the opposite end of the spectrum I pulled my cover and checked the bolts on my SE. They were installed extremely well. I hope that I got them in as good as the previous installer did.

[men8ifr]

What's involved in checking these bolts? Is it as simple as removing the ganerator cover and visually inspecting?

The OP's bolts has snapped - not really any way to check that unless I were to replace all the bolts as a precaution - what do you guys think - check, replace?

[erappaport]

What's involved in checking these bolts? Is it as simple as removing the ganerator cover and visually inspecting?

The OP's bolts has snapped - not really any way to check that unless I were to replace all the bolts as a precaution - what do you guys think - check, replace?

Presumably just go around and check to be sure they're torqued? I assume that if any are broken they'd spin in place.. I'm getting ready to check this myself. (winter here) Does anyone know the torque value for these bolts?

[GoNOW]

Been putting off checking my 04. Just did today. Bolts are tight, but not very tight. I cleaned them properly, used 648 as it says in the TSB, and torqued them down. Just to be on the safe side.

[MortimerSickle]

Originally Posted by erappaport

Presumably just go around and check to be sure they're torqued? I assume that if any are broken they'd spin in place.. I'm getting ready to check this myself. (winter here) Does anyone know the torque value for these bolts?

Checking the torque could break the bond of the Loctite. Better to remove, re-Loctite, and then retorque.

Be careful in removal: I broke off a bolt head because the old Loctite held too well. I got the rest of the bolt out, but it was not fun.

[GoNOW]

Originally Posted by Lil' Irv

Should I consider updating with torque limiter or is it even applicable to the '04's? What is the torque limiter intended to protect in the motor? And what is the nasty snap sound I've been hearing on startup if not the torque limiter?

Full of questions this morning...

The torque limiter helps save the starter in the case of kick back. The 9x0 has very low rotating mass. That's why it likes to rev so quick. A misfire during starting can cause the engine to rotate backwards and this can create a lot of stress on the starter and the loud clack.
KTM tried to fix the issue with a torque limiter in the later models, but that would slip too soon and caused more problems. They got it right in the next revision.

However, I don't know of anyone who has ever had a problem with the original system without the torque limiter. I noticed my bike only clacks (aka kicks back) if I am starting it when holding the throttle open. If I don't give the bike any throttle when starting, no clack.

[Head2Wind]

First off, bummer deal...

Personally, I would not "update" the starter gear of a early 03-04 bike with a torque limiting style unit. Aside from the gear, the outer cover needs to be replaced with the newer PN as well.

If the cores of the alternator is not messed up, you can have it rewound for far less than a new one and output will be higher too if you want it to be.. I will have to dig for the reference of some guy in the SE USA somewhere, under $100 if I recall correctly.

EDIT: from the 950 HOW: http://www.ktm950.info/how/Orange%20...or_rewind.html

Custom Rewind
2014 Pratt Highway
Birmingham, AL 35214
Phone: 205-798-7282
Tool Free: 800-798-7282

However.... their website URL is dead.. so I don't know if they are still in business or they may just have let the DNS/Web expire and go old school. Try giving them a call and see what happens.

EDIT2:
If you get a hold of Gary, and have him rewind the stator windings, ask to have the "green coating" applied as extra insurance for long life of the stator windings. Cyborg (aka Clif) had them apply to his RXV550 stator, details here: http://www.apriliaforum.com/forums/s...-Stator-Rewind

[erappaport]

Checking the torque could break the bond of the Loctite. Better to remove, re-Loctite, and then retorque.

Be careful in removal: I broke off a bolt head because the old Loctite held too well. I got the rest of the bolt out, but it was not fun.

Ah, yup. That's what I was hoping to avoid. But you make a good point. With my luck I'll find five of them loose, and break the sixth one off.