KTM 640 Horrible engine noise!!!! - Page 2

gunnerbuck · 02-09-2013, 04:02 PM

What year is your bike?

klxmack · 02-09-2013, 06:38 PM

Ha ha, Hold it up to the phone again! wait, it sound like opportunity knocking.

If motor was quiet, then got loud and you have oil in the motor, then its tear down time.

Taking a pole and getting advise is kinda silly.

Sorry my friend, shit happens.

Cheers

gunnerbuck · 02-10-2013, 06:49 AM

[quote
Refer to that thread now, so far no end float in either side of crank, clutch seems fine. Counter balance outer case bearing is fine, but without removing there seems to be a lot of play on the inner bearing. Waiting for tools to arrive to remove. I have a sneaking suspicion it is the counter balance and the cam rockers.quote]

There doesn't have to be end float on either end of the crank for the bearing to be bad, the running surface of the races only need to be galled... If you have the head/cylinder off you can spin the crank rapidly around in the case and listen for the grinding noise to indicate a rough bearing...

As for the balancer being shot, I have a sneaking suspicion that you won't get away that easy, but one can only hope...

moto_psycho · 02-10-2013, 07:10 AM

Turning it over by hand with the spark plug out doesnt give me any noise, atm I am suspecting counter balance and possibly cam... just waiting for strap wrench to arrive to get clutch off

Boon Booni · 02-10-2013, 07:17 AM

So, what's the oil look like?

moto_psycho · 02-10-2013, 08:43 AM

Fair amount of pulverised steel on the plug,

corrr

Kawidad · 02-10-2013, 12:23 PM

Quote:

Originally Posted by moto_psycho

Fair amount of pulverised steel on the plug,

corrr

Well that ain't good.................

wrk2surf · 02-10-2013, 01:38 PM

my money is on a bad big end .. scored cylinder

bmwktmbill · 02-10-2013, 09:52 PM

Quote:

Originally Posted by moto_psycho

PayPal have locked my account until £5 clears, so hopefully mid week I will have a strap wrench to take the clutch basket off, afterwards I will take the counter shaft out and start her up again, I'll make the same video again we'll see what wee get!

Do you have an air wrench?
To loosen the nut I'd heat it with propane first in case someone used red loctite on it, then put it in gear and have someone stand on the rear brake and knock it loose with the air or a hammer.

Think that should work if the chain is on...or does the basket just spin?

bill

moto_psycho · 02-10-2013, 09:54 PM

If that is the case, am I better off getting just a new bearing, or buying a whole crank assembly?

The noise was definately loudest at the front left of the engine. It actually seemed quite quiet when you got your head right up to the right side.... but we will see....

ericGSsti · 02-11-2013, 05:05 AM

Not sure how relivent it is to you but I posted I had similar knocking noise to your bike in mine. Thought it was clutch related as it sounded noisiest there. Dropped the oil and found metal on the sump same as yourself, no obvious sign of wear anywhere. He pulled the starter cover and the ring gear on the motor had shredded. So for me easy fix. Replace gear and ring bearing on the starter.

moto_psycho · 02-11-2013, 07:50 AM

Was the bike still starting fine on the button?

moto_psycho · 02-11-2013, 08:40 AM

Also, has anyone ridden their 640 long term without a balance shaft? Generally I don't care about vibrations, and just imagine... 0.0001 extra hp at the rear wheel!

ericGSsti · 02-11-2013, 09:19 AM

Yes started first time every time.

MORT666 · 02-11-2013, 09:44 AM

SOUNDS ok to me.

View Results: What is the horrible noise?
Cam chain tensioner	2	5.13%
Camshaft rockers / bearings	10	25.64%
Big end	10	25.64%
Gearbox main shaft bearing	3	7.69%
Crankshaft bearings	8	20.51%
Other?	6	15.38%
Voters: 39. You may not vote on this poll

02-09-2013, 04:02 PM	#16
gunnerbuck I.Hopp. Joined: Nov 2005 Location: N.V.I, B.C. Oddometer: 3,078	What year is your bike? __________________ 640 A x 2

02-09-2013, 06:38 PM	#17
klxmack boss of the box Joined: Nov 2006 Location: Toronto Oddometer: 463	Ha ha, Hold it up to the phone again! wait, it sound like opportunity knocking. If motor was quiet, then got loud and you have oil in the motor, then its tear down time. Taking a pole and getting advise is kinda silly. Sorry my friend, shit happens. Cheers __________________ Laws of the motorcycle universe. 1. Ya don't need a faster bike, just ride faster. 2. The natural state of a motorcycle is on its side. 3. My bike and its owner are faster than yours. http://www.advrider.com/forums/showt...hlight=klxmack

02-10-2013, 06:49 AM	#18
gunnerbuck I.Hopp. Joined: Nov 2005 Location: N.V.I, B.C. Oddometer: 3,078	[quote Refer to that thread now, so far no end float in either side of crank, clutch seems fine. Counter balance outer case bearing is fine, but without removing there seems to be a lot of play on the inner bearing. Waiting for tools to arrive to remove. I have a sneaking suspicion it is the counter balance and the cam rockers.quote] There doesn't have to be end float on either end of the crank for the bearing to be bad, the running surface of the races only need to be galled... If you have the head/cylinder off you can spin the crank rapidly around in the case and listen for the grinding noise to indicate a rough bearing... As for the balancer being shot, I have a sneaking suspicion that you won't get away that easy, but one can only hope... __________________ 640 A x 2 gunnerbuck screwed with this post 02-10-2013 at 06:55 AM

02-10-2013, 07:10 AM	#19
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Turning it over by hand with the spark plug out doesnt give me any noise, atm I am suspecting counter balance and possibly cam... just waiting for strap wrench to arrive to get clutch off __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-10-2013, 07:17 AM	#20
Boon Booni Red Clay Halo Joined: Aug 2003 Location: Richmond, Va Oddometer: 11,162	So, what's the oil look like? __________________ Maybe Old's Cool is a bunch of dirty old men who swear because , let's face it, old bikes run on blasphemy as much as they do gasoline and oil. --Jinx You can be Han Solo, and I can be another Han Solo...

02-10-2013, 08:43 AM	#21
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Fair amount of pulverised steel on the plug, corrr __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-10-2013, 01:38 PM	#23
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,306	my money is on a bad big end .. scored cylinder __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

02-10-2013, 09:54 PM	#25
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	If that is the case, am I better off getting just a new bearing, or buying a whole crank assembly? The noise was definately loudest at the front left of the engine. It actually seemed quite quiet when you got your head right up to the right side.... but we will see.... __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-11-2013, 05:05 AM	#26
ericGSsti Gnarly Adventurer Joined: Oct 2009 Location: Dublin, Ireland Oddometer: 253	Not sure how relivent it is to you but I posted I had similar knocking noise to your bike in mine. Thought it was clutch related as it sounded noisiest there. Dropped the oil and found metal on the sump same as yourself, no obvious sign of wear anywhere. He pulled the starter cover and the ring gear on the motor had shredded. So for me easy fix. Replace gear and ring bearing on the starter. __________________ 2008 KTM 640 adventure. Africa Twin XRV750 RD04 IBA membership no.35934 "In the spirit of adventure, open to all riders and carrying a message of friendship between all men"- Thierry Sabine 1977 founder of the Paris Dakar -

02-11-2013, 07:50 AM	#27
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Was the bike still starting fine on the button? __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-11-2013, 08:40 AM	#28
moto_psycho ^OP Nob. Joined: Nov 2008 Location: ipswich, england Oddometer: 122	Also, has anyone ridden their 640 long term without a balance shaft? Generally I don't care about vibrations, and just imagine... 0.0001 extra hp at the rear wheel! __________________ AR50,TS125X,DTR125,MTX125,KDX200,KL250,DR400S,DRZ4 00S,XJ400N,XR400R,CBR600F,DR650,XS650,GSX750F all helped me whittle myself down to a KTM640E perfect bike!

02-11-2013, 09:19 AM	#29
ericGSsti Gnarly Adventurer Joined: Oct 2009 Location: Dublin, Ireland Oddometer: 253	Yes started first time every time. __________________ 2008 KTM 640 adventure. Africa Twin XRV750 RD04 IBA membership no.35934 "In the spirit of adventure, open to all riders and carrying a message of friendship between all men"- Thierry Sabine 1977 founder of the Paris Dakar - ericGSsti screwed with this post 02-11-2013 at 10:14 AM

02-11-2013, 09:44 AM	#30
MORT666 Gnarly Adventurer Joined: Aug 2009 Location: U.K Oddometer: 199	SOUNDS ok to me.

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