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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

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Old 02-12-2013, 11:28 AM   #31
moto_psycho OP
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I must admit, the video makes the bike sound like its going to explode. It is no way near as bad as that, I've just put it back together sans counter balance shaft. It sounds better, but not completely. My guess is rod bearings.


So, who's done this job before? What are the main things to look out for? Which rebuild kit is better? Am I better off buying a full crankshaft assembly pre made instead of getting an engineer to press out the webbs? Or is it easy enough to do yourself?
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Old 02-12-2013, 11:43 AM   #32
Foot dragger
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That vid does make it sound like a threshing machine eating a box of rocks. Sounds like having an experienced mechanic look at it might be a good idea.
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Old 02-12-2013, 12:55 PM   #33
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I am a qualified mechanic, and in 3 months a qualified mechanical engineer. It's not that. It's the fact I may need to buy special tools etc to complete certain jobs. I was considering just replacing the main bearing for a phosphor bronze shell bearing (the company I work for supplies aluminium / phosphor bronzes to the aerospace industry).

So yeah, I'm happy to strip the engine down. Just buying certain tools etc may eventually cost more. Plus there is the effort involved... but then there is the piece of mind that I know everything about the engine inside and out. Regardless it is going to cost me a bomb and I am very pissed off as I only bought the bike a few months ago (I researched the bike before and everyone goes on about how they are noisy, so the slightly off noise I heard then I didn't acknowledge.

But, I suppose I will just have to take my time, strip and rebuild everything, and have the best 640 enduro THAR EVER BE! (within reason :p). It's just gonna take some time, moving house, holiday etc... funds be low.

*sigh*

Btw, I bought a strap wrench for getting the clutch apart, it broke. So I thought, what is a modern world use for karate?
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Old 02-12-2013, 12:57 PM   #34
wrk2surf
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an impact should do the job
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Old 02-12-2013, 01:00 PM   #35
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Another tool I didn't have to hand! Hence the belt. Worked perfect off and on . Torqued to 90nm + loctite 243. It's gotta ride to the new house, then it'll be in bits for months. Powder coat the frame, rebuild the forks... it will be mint. And I will document it on here... no doubt nothing will possibly go wrong :p.
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Old 02-12-2013, 06:32 PM   #36
gunnerbuck
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Put the transmission in 5th gear and have someone step on the brake while you loosen the clutch nut... Do the same thing when the time comes to torque it back up...
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Old 02-14-2013, 02:19 PM   #37
ericGSsti
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Hope you get yours sorted. My machanic changes the gear and ring bearing on mine. Did all the filters and topped up the oil.

I was delighted until he started it. No difference at all.

Dropped it in to KTM this evening.
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Old 02-16-2013, 01:23 AM   #38
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Is that on the starter motor?


I'd be grateful if anyone could give me a hand just describing what order is best to strip the engine in. I have a copy of the manual but experience suggests there are always better ways, especially when considering all the special tools are not to hand! So obv clutch, crank nut and stator loosened in frame, anything else?
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Old 02-16-2013, 01:35 AM   #39
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Quote:
Originally Posted by moto_psycho View Post
Is that on the starter motor?


I'd be grateful if anyone could give me a hand just describing what order is best to strip the engine in. I have a copy of the manual but experience suggests there are always better ways, especially when considering all the special tools are not to hand! So obv clutch, crank nut and stator loosened in frame, anything else?

The one tool you will really need is a fly wheel puller...
Here are some threads that may be helpful:

http://advrider.com/forums/showthread.php?t=632893

http://advrider.com/forums/showthread.php?t=633753

http://advrider.com/forums/showthread.php?t=628511
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Old 02-17-2013, 07:11 AM   #40
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Cheers for that!

Does the full gasket set have the seals for the water pump?
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Old 02-17-2013, 10:13 AM   #41
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Originally Posted by moto_psycho View Post
Cheers for that!

Does the full gasket set have the seals for the water pump?
Yes the seals are there, but you may have to replace the shaft if it shows a wear ring on the sealing surface...
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Old 02-20-2013, 10:07 AM   #42
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Just to let you know my finding. The head Mechanic from KTM here in Dublin rang me to call into him today so he could show me the damage and wear that had caused my noise and metal that was found on the sump magnets. He was concerned when I had dropped it in and I had told him it had broken the teeth on the starter gear so that where he headed for first to investigate. Turns out all my noise is caused by the starter clutch assemble and fly wheel. There is a lot of wear on the starter clutch and it's relivent components. The clutch itself should only spin one direction but turned both ways and there was wear on every thing else so he's replacing the whole starter clutch assembly and I'll have it back Friday.

Hope your finding aren't to bad.
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Old 02-20-2013, 03:54 PM   #43
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It will probably now need a flywheel or some machining on it to get the gouges out.. surpised the sprague would not have disintegrated
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Old 02-20-2013, 11:09 PM   #44
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Quote:
Originally Posted by wrk2surf View Post
It will probably now need a flywheel or some machining on it to get the gouges out.. surpised the sprague would not have disintegrated
Fly wheel is been replaced with a new one.
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Old 02-25-2013, 09:26 AM   #45
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Probably gonna ditch the starter motor on mine, so no worries if it is the cause
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