99' KTM LC4 640 Rocker Cover Repair & Pics

Discussion in 'Thumpers' started by fujian, Mar 5, 2012.

  1. fujian

    fujian Been here awhile

    Joined:
    May 6, 2010
    Oddometer:
    215
    Location:
    Langford ( Victoria ) British Columbia, Canada
    Wanted to start this thread ( as a record ) posting all the glorious photos of my new LC4....( which have been on three threads and is posted in the flea market) :rofl

    Removed cover, removed old silicone sealant, reapplied sealant, waited three days, another leak...

    Have the rocker cover off for the second time now I'm going to do it the correct way this time and torque the bolts down according to the " Man "


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    View of right side ( seat, tank, and side panel removed )

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    Good kind of green? Drained it a few hours ago, going to replace it with the fresh stuff, still unsure of what kind of coolant I need an how much is needed? 2 liters perhaps? I know just to fill it up full but a number would be nice. :D

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    Right side of lower engine, wires leading into the case? Green & White wires are for what? :huh

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    1696 ? What does this number mean?

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    No reason

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    Moved inside the garage, ( neighbors garage )

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    With the secondary transporter ( my pink scooter ) 2007 Arqin Sprint ( Shit don't buy one )

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    The other angle

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    Hondabond HT ( High temperature ) $40 bucks from the local Perth Honda Dealership

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    Curious to know what people think of this coolant in the LC4?

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    Really stuck at this point, what needs to be done to remove the cover? All that is holding the cover on ( to my knowledge ) is the old sealant.

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    Blurry image, 11 bolts removed from the cylinder cover. As stated in the repair manual

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    Bolts removed :)

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    Just removed the cover, kicked by hand the kick starter to move the piston to break the seal.
    #1
  2. overlandr

    overlandr Dystopist

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    If you want to show what steps you're taking, why not personalise the thread title to describe what the thread is about - something like "Fixing the rocker cover leak on my 640"? BTW its not an adventure you have there more like the enduro - still a very nice setup with that 18l tank. A line or two under each photo describing keys events would also help.
    #2
  3. juames

    juames Have Fun, Don't Die!

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    Nice looking bike!

    But it's a 640 Enduro not Adventure...

    640Adv looks like this.:D
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    #3
  4. dnrobertson

    dnrobertson Big Bike, Slow Rider

    Joined:
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    So in the space of a week you have:

    1. Bought the bike.
    2. Found it has more miles on it than you thought.
    3. Posted nearly the same question in 3 forums
    4. Put the bike up for sale in the Aus Flea market.

    Is this some sort of record? :rofl
    #4
  5. fujian

    fujian Been here awhile

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    Langford ( Victoria ) British Columbia, Canada
    Basically, excited about the new purchase, want to repair it, then sell or trade. Don't like having to maintain a bike this much.
    #5
  6. wrk2surf

    wrk2surf on the gas or brakes

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    thread title should REALLY be changed... you have a LC4 Enduro.. search engines will steer people here that are looking for pictures of A KTM LC4 640 ADVENTURE.

    btw... with some work initally your bike would need very little maintainance... and take you pretty much anywhere in the world..
    #6
  7. laramie LC4

    laramie LC4 crash test dummy!

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    you forgot #5

    5. ask for free help from everyone without any intent of returning anything to knowledge pool.

    gotta love the world wide web....

    laramie :beer
    #7
  8. fujian

    fujian Been here awhile

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    I can't change the title, I've tired...

    This is what I'm aiming for, I believe I'll keep the bike and take it around Australia possibly ship it back to North America If it's financially possible ( At the end of the 2012 )
    #8
  9. fujian

    fujian Been here awhile

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    Thanks for the positive comment Laramie, Where did you get the idea that I'll not be returning anything to the knowledge pool ?
    #9
  10. fujian

    fujian Been here awhile

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    Thanks for the tips, I agree that the thread title needs to be changed, Could you change it for me? " LC4 640 Enduro - Rocker Cover Leak "
    #10
  11. fujian

    fujian Been here awhile

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    Thanks for the tips, I agree that the thread title needs to be changed, Could you change it for me? " LC4 640 Enduro - Rocker Cover Leak " that would be a more fitting title.
    #11
  12. joe cool

    joe cool Been here awhile

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    Fujian, when you put it back together be a lot more sparing with the sealant than the po.
    #12
  13. motomark39

    motomark39 I reckon so

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    #13
  14. fujian

    fujian Been here awhile

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    #14
  15. fujian

    fujian Been here awhile

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    Nice tip, I'll keep that in mind when I apply the sealant to the cover side, I think it will be easier on that mating surface.
    #15
  16. overlandr

    overlandr Dystopist

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    This may help.

    http://www.advrider.com/forums/showthread.php?t=741009

    Also, learning how to search for stuff on ADV using google is very useful as there is a wealth of collective wisdom on here. One just has to know how to locate it.
    #16
  17. laramie LC4

    laramie LC4 crash test dummy!

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    sorry dude, sounded like you were going to fly in and fly out. we get lot's of guys that just expect help, then do very little to return the favor. did i rush to judgement? :D

    laramie :beer
    #17
  18. fujian

    fujian Been here awhile

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    No drama's, I'll try and return the favor by uploading original material in the form of photos.
    #18
  19. makazica

    makazica Been here awhile

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    Man.....rocker covers on these bikes usually leak from the exhaust side of the engine.....in your case I think you could fix the leak without taking the cover off....tip: try changing the o-rings on rocker shafts....

    BTW Have you managed to take the cover off? If not, the water pump shaft is holding it in place, turn the engine slowly to free it up!
    #19
  20. wrk2surf

    wrk2surf on the gas or brakes

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    ask a moderator in a PM they are listed at the bottom of each main page..
    #20