Generator cover

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Lil' Irv, Jun 3, 2012.

  1. sstewart

    sstewart Long timer

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    Nov 21, 2009
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    Boaz,Alabama
    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.:clap
    #21
  2. Uller

    Uller Long timer

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    Arlington, WA
    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.
    #22
  3. v8toilet

    v8toilet Nothing to see here.

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    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.
    #23
  4. men8ifr

    men8ifr Been here awhile

    Joined:
    Jan 28, 2008
    Oddometer:
    383
    Location:
    Midlands UK
    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?
    #24
  5. erappaport

    erappaport pray for rain

    Joined:
    Jun 23, 2004
    Oddometer:
    294
    Location:
    Maine
    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?
    #25
  6. GoNOW

    GoNOW Long timer

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    Feb 22, 2006
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    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.
    #26
  7. MortimerSickle

    MortimerSickle Semi-Adventurer

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    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.
    #27
  8. GoNOW

    GoNOW Long timer

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    Feb 22, 2006
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    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.
    #28
  9. Head2Wind

    Head2Wind MotorcycleMayhem

    Joined:
    Mar 13, 2006
    Oddometer:
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    Location:
    NorthWet Washington
    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%20Garage/Engine/stator/stator_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/showthread.php?182754-Stator-Rewind
    #29
  10. erappaport

    erappaport pray for rain

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    Jun 23, 2004
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    Maine
    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. :lol3
    #30
  11. MortimerSickle

    MortimerSickle Semi-Adventurer

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    Dec 1, 2005
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    Location:
    Rainville, Orygun, where moss is a road hazard.
    If they resist, use heat. I held a soldering iron to the stub of the broken one, and was able to remove it with vise-grips.
    #31