KTM 620 rebuild/refresh

Discussion in 'Thumpers' started by gravityisnotmyfriend, Feb 28, 2013.

  1. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    Of all places - Boats.net has them for $2.04/piece with $1.75 shipping. I can live with that!
    #21
  2. bmwktmbill

    bmwktmbill Traveler

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    When I was in Bolivia I crashed hard and tore the instruments off my BMW.

    I used my GPS for the rest of the trip south then back to the USA.

    Speed and total miles plus gas reset miles, no problem

    Never missed the instruments and ran the machine another 100K miles.

    Got to like the clean look. Utilitarian.
    bill
    #22
  3. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I did the same thing to my '71 350. Except, I used wrenches to take them off!

    [​IMG]


    Most of the time, I just guess at my speed. But, if I want to know I'll put my GPS on. You can see the handlebar mount in that pic.

    I'm not too concerned about most of the lights. But, if my low oil or over temp lights aren't working, I fear cooking my engine. I can live without the rest.
    #23
  4. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I don't know what's going on with photobucket. Thumbnail images are tiny and direct you to a photobucket page with a small version of the picture. Direct [​IMG] makes them show up huge. Weird. So, bear with me while I struggle through figuring it out.

    I got my parts in the mail yesterday. Had to spend all night on homework and not fixing my bike. If any of you are considering your master's in engineering I would strongly advice against it. It really gets in the way of wrenching time!


    Anyway, here's all the parts ready to go together:

    [​IMG]

    After smearing a bunch of loctite on my fingers - and a little on the seal, I was able to get that seated:

    [​IMG]

    Then, the bearing went on the shaft easily - with a little help from an arbor press:
    [​IMG]

    Bearings and shaft ready to go in. I smeared some grease in the recess of the seal to help get the shaft to slide through and maybe help keep the oil out of the coolant and the coolant out of the oil:
    [​IMG]

    Bearings and shaft went in easily. New clips and o-rings installed
    [​IMG]

    Slid the impellor back on and put on a new washer with the old bolt. She's ready to go back on the bike!

    [​IMG]

    [​IMG]
    #24
  5. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    New project for the night. Install the sprocket shaft seal. I have a look at what I'm working with. Too much grease and gunk built up:
    [​IMG]

    After a little cleaning:
    [​IMG]

    Find the new parts:
    [​IMG]


    Line up the seal....
    [​IMG]



    Huh. I guess I didn't need that driver after all. There's a good 1/8" all around the outside of the seal. The weird thing is that the spacer is a perfect fit. Huh. I guess I gotta call the folks at KTM-Parts and find out what their exchange policy is. Crap.


    The night wasn't lost. I did get my water pump installed and my valve cover back on and sealed. Apparently, I didn't take any pictures though.
    #25
  6. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    So, I double checked my invoice. I ordered a 0760324771 and that's what the package that it came is says as well. It also says 32X47X7

    Which I interpret as 32mm ID, 47mm OD, and 7mm thick. Let's see:

    Thickness? Check.
    [​IMG]

    ID? Check.
    [​IMG]

    OD? Hmmm....
    [​IMG]

    Its actually about 42.2mm. Hopefully I can get a new part coming soon. I had hopes of having this bike back together this weekend.
    #26
  7. johnno950

    johnno950 Long timer

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    if you could do time for "crimes against motorcycle maintence" i think you would get about 5yrs
    #27
  8. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    Thanks for your insightful post... I guess.

    Maintence? Maintence? Is that the act of mainting your bike? How do you maint?




















    Oh, you mean maintenance. Yes, this bike is in a sorry state - but if anyone deserves time, it's the PO.
    #28
  9. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I got a little bit of quality time with the bike last night. I tried to get some pics - but nothing really turned out. But, I got the water pump back together. Got the new jets installed and the carb back together. And, I got all the dash lights in and the front end back together. So, I'm making forward progress and actually putting stuff back together.


    Here's the list. Plain black is yet to be addressed. Green is repairs in progress. Yellow is done.

    Valves - need to check lash.

    Front shocks – leak

    Clutch – slips

    Plastics – plain white

    Spark plug – New one will go in after checking valve lash.

    Turnsignals – Needs a new flasher relay

    Sprocket Shaft Seal Leaks - needs a new seal. Should be here tomorrow

    Instrument lights – bulbs replaced

    Waterpump – rebuilt.

    Headlight – flickers
    Just a loose connection.


    Tail light – doesn’t work
    Handlebar wiring was redone - poorly


    Parking light – doesn’t work
    Parking light deosn't exist. Need to buy a replacement.


    Rear shock – shot
    Replaced


    Carbs – jetted too fat
    New jets ordered. 195-170MJ; 52-45 idle jet.


    Seat – I hate the white seat
    Painted with vinyl interior paint. Not lasting very well.


    Luggage – none
    Luggage rack built. Top box acquired - but I need to mount it.


    Handlebars – too low
    Rotated back too far. Moved them forward and I think It'll work


    Steering - spooky at highway speeds.
    Steering stem had too much slack. Tightened her up.
    #29
  10. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    Oh, and I got a package in the mail over lunch.

    [​IMG]

    This one should do the trick! Hopefully I can get that put in this evening.
    #30
  11. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I was all excited to get my bike put back together last night. Had a couple of hours to spare and thought I could get it all done. First up? Valve lash. Something I've done a dozen times, and it went smooth. So, I put the rocker covers back on and then, it was time to put on the tank, seat, and all the plastics. But, before I did, I thought maybe I oughta hook up my throttle cable to my handlebar grip.

    Good thing I did. While doing so, I found out that my throttle cable is fraying and hanging up in the sheath. I'm not sure why I decided to do that before putting the tank on, but I'm darn glad I did - or I would have been taking everything right back off!

    Well, what else could I do?

    I did drive the new sprocket shaft seal on. That went without a hitch. I do need to remember to tighten that sprocket nut down, though. I took it off by holding the back brake too keep the sprocket from turning. But, I've got to put the chain back on - after I put the back wheel back on - after I mount my new tire.

    So, I'm making progress, but I'm losing ground too. Seems like I'm leaving the bike in a more disassembled state every night. I should have had it looking like a motorcycle again, but instead it looks pretty much the same - just without a back wheel or throttle cable!













    Here's the list. Plain black is yet to be addressed. Green is repairs in progress. Yellow is done.

    Rear tire - mount a meatier off road tire to replace the 80/20 street tire

    Throttle cable - shot, needs replaced

    Clutch – adjust



    Spark plug – New one will go in after checking valve lash.

    Turnsignals – Needs a new flasher relay





    Sprocket Shaft Seal Leaks - seal installed

    Valves - lash set

    Instrument lights – bulbs replaced

    Waterpump – rebuilt.

    Headlight – flickers
    Just a loose connection.


    Tail light – doesn’t work
    Handlebar wiring was redone - poorly


    Parking light – doesn’t work
    Parking light deosn't exist. Need to buy a replacement.


    Rear shock – shot
    Replaced


    Carbs – jetted too fat
    New jets ordered. 195-170MJ; 52-45 idle jet.


    Seat – I hate the white seat
    Painted with vinyl interior paint. Not lasting very well.


    Luggage – none
    Luggage rack built. Top box acquired - but I need to mount it.


    Handlebars – too low
    Rotated back too far. Moved them forward and I think It'll work


    Steering - spooky at highway speeds.
    Steering stem had too much slack. Tightened her up.
    #31
  12. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    And, of course, when I say the text is plain black - I mean black in the post box. It's whitish gray text obviously. Anyway, the project is stalled until I can get my throttle cable. But, there was the issue of the turnsignals.


    The flasher relay box has a couple of cracks in it. No idea how that happened, but the signals did flash occasionally. But, it's just a little circuit board in a box. Flasher relays for cars are around $15. I'll just grab a new one. I checked out the parts fiche, looked up the part number...

    It was over $100.

    Now, in the state of IA, the rules are that if you have turnsignals on your bike they have to work. But, you don't have to have turn signals. So, for $120, I'm thinking I'll just pull the damns things off and call it good. But, I figured I'd open up the flasher relay and have a look to see if I could fix it myself. What do I got to lose?

    So, I popped the case off the board and here is what I see:

    [​IMG]

    The long oval is around a section of conductor that seems to have become de-tinned. The more circlish oval is around an obviously bad solder joint. This looks promising! So, I get out my tools and put some heat and fresh solder to it:

    [​IMG]

    I should have taken another picture after I cleaned up the flux. But, I snapped the cover back on the put it on the bike.

    Works perfectly. The signals signaled every time. I couldn't get them to not. Perfect! One more thing off the list.

    The sad thing is that if the relay had been cheaper - I wouldn't have bothered. I woulda just thrown this one in the land fill and paid for a new one. I'm glad I took the time to inspect it.







    Here's the list. Plain white is yet to be addressed. Green is repairs in progress. Yellow is done.

    Rear tire - mount a meatier off road tire to replace the 80/20 street tire

    Throttle cable - shot, needs replaced

    Clutch – adjust



    Spark plug – New one will go in after checking valve lash.







    Turnsignals – bad solder joint resoldered

    Sprocket Shaft Seal Leaks - seal installed

    Valves - lash set

    Instrument lights – bulbs replaced

    Waterpump – rebuilt.

    Headlight – flickers
    Just a loose connection.


    Tail light – doesn’t work
    Handlebar wiring was redone - poorly


    Parking light – doesn’t work
    Parking light deosn't exist. Need to buy a replacement.


    Rear shock – shot
    Replaced


    Carbs – jetted too fat
    New jets ordered. 195-170MJ; 52-45 idle jet.


    Seat – I hate the white seat
    Painted with vinyl interior paint. Not lasting very well.


    Luggage – none
    Luggage rack built. Top box acquired - but I need to mount it.


    Handlebars – too low
    Rotated back too far. Moved them forward and I think It'll work


    Steering - spooky at highway speeds.
    Steering stem had too much slack. Tightened her up.
    #32
  13. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    So, I got my new throttle cable. I was hoping it would be everything from the grip to carb. But, there's a short piece of tubing on the carb end that needs to be replaced. I'm pretty sure that was the piece that wore through and caused the cable to fray in the first place.

    I need #60:
    [​IMG]

    But, it'll be $30 to order and it'll be another 2 weeks to get it.

    It's a good thing I've got other bikes to ride, cause the weather is threatening to turn nice and this bike may never leave the garage at this rate!
    #33
  14. Dolly Sod

    Dolly Sod I want to do right, but not right now

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    Love it when the fix is that easy.

    What about the line at the top that is also de-tinned?
    #34
  15. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    I noticed that one too - after I uploaded the pics. I honestly don't think the de-tinned paths had anything to do with the problem. I'd bet that it was all do to the one bad solder joint. I did a continuity test of the one path I did fix. There was no appreciable difference before or after re-soldering it.

    I'm just glad that my winkers wink and it didn't' cost be $120 to make that happen!
    #35
  16. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    So, I just couldn't wait 2 weeks on another part. It's just a peice of tubing, right? May as well fab something up.

    Here's why I'm replacing it:
    [​IMG]

    The old tube appears to be copper and is completely worn through. I'm sure that's what caused my cable to start fraying.

    So, I found a piece of thickwalled 5/8" stainless tubing:
    [​IMG]

    Grabbed my handy dandy tube bender:
    [​IMG]

    And put in a radius:
    [​IMG]

    Then, I threaded the end to match the cable end and put her together:
    [​IMG]

    And, on the bike:

    [​IMG]

    The throttle is now silky smooth, and no feeling of anything dragging. That last picture makes it look like the tube is bent a bit too much. I didn't notice that on the bike - only looking at the picture.

    I'll have to take a close look at it before I put the tank on. But, I've got plenty of tubing. If I have to build a new one, it's no big deal.

    So, I took a $5 piece of tubing and about 30 minutes and saved myself $30 and a two week wait.

    I also got the new tire on the wheel and the wheel back on the bike. With any luck, I'll be driving this bad boy this weekend.
    #36
  17. tileman

    tileman Long timer

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    gotta ask, where did you get the bender?
    #37
  18. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    Same place I get my lathe, plasma cutter, mill, and any other tool that I don't use enough to justify the cost.

    The maintenance shop at work! It's a great perk of the job - though I'm sure that doesn't help you out at all.



    Made good progress last night despite getting a late start. Got the the tank back on and while there isn't much clearance between that throttle tube and the bottom of the tank, there is clearance. The throttle doesn't bind at all, so that's good enough for me! got the seat and all the plastics on, just gotta wrap up a few things.

    Still gotta figure out how to adjust the clutch. It was slipping on me a little bit - but it seems to me it started doing that after my last oil change. So, I'll adjust the clutch first. If that doesn't take care of it, I'll wade through the billions of oil posts on this site and see if I can find whats good for the bike and change it out. I really hope I don't have to replace the actual clutch.
    #38
  19. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    With any luck, I'll be riding the old girl tomorrow. I seem to have lost a couple of bolts for the rear of my luggage rack, but I'll pick up those after work, along with a gallon of fresh anitfreeze and see if she'll run.

    The clutch appears to be a simple fix. Looks like the arm spun on the shaft a little bit. I was able to fully slack the cable at the handle bar perch, then rotate the arm on the shaft, then tighten the perch a little bit. I guess I'll find out tomorrow if it doesn't rain all day.
    #39
  20. gravityisnotmyfriend

    gravityisnotmyfriend Long timer

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    Or, maybe I'll ride her today! Got home from work and had a sneaking suspicion I had a full jug of 50/50 antifreeze in the shed. Sure enough. So I topped of the KTM and tightened down the remaining bolts and fasteners.

    Then the moment of truth - would she start?

    Turn the gas on, turn the key on, check the kill switch - it says "run", pull the choke and go through the ole 4T kick routine and kick and kick and kick and kick.

    Check the kill switch - it says run

    Pull the decomp and clear out the cylinder.

    and kickand kick and kick and kick and kick and kick and kick and kick and kick and kick and kick and kick

    Check the kill switch - it says run. Make sure the key is on. Try the hot start button

    kick kick

    Try half choke

    kick kick.

    Nothing. Not a pop. Not a fire, not a noise. I smell gas, so I know it's getting it. I check the spark plug wire, it's on. I check the kill switch - it says run.

    It says run WITH A FUCKING ARROW UNDER IT!!!

    It means slide the switch that way for it to fucking run. I knew this. I rode the bike all last summer. I dont' know why it didn't occur to me until 15 minutes of kicking the beast.

    So I slide the swtich, and kick, and Pop!

    I set the choke to half, and kick, and Pop, pa-POP! Pa PUPUPUPUPUPUPUP. Hurray! my bike runs and I'm an idiot!

    So, I threw on the helmet and gloves and took her for a short spin. It took a little adjustment on the perch, but the clutch is working perfectly. No slipping at all. I really forgot how much I like this bike! It lofts the front soooo easily. And its so much more predictable with a good shock under the rear end.

    But, there is a hesitation when go WOT. I'm guessing I've gone too lean on the main jet as I dropped from a 190 to a 170. I'll put the 190 back in this evening to see if it takes care of the problem. Then, I'll either leave it as is or maybe drop to a 180. Or, maybe I'll put the 170 in and raise the needle a click or two. It'll just take a bit of tweaking, but everything seems to be working like it should. No leaks on the sprocket shaft and no more smell of antifreeze when she's running. I'll post up some pics once I get her a much needed bath.
    #40