NOOB Fixing up 2004 625 SXC

Discussion in 'Thumpers' started by MNCherryinCA, Mar 29, 2011.

  1. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Hi All,
    I'm new to dirt bikes and most maintenance. I've been asking for help in a lot of areas and have been getting it. Thanks!




    My bike has about 5500 miles on it, but it's been sitting a while. I am in the process of:

    UPDATES AS OF JAN 2012 in GREEN
    UPDATES AS OF FEB 2012 In YELLOW
    • replacing tires (just took wheels off tonight) Front on...but i need to refill the brakes before torquing down
    • re-filling the front brakes (screwed this up tonight, too) Done...mighty vac did great!
    • fixing a coolant leak at the thermostat o-ring (waiting for parts) Done!!!
    • changing the oil (waiting until I get my wheels back on) Done...couldn't wait for the springs...it was actually pretty easy...not as hard or messy as everyone thinks it will be.Changed again yesterday - lots of metal on the magnet and I broke the banjo bolt!!
    • having stiff springs installed (I'm too hefty for the stock springs at 250 lbs) Can't affor this month Done by Trailtricks!! Awesome!!
    • figuring out why my radiator fan doesn't get power.replaced thermoswitch and it works fine. I just may need to get a lower temperature thermo to cool it off before 98C.Got new Thermo and radiator cap...works great! I think the fan is broken again - need to check the wiring and fuse.
    • buying lots of metric tools I don't already have still acquiring...bought a carb adjust tool - makes that a lot easier
    • cleaning everything Done!!! enough for now...it IS a DIRT bike after all. needs more love here!!
    • getting a new license plate (mine is split in two) DONE!
    • annoying my wife Done daily!! stepping this up to twice daily.
    • Brake light fixed today, too!!!
    • Need C/S sprocket with more teeth to go faster on hwys.Had a 42T put on the rear and the bike runs comfortably at 75 mph. However, I can feel the difference in giddyup in second gear big time.
    • New, bigger Gas tank (IMS 4 gal) installed at TT
    • Coyote bag for overnighters
    • rear fender bag for extra tubes and tools
    • renthal fatbars and bar risers
    • Started adding Star Tron to the fuel to get rid of the ethanol goo
    many more question will come, but i will try to get them on this thread.:D
    #1
  2. wrk2surf

    wrk2surf on the gas or brakes

    Joined:
    Dec 16, 2007
    Oddometer:
    7,745
    Location:
    THE exact center of California/Bass lake/Yosemite
    Ok .. when the wheels are off clean em up well and chrome polish the spokes and rims while they are off.. check your bearings for smooth rolling with your fingers.. ALWAYS ALWAYS check your sprocket bolts and make sure they are tight as the sxc has a non cushioned rear hub and are prone to breaking or cracking which I have two blown out to my credit until I got a cush setup.. when they are back on check and tighten the spokes.. also clean up your linkage area (and grease the zerk fitting).. clean the airbox inside and out including the filter and dont over oil it.... those areas are hard to clean when the wheel, seat, chain and plastic are on.. you can pull the cdi box out of the rubber band to clean underneath and check for chaffed wires in the area and around the battery.. those and the front harness area is where most problems hide. while you are waiting.. start to learn you bike by removing all plastic.. keep all bolts either in the place they came out of or taping to area they go.. wash and wax the plastic while off.. once you get the wheels and new tires on then you need to REALLY clean it .. once its clean then we can start on the oil change and brake fluid bleed.. also something that bothers me about the fan is the SXC is wired for the fan (two wires under the tank coming off the wiring harness)..and yours shouldnt be hooked straight to the battery.. when you do the front fork springs you can repack the head tube bearings... also with the SXC you should change the oil about every 1000 mi.. it lacks a quart that the lc4 and adventures hold in the frame reservoir .. I am jealous you have the 04 with the Kehin 41mm carb.. The bike is awesome and has a few maintanance things that once you know the bike is really simple to work on.. remember its easier to work on a clean bike .. this should keep you busy for a day ..
    #2
  3. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Thanks. A lot to do!
    The fan is not currently direct to the battery. It is coming off the right connector, I just don't think the connector is getting any power. I haven't tried checking if it is hot with the bike running...only with the engine off and the ignition on.
    #3
  4. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    3,915
    Location:
    Rotoiti, North Is, New Zealand
    Congrats on the new bike, that's a great ride.

    The fan is switched by the thermoswitch in the bottom of the RH radiator - you'll be able to trace the wire easily. So check if the thermoswitch is getting juice. Check the fuses too. The fan doesn't start until the bike gets fairly hot, I think the thermoswitch turns on at around 98 degC. Mine actually jammed open a while back, wouldn't switch in boiling water, I gave it a touch of the propane torch & it came unstuck & now it's working fine.

    Cheers
    Clint
    #4
  5. Ned1

    Ned1 Lend Me Yu Choppa

    Joined:
    Dec 20, 2005
    Oddometer:
    587
    Location:
    Redmond WA/Gold Bridge BC
    Only 5500 miles? Nice. Up well up and above 30k on mine. I always accuse mine of being a piggish bike but that's after riding a 225lb smoker in the woods. It's a damn good bike.

    If you blow your rigid rear hub contact me, I have a spare I'm gonna sell at some point.
    #5
  6. wrk2surf

    wrk2surf on the gas or brakes

    Joined:
    Dec 16, 2007
    Oddometer:
    7,745
    Location:
    THE exact center of California/Bass lake/Yosemite

    Dibs..I need one for a spare wheel i am building to take to Austrailia for a 7 day rally race..
    #6
  7. Ned1

    Ned1 Lend Me Yu Choppa

    Joined:
    Dec 20, 2005
    Oddometer:
    587
    Location:
    Redmond WA/Gold Bridge BC
    Sure, I figured you'd be interested.

    Send PM, we can figure it out.
    #7
  8. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    I don't want to replace the springs yet since I have spent too much on her this month already. Anyway...she's down to a cleanable level. Pics tomorrow when the light is better...

    I checked the tail light again...for some reason, with a brand new bulb, the regular light is on, but when I press the brake, the light doesn't brighten (the second coil doesn't light up). Anyone heard of this?:hmmmmm

    On to cleaning the parts, greasing, oiling, polishing, etc tomorrow.

    Attached Files:

    #8
  9. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Here it is stripped down

    Attached Files:

    #9
  10. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    The right side seems really filthy

    Attached Files:

    #10
  11. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    I replaced the thermo and oring and it is still leaking!! The threaded holes break through into the same compartment. How are the threaded holes supposed to seal? I have a brand new oring in there and it still leaks! Does anyone have ideas for thread sealant? Will teflon tape withstand the hot coolant?

    DSCN2962.jpg
    #11
  12. bmwktmbill

    bmwktmbill Traveler

    Joined:
    Jul 16, 2005
    Oddometer:
    5,600
    Location:
    Traveler
    Dot 4 for the brakes!!!!
    b
    #12
  13. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    #13
  14. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Hi All,
    I gotthe bike back in one piece today, but have a few questions...

    I notived the chain tensioner on the chain side is in a different position from the left side. If I try to make them even, it seems like the wheel will be crooked and the brake disk won't fit straight. If this a normal thing for a dirt bike? The wheel seems to be straight with the rest of the bike and rotates freely without any interference.

    I will follow with a couple of pics. Right side, then left side.
    #14
  15. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    here is the right side showing the chain tensioner in its original position.

    Attached Files:

    #15
  16. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Here is the left side...notice the difference? Does it matter?

    Attached Files:

    #16
  17. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    I had new tires mounted by a shop. they asked if I wanted them balanced and I said no.
    I mounted them today on the bike and noticed these things on the spokes. Are they weights? Are they actually broked and need to be removed or are they there and need to be clamped down on the spoke 9like a fishing weight?)??

    Attached Files:

    #17
  18. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    3,915
    Location:
    Rotoiti, North Is, New Zealand
    You just need to flip over the axle block on one side so they are the same, then set the chain tension correctly with the adjuster bolts with the marks on the axle blocks being in the same place vs the notches in the swingarm on both sides.

    Those things on your spokes are balancing weights & yes they should be clamped on tight.

    Cheers
    Clint
    #18
  19. MNCherryinCA

    MNCherryinCA KTM Noob

    Joined:
    Mar 13, 2011
    Oddometer:
    577
    Location:
    Santa Clarita, CA
    Oh!!! Of course...one is on backwards! Thanks Clint!
    #19
  20. wrk2surf

    wrk2surf on the gas or brakes

    Joined:
    Dec 16, 2007
    Oddometer:
    7,745
    Location:
    THE exact center of California/Bass lake/Yosemite
    Make sure your chain is adjusted correctly (loose), your brake light switch is either shorted or bad.. just take the weights all off.. ride it for a while when having em correctly weighted have em use the stick on flat type.. the spoke type ALWAYS rattle loose or off.. You still leaking out of the weep hole? You may have a bad head gasket
    #20