Oil Change OUCH!

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by 950slider, Apr 15, 2013.

  1. 950slider

    950slider Been here awhile

    Joined:
    May 23, 2006
    Oddometer:
    165
    :cry Doing an oil change on my '04 Adventure and found 4 roller bearings (2.0 X 4.5mm) and a partially mangled bearing cage attached to my magnetic drain plug...looks like the some of the cage pieces found their way to the filter screen above the check valve screen in the oil tank, and some bits landed on the flat screen below the clutch cover.
    Any ideas where those puppies came from?
    Bike sounds fine before and after the oil change, shifts like normal, but a touch cautious about driving it until I can locate where those pieces 'fell' from...
    Looking through parts fiche and not seeing it...anyone want to chime in? :evil:baldy
    #1
  2. Orangecicle

    Orangecicle On a "Quest"

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    West Des Moines, IA
    Riding it like that is asking for trouble.
    #2
  3. FakeName

    FakeName Wile E Coyote SuperGenius

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    My condolences on your loss.
    #3
  4. Leodis41

    Leodis41 I wanna Orange one!!

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    Looking at the schematic, there is no way it can get from the engine to the oil tank, there is a filter screen before the scavenger pump and then there is the pumps itself. Cannot see how the bits could get through there to the oil tank.

    Pictures of the bits would help to try and id the bearing, only bearing that springs to mind is the top cam gear bearing, I suppose if that had collapsed that could explain the bits if the sump, but not the oil tank.

    Sorry can't help further.

    :waysad
    #4
  5. 950slider

    950slider Been here awhile

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    If I e-mail someone an image of my parts, would someone please put 'em up for me.
    I seem to have a problem attaching the photo here... :baldy
    Thanks.... :clap
    #5
  6. crazybrit

    crazybrit Long timer

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    http://advrider.com/forums/showthread.php?t=919

    Signup for a free photobucket account. When you've uploaded the image. Select "get links" and copy the IMG link. Paste that into your post (ctrl-v).
    #6
  7. Katoom72

    Katoom72 Been here awhile

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    Belgium
    #7
  8. Supahflid

    Supahflid Wheelieless

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    Here for reals.
    The owner of this site, Baldy, also owns Smugmug. A lot of folks on this site think it's nice way to kick him a few bucks by paying Smugmug for image hosting, although you can use other image hosting sites.

    Sorry about your troubles; I probably won't be much help, but I'm hoping the best for you!
    #8
  9. Motomedic

    Motomedic Over-caffienated Raconteur

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    How's your shifting? I can't remember for sure, and I'm really grasping at straws here, but I'd wonder about the shift drum bearings if it were me. I thought they were both ball bearings (schematic shows both being balls), but I could be wrong.

    None of the other bearings, especially any of the "roller" or "needle" bearings are 4.5mm wide. Crank is supported by plain bearings, the balance shaft (or combination shaft, or whatever the hell KTM calls it) is supported by ball bearings, as are 3 of the 4 trans shaft bearings, outboard countershaft is a roller bearing.

    The only other thing I'd wonder about is the bearings the shift shaft runs in, but the schematic calls for a 12mm wide needle bearing.
    #9
  10. Orangecicle

    Orangecicle On a "Quest"

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    How I'd feel if that happened to me:

    <iframe width="640" height="480" src="http://www.youtube.com/embed/1okb5EIo1nw" frameborder="0" allowfullscreen></iframe>​
    #10
  11. Brokein2

    Brokein2 Been here awhile

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    With a twin like we have.....there is usually no harm riding it until you find a piston stuck to the drain plug. :lol3
    #11
  12. Zuber

    Zuber Zoob

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    Just to clarify: you found these in the OIL TANK? or in the ENGINE? drain plug magnet.

    I assume the engine drain plug, because there is NO WAY these items can get into the oil tank unless they fell out of an oil bottle when you filled it.

    KTM has had some problems with the bearing on the transmission main shaft right behind the clutch on other models. Easy to check. Pull the inspection cover and wiggle the clutch up/down, front/back. If you get more than a few thou... start saving your money.
    #12
  13. sstewart

    sstewart Long timer

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    He should know,had his bike scattered all over my damn shop,just saying.:eek1
    #13
  14. ciedema

    ciedema мотоциклист

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    I have an engine in pieces, the only small rollers I remember in the motor are the gear shaft ones.
    #14
  15. Motomedic

    Motomedic Over-caffienated Raconteur

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    When this happens (notice the large chunk missing from the one on the right)on a 6 month 25k mile odyssey:
    [​IMG]

    It's followed by this:

    [​IMG]
    [​IMG]

    :D

    Notice the size of the bearing lands on the shift drum, hence my guess that that's the bearing that let go. If it's not the shift drum bearings, I'd go with the shift shaft.

    [​IMG]

    If you look close, you can see one of the shift shaft needle bearings.

    As for riding it like that, imagine what could happen if one of those rollers found it's way into the scavenge oil pump, stopping the rotors and shearing the drive pin in there. No oil pressure usually means a quick death for the plain bearings that support the crank. Or how about what would happen if it found it's way into the trans, between gears? It could lock the trans, causing a sever and drastic loss of control as the back wheel locks up at speed.

    Park it until you fix it. Sorry, but it looks like you're splitting cases. Look at the bright side though- if I did it in a redneck's (oops-I mean inmate's) garage in Alabama (Hi Scott! :D), how hard can it be?
    #15
  16. 950slider

    950slider Been here awhile

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    May 23, 2006
    Oddometer:
    165
    Yes... I'm starting to think Trans related bearing. I'll pull things apart on the weekend and check the clutch drum first. I suspect the shifter shaft for the size of the bearing.
    As I've only seen 4 bearings thus far...I think I'll use a strong magnet and hope I can move 'em out the drain plug hole. This is wishful thinking that those bearings are in the crankcase pan!
    Only small metal fragments were found on the screens, but no large particles or pins.
    The hunt will go on!
    Thanks for all who have pitched in so far.
    Can't 'Slide' without the 950! :wink:


    #16
  17. Qwik

    Qwik Adrenaline Addict

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    I dont have a transmission but if there is anything else you need for the motor let me know. I have a motor I am dismantling.
    T
    #17
  18. 950slider

    950slider Been here awhile

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    Here's a pic
    Edit: no, didn't find the dime in there
    [​IMG]
    #18
  19. Zuber

    Zuber Zoob

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    Those bearings are tiny. Not from a main bearing in the tranny or engine. They are about the size of the needles for the bearing on the RH end of the shift drum. Too small for the locating pins on the end of the shift drum.

    This debris can't get into the oil pumps because of the two screens on the pump intakes.

    I'd pull the RH engine cover first.
    #19
  20. 950slider

    950slider Been here awhile

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    Oddometer:
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    Looked through the parts diagrams and have come up with Zip/Zero/Nada... so a hint of any lead is encouraging... thanks!
    Time to get my hands grubby once again. :clap
    #20