Replacing Top Triple Clamp on 2007 990

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

  1. Rockwell

    Rockwell Been here awhile

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    #1
  2. Denalidirt

    Denalidirt High Plains Drifter

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    make sure you dont bite off more than you can chew.

    you can remove the top triple with everything attached. The two towers that hold the handle bars can be remove once the handle bars or off. There is a nut on the underside of the clamps that will release the towers. Remove handle bars and you will see the other bolt head
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  3. Denalidirt

    Denalidirt High Plains Drifter

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  4. LukasM

    LukasM Long timer

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    Nothing tricky to it Rocky.

    Remove the 4 bolts that hold the upper halves of the handlebar mounts, lift off the handlebars, then you will have access to to the 2x M10 bolts that hold down the lower halves. Should be a 5 or 6mm hex I think. Hold the bolts from the top, remove the nut on the bottom side, and you are done.
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  5. Rockwell

    Rockwell Been here awhile

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    That link will come in handy. I'm replacing the entire fork assembly, including triple claps. Had a trip-pausing accident in El Salvador back in January. Doing the rebuild now. Replaced the frame and about to put the front end together.

    I have the triple clamps off. Don't see a way of removing those top pieces, unless they just pull apart once removed.

    [​IMG]

    [​IMG]
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  6. Rockwell

    Rockwell Been here awhile

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    Hey Lukas! About to finally put together the forks that you sent me!
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  7. LukasM

    LukasM Long timer

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    Glad to hear it, looking forward to seeing her finished. You definitely will know that bike well after it's been stripped down to a bare frame!

    There is a small metal tube inside those rubber bushings, if you knock it out then they will come apart, and you can just pull out the top one and the bottom separately. They are not one piece, and the metal thing on the bottom is just a cover so that the nut doesn't tighten directly against the soft(ish) rubber.
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  8. Rockwell

    Rockwell Been here awhile

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    thank you, that worked. how do i take the rubber dampener out? just tap it?
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  9. LukasM

    LukasM Long timer

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    Yeah just use some kind of driver that fits through the hole and tap on it from the opposite side, just like you would tap out a wheel bearing.
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  10. Rockwell

    Rockwell Been here awhile

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    OK...that was easy. I guess I should have looked at the assembly diagram (patrs 8, 9 & 10):

    [​IMG]

    Going to be tacking the entire fork assembly today. I got stuck on that damn air box for so long yesterday. I usually have Paula and her small hands around to help out with the clamps and throttle cables, but I had to struggle with them myself yesterday.

    I'll have to check through all my parts, but I am not sure that I received a new o-ring support (part 17). If not, can I reuse the old one, or should I wait and order a new one?

    Any other pointers on the fork assembly?

    I found this video on the HOW which seems really informative:
    http://www.ktm950.info/how/Orange G...gs/steeringhead_rr.html?p=7421097&postcount=1
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  11. LukasM

    LukasM Long timer

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    If you have access to a hydraulic press you can just press out the stem from your old lower triple without damaging the seal that the lower bearings sits on, then it's not a problem to reuse it.

    If you remove it with a puller it will be hard to keep it in good shape due to the interference fit of the lower bearing and because the seal will prevent your puller from getting a bite on the edge.

    I've got about ten of those here and you'd be welcome to have one, but I'm afraid it won't get to you any quicker than if you order locally...
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  12. Rockwell

    Rockwell Been here awhile

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    No hydraulic press here.

    I was sure that I did order a new one. I have two new bearings (upper and lower), new stem, etc. Maybe the seal is sitting at the bottom of a box. I'll have to take a look.

    If I didn't order one, I should be able to pick one of these up at the local dual sport shop. These seals are standard/common parts, aren't they, or are they specific to these bikes?

    My general plan is to assemble the bearings, stem and triple clamp onto the bike. If I do this first, will I then be able to insert the fork legs from the bottom? This is my first time doing this, so I'm not sure about the best plan of action.

    Thanks for all your help. If all goes well and the bike starts up after the rebuild, we hope to be somewhere in Europe by next summer.
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  13. LukasM

    LukasM Long timer

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    Not sure if you will find the seals at a local bike shop, they are specific to this size bearing which probably not a lot of other bikes have (all KTMs do however). Maybe an industrial or bearing supplier?

    Is the new stem already in the lower clamp? You will definitely need a hydraulic press for that. The lower bearing can be softly hammered on by using a tube that just fits over the stem but is small enough to only contact the inner part of the bearing so that it doesn't get damaged.

    When that is done and you have replaced both cups in the frame, grease up both bearings, slide the lower triple in from the bottom, put the upper bearing in on the stem, then the metal cover with the rubber O-ring inside, then the upper triple, and then the top nut to hold everything together. The manual should have instructions on how to get the correct torque / preload on the bearings. Once the triples are held together then you can slide in the fork tubes one by one.

    Definitely let me know when you make it to Austria and I'll set you up with a garage and a place to crash. :freaky
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  14. gefr

    gefr Life is a trip

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    Or at least that was the initial plan. What we found out was the ID of the triple clamps has changed on 990 models, so we had to exchange all inner parts, keeping outside of the legs OEM. So in case you collected pieces from different year bikes, be warned.
    Cheers.
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  15. LukasM

    LukasM Long timer

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    I don't think so. All 48mm WP forks have a diameter of 54mm in the upper clamping area and 60mm on the bottom, regardless of the year.

    What measurements did you get? :huh
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  16. Rockwell

    Rockwell Been here awhile

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    Thanks!

    Took the lower triple and stem to a shop yesterday to get it pressed on. I have the lower bearing and seal on, but trying to get both bearing cups to seat fully. I don't have my old cups, which would have helped.

    Any tips on getting this cups in fully? I have both opper and lower flush the the top and bottom of the steering column. There is still around 5mm of space between each cup and each lip.
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  17. LukasM

    LukasM Long timer

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    Do you like buying new tools? :D Park tools makes an excellent one for that purpose....

    [​IMG]


    If you are going to improvise, then you want to make sure that you don't damaged the cup. You could use a suitable driver that has the exact same outer diameter so it only presses on the outside, e.g. big socket or even an old cup with a slit cut in it so you can get it out again.

    If you don't have anything like that and it's already sitting flush so there is no real risk kinking it in the bore, you could carefully knock it in using soft-ish piece of wood as a driver. Try to hit only the outer part of the cup though.
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  18. Rockwell

    Rockwell Been here awhile

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    The biggest socket I have is the one for the main engine mount nut.

    I'll try a piece of wood. I was thinking about using a head of a screw driver on the rim of the cup, but I was afraid of somehow damaging the cup that way.
    #18