The KTM Repair Manual is a joke

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by RedRupert, Jul 23, 2013.

  1. RedRupert

    RedRupert Brit in the Soviet Union

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    From time to time I notice something in the Repair Manual that's wrong, or just odd.

    Here they show that there's a spacer washer underneath the INLET valve springs, but actually the spacers should be under the EXHAUST valve springs:

    [​IMG]

    This is how it should be (I'm sure because it's how I've found factory-built engines):

    [​IMG]

    Has anybody else noticed other inaccuracies or odd advice?
    #1
  2. RedRupert

    RedRupert Brit in the Soviet Union

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    KTM say:

    [​IMG]

    Why must the sharp edges on all the disks point in the same direction? Which direction is best?

    Why does the last lining disk need to be 'turned one meshing'?

    Ignoring this advice makes absolutely no difference.
    #2
  3. JohnnyWaffles

    JohnnyWaffles Been here awhile

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    As a new motorcycle owner, I read it cover to cover. Twice. I enjoy it has an extensive manual and tool kit (even impressing the wife) and am appreciative of having such documentation.

    I'm sure there are a few peculiarities and inconsistencies, as you have discovered. Most likely I would come on here for anything anyway, and use the manual as a secondary overall reference. Again, I don't know any better than you experienced gearheads and riders on how manuals are normally. To me it's great.
    :beer
    John
    #3
  4. RedRupert

    RedRupert Brit in the Soviet Union

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    Why is it SO important not to tilt the cam-shaft when removing? There is no chance of damaging the bearing surface or cams. What do they mean?

    It would have been nice if KTM had had the cam-lobes ground perfectly square in the first place!


    [​IMG]
    #4
  5. RedRupert

    RedRupert Brit in the Soviet Union

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    I'm talking about the Repair Manual, not the Owner's Manual. The Repair manual is in no way extensive. If you think it is, I'd suggest you check a Yamaha or Kawasaki workshop manual. The KTM one is more what I'd expect from a cheap Chinese bike.

    Also, the bike has been around for ten years now; enough time for KTM to make corrections.
    #5
  6. Yascher

    Yascher Been here awhile

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    Since INTAKE valve has a bigger dia and therefore is heavier, it could be that this one needs more preload not to hang at high RPM...
    #6
  7. Dearnla

    Dearnla Been here awhile

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    I'm lucky enough to have a new bike and therefore (hopefully) don't need a repair manual for a good while yet.

    Saying that, my son had a problem with his GSX750 a couple of years back that required a top-end rebuild. I took to it like a duck to water with only a Haynes manual for reference.

    I had a deja-vu attack midway through when I announced to him that "the last time I had to do this was 1986!":eek1
    #7
  8. Yascher

    Yascher Been here awhile

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    that is correct procedure for all the bikes with wet multiclutch,
    last disc is turned to reduce the load on the splines and avoid breaking the tips with pressure from 2 discs
    #8
  9. RedRupert

    RedRupert Brit in the Soviet Union

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    But KTM do fit the spacer under the EXHAUST spring at the factory, and they do show that it fits under the EXHAUST in their fiche.

    Either way, KTM are sloppy with their info.
    #9
  10. Yascher

    Yascher Been here awhile

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    how many bikes have you taken apart before?
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  11. Yascher

    Yascher Been here awhile

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    in your initial fische it shows preload on the INTAKE
    #11
  12. RedRupert

    RedRupert Brit in the Soviet Union

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    Many. I have lost count.

    Maybe you could show me a Jap manual where the same advice is given. I can show you at least one where it is not.
    #12
  13. cross-country

    cross-country .

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    If the cams are rolled over far enough to push down against the valve springs while you are torquing the bridge bolts you will destroy the bridge. Pretty simple.
    #13
  14. RedRupert

    RedRupert Brit in the Soviet Union

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    Yes, you are correct.

    The first picture is from KTM's Repair Manual.

    The second picture is from KTM's fiche.

    Both diagrams are from KTM, yet they conflict. It's my point.
    #14
  15. RedRupert

    RedRupert Brit in the Soviet Union

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    That's not what I'm complaining about. Please look at the last sentence.
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  16. Foot dragger

    Foot dragger singletracker

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    Im guessing KTM doesnt want the sharp edges of the clutch plates to be the ones digging into the clutch basket. This would make sense to a mechanic.
    #16
  17. Foot dragger

    Foot dragger singletracker

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    Rupert is on a roll,hes got a rant going.
    Dont bring in facts or common sense.:rofl
    #17
  18. RedRupert

    RedRupert Brit in the Soviet Union

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    Please explain in more detail.

    It's the HUB that they rest against, not the basket - I'm assuming KTM are referring to the steel plates, as they are the ones that have been punched out.

    KTM dose not state which way up they all should be, just that they should all be in the same direction. If they dig in, they will do so whether installed facing in or facing out.
    #18
  19. EastSideSM

    EastSideSM Isn't that dangerous?

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    It may not be perfect, but it has saved me literally thousands of dollars in addition to this forum in labor bills at a dealership. I'd rather deal with some inconsistencies win the repair manual than the incompetence of one of the local dealers I have had the displeasure of taking my bike to.
    #19
  20. charlie264

    charlie264 Long timer

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    I wondered what that noise was.....washers. :lol3
    #20