The truly EXCESSIVE KTM tool kit

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by duncan, May 11, 2006.

  1. duncan

    duncan Adventurer

    Joined:
    Nov 3, 2003
    Oddometer:
    56
    Location:
    Salt Lake City
    This winter I did a COMPLETE engine tear down. Split the cases. I tried to just use the tools I had put together for my bikes tool kit. I go overboard on the tools I keep on my bike. Anyway here is the list of everything you
    need to tear apart your engine -- and how to carry it all INSIDE of your bike.




    KTM TOOL BAG (for under the seat tool space)

    1/4" hex bit driver (Slim handle and just the width of tool box)
    3/8" rachet (S&K -- because the round handle fits snugly in the KTM spark plug extension pieces. It is just the width of the tool box, but with extensions I have about a 15" leverage handle -- and can add to that for about 30 inches of leverage with a tire iron from my tire wizard. It worked for me.)
    KTM pliers
    Small pair of side cutter pliers
    KTM spark plug socket, extension and handle
    KTM allen wrench T nandle and KTM hex extension (6 mm)
    stubby 14 mm combination end wrench
    3/32" drift
    KTM allen wrenches (5 and 8 mm)
    mini needle nose vise grips
    1/4" socket extension
    3/8" socket extension
    KTM wrenches (8x10 and 10x13)
    2 Large KTM wrenches for axle removal (27mm and 19?? mm)
    full set of socket reducers and expanders (1/4 to 3/8 -- 3/8 to 1/2 -- 1/2 to 3/8 -- 3/8 to 1/4)

    *****************************************************************************
    PLASTIC SOCKET BOX (Small Sucrets cough drop box worked GREAT - holds 28 items)
    (This fits under the seat in the tool space)

    1/4" hex bits include
    3 mm allen
    4 mm allen
    5 mm allen
    6 mm allen
    8 mm allen
    narrow slot screwdriver
    wide slot screwdriver
    #1 philips
    #2 philips
    T25 torx
    adaptor for 1/4" square drive

    Sockets include
    19 mm
    17 mm
    14 mm
    13 mm
    12 mm
    10 mm
    8 mm
    7 mm
    6 mm
    Adaptor from 3/8 square to 1/4 inch hex drive

    KTM sockets include (driven by 6 mm T handle)
    6 mm
    8 mm
    10 mm

    A 3 cm length of 14 mm allen wrench (driven with 14 mm socket)
    A 3 cm length of 10 mm allen wrench (driven with 10 mm socket)

    Small button magnet with keeper

    *****************************************************************************
    OTHER ITEMS UNDER THE SEAT

    Electric air compressor (Cycle pump)
    Tire gauge
    Credit card multimeter
    Leatherman wave multitool (has knife, scissors, and needle nose pliers)

    In the slot under the seat is the KTM extension for the large KTM wrenches

    *****************************************************************************
    UNDER THE REAR FENDER

    Using some hose clamps I have a Tire wizard bead breaker/tire irons attached
    to the rear sub frame. I have broken the front and rear beads with this tool.

    *****************************************************************************
    LEFT FRONT SIDE PANEL (Removed the charcoal canister and built a tool box)

    Small Butane torch (Cost 4 or 5 dollars. Can solder or heat something)
    solder
    Small epoxy kit
    Extra bolt assortment (10 bolts with nuts and washers)
    Spare tube (21" tube -- can put in back in real emergency)
    Tube patch kit
    KTM Engine blocking bolt
    A small feeler gauge set (with sizes needed to adjust the valves)
    Small roll of Electrical tape
    Extra clutch lever (actually an already broken one, but usable in a pinch)

    *****************************************************************************
    RIGHT FRONT SIDE PANEL (Built tool box after removal of charcoal canister)

    15' nylon tow strap
    12' roll of mechanics wire
    12' roll of electrical wire
    aluminum space blanket
    chain saw (about 16 inches of light chain saw)
    27 mm socket (fits the swingarm bolt)
    30 mm socket (engine internals)
    32 mm socket (engine internals)
    M20 bolt with 1.5 pitch threads (fine). 20 mm long (generator removal)
    13 mm crows foot (used on the cylinder head nuts)
    1/4 drive universal wobbler (just makes life easier in 1 or 2 tight spots)

    *****************************************************************************
    'GLOVE BOX' in between tanks
    Really bright LED head lamp.
    4 or 5 zip ties
    A few first aid kit items.

    *****************************************************************************
    *****************************************************************************
    *****************************************************************************
    *****************************************************************************
    TOOLS REQUIRED TO DISSASSEMBLE AND REASSEMBLE THE ENGINE THAT ARE NOT ON BIKE

    Impact wrench
    Large torque wrench
    Small torque wrench
    rubber mallet
    circlip pliers


    *****************************************************************************
    COMMENTS

    I really did do a COMPLETE tear down of my engine. I hit a rock hard enough
    that I put a hairline crack in the left engine case, and
    also had the main case gasket leaking. Using just the tools listed above,
    I was able to split the engine, and put it all back together again.
    I didn't pull the transmission shafts out, but I was looking at them and it
    would have been another 3 or 4 minutes.

    Note that ALL this stuff is INSIDE the bike. There is no tool bag on the
    rear fender or anywhere else. The tool box under the seat is REALLY big if
    you choose your tools right. After a canisterectomy, some work, good plastic
    pieces and plastic welding on the inside converts the side
    panels into capacious storage spots. Great spot for a spare tube even
    without any work.

    1)
    These 4 tools are REALLY excessive. Only needed if you want to dissemble
    your engine. Of course, if you were in some really out of the way place,
    I bet you could find a tire shop with an impact wrench and rubber mallet, but
    much less likely to find these 4 tools. I only put these items in after
    I dissembled my engine. I might take them out since they are kind of heavy.
    There was PLENTY of space though.

    The T25 torx bit (holds bearings inside engine)
    The 32 mm socket
    The 30 mm socket (although this is needed for the clutch pack)
    M20 bolt for pulling the alternator

    2)
    Tools and other items that might get added to make the tool kit
    __REALLY EXCESSIVE__. The left side panel tool bin has lots of space left :)

    The circlip pliers
    A small chain breaker and press
    A master link and 3 or 4 links of chain
    Water pump shaft, seal, and circlips
    Spare o-ring for the clutch.
    Set of valve shims (just one in each size would take MINIMAL size and weight)

    The clutch o-ring and water pump seem to be the only real problems with
    the LC8 engine. Small and light to carry. Much lighter than the rotor
    and diode boards I saw lots of BMW airhead riders carry around.

    3)
    I have replaced several otiker clamps on the oil lines and coolant
    lines with reusable stainless steel clamps.

    4)
    Tricks in the tear down with these tools.

    I wired the clutch hub to keep it from turning when I was removing the
    bolt that holds it. Make sure the mechanics wire is small enough to fit
    through the holes in the hub for this to work. For a garage tool, I would
    order the special tool before I did this again. Getting enough wires on to
    hold a nut tightened to 200NM took 35-40 minutes. The special tool would
    take about 35 seconds.

    My tire wizard tire irons were good to drive out the pivot arm bolt in the
    swing arm. I suspect most tire irons would be too big of diameter or not
    long enough. I LIKE my tire wizard.

    Timing is EASY to set on the KTM if you have a bright light and
    remove the engine blocking bolt so you can look for the indents on the
    crankshaft counterweight. Get the official KTM engine blocking bolt. It
    is cheap, and really works well.

    5)
    Not yet on the KTM, but on my R100GS that I have had for 16 years, I've
    done all sorts of crazy repairs in motel parking lots.
    opened transmission cases, replaced bearings (pivot,paralever,steering head),
    lots of other stuff.

    So far the KTM is WAY better about not breaking.
    If I had not put the crack in my engine case, it would have been nothing but
    owners manual maintenance in 17,000 miles.




    Wendell
    #1
  2. Katoum

    Katoum Adventurer

    Joined:
    Feb 26, 2004
    Oddometer:
    760
    Location:
    British Columbia, Canada
    Excellant report, lots of great info, thanks for taking the time to share with us.
    Cheers,
    Katoum :clap :beer
    #2
  3. powerslider

    powerslider SUA* SPONTE

    Joined:
    Sep 27, 2004
    Oddometer:
    150
    Location:
    Peeples Valley, AZ
    I see you only have 53 posts. I guess this is just proof that you do not need 10,000 post's to provide excellent information. Thank you Duncan, for your time and effort.

    Powerslider
    #3
  4. barbasma

    barbasma 100% CAROTONE

    Joined:
    Aug 19, 2002
    Oddometer:
    1,821
    Location:
    Sondrio (In the middle of the Alps) Italy
    good info!!!:clap
    #4
  5. Joey

    Joey READZ

    Joined:
    Aug 15, 2005
    Oddometer:
    81
    all I can say is BLOODY HELL very impressive report, your obviously a serious Adventure Rider. Thanks for all the information, I have saved it in my KTM file just in case I ever get round to doing that proper journey (one day). Would love to see a few pics of your modifications.
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    Many thanks
    <o:p></o:p>
    Joe
    #5
  6. k7

    k7 Ancien cyclist

    Joined:
    Jul 15, 2002
    Oddometer:
    22,224
    Location:
    SOP - south of Phoenix, hotter n hell
    The large flat area under the seat is perfect for tools also. Get some closed cell foam and carve outlines in it of the tools you want to carry there.
    #6
  7. racer

    racer Long timer

    Joined:
    May 5, 2004
    Oddometer:
    1,717
    Location:
    Indiana
    Too bad you have to carry that many tools when you ride your KTM. :evil
    #7
  8. k7

    k7 Ancien cyclist

    Joined:
    Jul 15, 2002
    Oddometer:
    22,224
    Location:
    SOP - south of Phoenix, hotter n hell
    Ain't it the truth. There's always the option of calling for a tow truck and taking it back to the dealer where only the truly qualified can hook up a computer to the can-bus thingy to get the electrics from draining the battery - again.


    :lol3
    #8
  9. 9Dave

    9Dave Bazinga!

    Joined:
    Aug 4, 2005
    Oddometer:
    13,529
    Location:
    Central Ohio
    Great report. Pic's please? Especially the tools stored in the side panels?

    You, too could have 10,000 posts if you said "hell, yeah!" to every post that comes along.......:rofl

    Dave
    #9
  10. Stephen

    Stephen Long timer

    Joined:
    Feb 19, 2002
    Oddometer:
    3,236
    Location:
    Austin, Texas, USA
    Damn fine job, Wendell! :thumb

    For the folks that don't know, Mr. Duncan has been of tremendous service to those of us who worked on our own airheads. He's done it quietly and modestly and effectively, and I'm really really glad he got a 950.

    Perhaps I should make it policy always to own the same kind of bike as he.

    As in the past, thank you, sir.
    #10
  11. Gregg Wannabe

    Gregg Wannabe Just killing time

    Joined:
    Nov 10, 2003
    Oddometer:
    2,691
    Location:
    San Diego
    Well done, thanks (I only did posted this to get my post count up)
    #11
  12. b0mb3r

    b0mb3r Old Git

    Joined:
    Jan 30, 2005
    Oddometer:
    1,989
    Location:
    Sunshine Coast QLD
    he he he :wink:
    tis a nice tool kit u got :lol3
    #12
  13. k7

    k7 Ancien cyclist

    Joined:
    Jul 15, 2002
    Oddometer:
    22,224
    Location:
    SOP - south of Phoenix, hotter n hell
    uh.... hell, yeah!

    :evil
    #13
  14. 9Dave

    9Dave Bazinga!

    Joined:
    Aug 4, 2005
    Oddometer:
    13,529
    Location:
    Central Ohio
    Oh, hell, yeah!:clap
    #14
  15. srosa

    srosa Been here awhile

    Joined:
    Apr 4, 2004
    Oddometer:
    196
    Location:
    Folsom, CA USA
    +1
    #15
  16. Wayne Weber

    Wayne Weber why are we stopping?

    Joined:
    Aug 29, 2003
    Oddometer:
    3,856
    Location:
    Golden CO
    Nice list of tools, and good tips as well! I'll have to compare my list to your list and see what I'm missing. I carry two m/c tie-downs in the front fairing, in case of major engine trouble/crash damage (meaning, ride in truck home!), and they work for a lot of things like strapping spare tires to the bike.

    I'll check out your tire irons!

    Thanks!!!!
    #16
  17. k7

    k7 Ancien cyclist

    Joined:
    Jul 15, 2002
    Oddometer:
    22,224
    Location:
    SOP - south of Phoenix, hotter n hell
    Oh right...Mr McGuiver needs "tools". I recall a story of Wayne making.... wheel spacers? bearings? out of a plastic cup in CO a few years ago. :wink:
    #17
  18. Wayne Weber

    Wayne Weber why are we stopping?

    Joined:
    Aug 29, 2003
    Oddometer:
    3,856
    Location:
    Golden CO
    I googled, and the Tire Wizard website seems to be gone now....any other way to find this? I found some pics on advrider, it looks like it works and doesn't scratch the rim.
    #18
  19. Wayne Weber

    Wayne Weber why are we stopping?

    Joined:
    Aug 29, 2003
    Oddometer:
    3,856
    Location:
    Golden CO
    :rofl linky to that

    http://www.advrider.com/forums/showthread.php?t=48092

    Duncan sounds like some one who does maintenance, so it will be a good laugh for him...

    my brothers bike, but Wes, JuanG and me all came up with the plastic cup bearing idea. P.S. we have cush drive LC4 hubs now!!
    #19
  20. duncan

    duncan Adventurer

    Joined:
    Nov 3, 2003
    Oddometer:
    56
    Location:
    Salt Lake City
    I think the guy making tire wizards had a crash (or got sick) about 5 years ago -- so they're not around unless you can find a used one. I got mine from ebay. about 4 years ago.

    Note that the instructions are almost unintelligible -- the product is good. Figure them out in the garage on your own schedule and you'll be happy. Figure them out at night with a flat and you'll hate them.

    I always do my own maintenance. Best way to learn how to keep it going when you break something -- and too many times I've asked a question at the shop and gotten scared by just how clueless the mechanics and parts guys are. Most recently, how can a guy working a parts counter in a motorcycle dealership not know what a valve shim (or spacer or the thingy that goes under the bucket when you adjust valve clearance -- nothing rang a bell) is? I ran into one about 5 months ago. I hope he at least knows 2-stroke motors, but I wouldn't bet on it.

    Wendell
    #20