Back Ordered Stator - Advice or Spare?

Discussion in 'Dakar champion (950/990)' started by sakurama, Jul 13, 2008.

  1. TMoore

    TMoore Arai Helmet Test Dummy Supporter

    Joined:
    Jan 8, 2005
    Oddometer:
    984
    Location:
    OK! (Formerly from The Peoples Republic of Mass)
    Yes mine is an 04 with 18k miles.

    I thought the 05s and up had a starter "clutch" that had a warranty
    issue? 04s have a different design. My starter had started to clack
    but I thought it was "normal". Now I think it was the first sign that these
    bolts were coming loose. The starter drives the crank through this
    assembly. I got the two snapped bolts out without removing the
    rotor.

    Thanks. Advice appreciated.
    Tim

    #41
  2. sakurama

    sakurama on an endless build

    Joined:
    Oct 20, 2004
    Oddometer:
    1,647
    Location:
    Portland, OR
    I agree, my charging system was on it's way out but I didn't think it was because my rotor was coming unglued and my shop didn't bother to check (and neither did I to be honest) and I did an entire track day in that condition. I'm guessing I dodged a bullet but there wasn't much in the oil when I changed it - most of the debris was contained in the cover.

    I'm going to say the rotor is fine - it's only galled on that inside and that back part isn't a "precision" fit. As long as it's still nicely round I'd bet you're fine.

    It's not all that hard although it seems daunting - an oil change and about a dozen screws (most of which you've already got out) but I understand if you've got other stuff going on. Goodluck!

    Gregor
    #42
  3. TMoore

    TMoore Arai Helmet Test Dummy Supporter

    Joined:
    Jan 8, 2005
    Oddometer:
    984
    Location:
    OK! (Formerly from The Peoples Republic of Mass)
    My stator is actually wrecked. No rewind for me. :(:
    #43
  4. TMoore

    TMoore Arai Helmet Test Dummy Supporter

    Joined:
    Jan 8, 2005
    Oddometer:
    984
    Location:
    OK! (Formerly from The Peoples Republic of Mass)
    My stator was wrecked from the bolt heads going round and round.
    Cliffs got me a new one in a week along with the 6 bolts and I sourced
    some Loctite 648 from McMaster. Cliffs also loaned me the factory rotor
    puller. I put it together wrong the first time
    and had to take it all apart and re-do it but it runs now. I did a 410 mile
    day on Saturday and it ran like a top. I still get a big clack out of the
    starter when I shut the motor off. It also clacks a lot if I bungle the
    start (when warm). I will probably do the 05 torque limter upgrade over
    the winter. New left side cover and a gear is all it is Im told.

    Anyway thanks for the help. I would have been up shit creek without this
    site and its inmates :thumb

    Tim
    #44
  5. apeirce

    apeirce So I was following Andrew

    Joined:
    Jan 28, 2003
    Oddometer:
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    CT USA
    Sorry that the whole thing happened, but glad you are back and running.
    #45
  6. zugy

    zugy My brother wheeling SXC

    Joined:
    Apr 23, 2005
    Oddometer:
    192
    Location:
    So. California
    You would think this would be covered under warranty. Mine just went out same deal....bolts loose. Maybe got hot and loosened the lock adhesive. Gary or Germany will be getting a call.
    #46
  7. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,130
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    What year? How many miles?
    #47
  8. pops

    pops Long timer

    Joined:
    May 15, 2007
    Oddometer:
    1,857
    Location:
    Stirling North South Australia
    Mine to a few years back :cry.
    I Had to ride it over 100km to get home .



    Bit of a mess.
    [​IMG]

    [​IMG]


    New stator and fly wheel $$$ and a good clean up, all is good .

    [​IMG]

    Cheers Ian
    #48
  9. sakurama

    sakurama on an endless build

    Joined:
    Oct 20, 2004
    Oddometer:
    1,647
    Location:
    Portland, OR
    FWIW, my rebuilt one is still going strong with about 56,000 so far. The base gaskets leak like sieves but the stator is doing fine still.

    Gregor
    #49
  10. zugy

    zugy My brother wheeling SXC

    Joined:
    Apr 23, 2005
    Oddometer:
    192
    Location:
    So. California
    #50
  11. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
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    Location:
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    Its amazxing KTM is still sending engines out without the proper loctite 648 application after all these years. That TB was issued Oct 2004. Musta' have been some newbie trolls hired in '05 and '07. Lotsa Mattighofen FUBARs those years.
    #51
  12. MortimerSickle

    MortimerSickle Semi-Adventurer

    Joined:
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    Oddometer:
    16,405
    Location:
    Rainville, Orygun, where moss is a road hazard.

    Zugy, did you mean that your '07 has suffered the loose-bolt problem?

    I ask, because I had thought that my "07 was safe from this.
    #52
  13. MAXVERT

    MAXVERT O.G. on da O.C.

    Joined:
    Jan 19, 2004
    Oddometer:
    2,386
    Location:
    Baja Arizona
    Don't count on it !
    I did my '07 after the first summer of riding and a couple of the fasteners
    were hand tight.
    I'm glad I got in there and did the job.
    It's a quick fix, especially if you already have the tanks off.
    Max
    #53
  14. MortimerSickle

    MortimerSickle Semi-Adventurer

    Joined:
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    Location:
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    It is a quick fix if you know it needs to be done: just take out the bolts, clean the threads, refit with the 648, and torque- little or no heat necessary.

    But, I don't see how to check to find whether it is already properly done: To check the torque would not tell me what kind of Loctite had been used. It would tell me whether it had already failed, but it would not tell me whether it was about to fail.

    I would think the only thing to do would be go ahead and do the R&R. But, I'm not too keen on having to heat the assembly to almost 500 degrees (necessary for 648) to remove and refit the bolts just to be sure. That is a lot of heat, and I would worry about damage.

    Someone please tell me all the 990s are safe. :D
    #54
  15. cpmodem

    cpmodem Orange Caveman

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    If the bolts have been done, there is supposed to be a spot of paint on each one and the adjacent part of the rotor. There will also be a spot of paint on the outside of the ignition cover at the top near the engine mount.
    #55
  16. MortimerSickle

    MortimerSickle Semi-Adventurer

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    Thanks.
    #56
  17. pops

    pops Long timer

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    Do you mean to say that the new stator i fitted will need to have the bolts taken out and some Loctite put on them?

    Cheers Ian.
    #57
  18. pops

    pops Long timer

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    Bump



    #58
  19. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
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    Location:
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    The questionable bolts are on the rotor. No need to remove the stator. My last post should read rotor not stator. Well into cocktail hour.
    #59
  20. pops

    pops Long timer

    Joined:
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    :thumbThank you.

    #60