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Discussion in 'Australia' started by overlandr, May 10, 2006.
Ha, got caught-out the first time I pulled swing-arm - needles everywhere!
Yes, I lost 3. So I took some out of a bearing I replaced and cut them to the correct length. Should be okay.
While the hose topic is (semi) fresh..
I used Calibre brand clamps from Super Cheap to fit this kit today, they're smooth internally with rounded edges so don't seem to bite the silicone. The lower two hoses on the pump were a bit too close so I had to Dremel a small portion of one clamp.
The T - shaped hose was a tighter fit running beneath/alongside the top of the mainframe which I could detect when fitting the tank but hey, it's all good now.
Thanks for that. I've just replaced the thermostat and coolant, will do hoses next year.
My OEM hoses have always clashed on the lower water pump connections. I was lucky that I discovered the clamp was cutting the hose against the ridge on the end of the outlet pipe, it failed when I removed the hose. I noticed that last time I had that hose off. Fortunately I could just cut the hose through the split to shorten in by 10 mm and it still fitted. But I could not get that clamp to sit inboard of the ridge like it is supposed to. Will make sure I do so when I do the full replacement.
I got some parts, specifically the bolts for mounting the subframe to the main frame.
The originals fasten by allen-key, these are a star-shaped key, a torx bit think. I checked the part numbers and they match, so it seems KTM are supplying bolts that require the use of a separate and different tool (torx bit) to the original (allen key), requiring an expanded tool kit for owners.
Is this the new normal? Anyone else had annoying crap like this?
I think so. Not the first time I've heard of this.
Torx are better, but yes it does mean updating the tool kit. They are rife on the 1190 - but the OEM tool kit has the bits.
Something like this is handy.
Any KTM bolt I have ordered for the last two years has been supplied with a torx head. 8mm/10mm/13mm.
Less weight in a torx bolt. Your bike will get lighter the more bolts that fall off.
I have found the part fiche usually shows the original part no. has been superseded by the torx part.
The subframe to main frame connection bolts on my 625 would work loose in its later years..they are Allen bolts ..some bitumen paint keeps them locked in but still easy to undo.
Also, my 625 has become very hard, almost impossible to push with engine off, clutch pulled in, but in gear...rolls freely when in neutral with engine off and clutch not pulled in..as it should...clutch problem ?. Master cylindar /slave cylidar. When riding it, the gear changes are smooth as silk up or down..no slip either...
Possibly clutch basket fingers worn, not letting the plates separate easily.
A question for the collective.
While trying to fit the front wheel, the pads keep just falling out of the caliper.(the rear likes to do the same trick...).
The pads in my original bike just sit in there, the pads on my current ride, Ratty, have a backing plate, just to add more bits to get right, but the biggie seems to be the spring clip in the centre of the caliper at the back of the pads. Mine had worked its way down to the bottom of the caliper and was preventing the pads from being remounted. When I removed it and attempted to refit it in its central location a bit of the spring steel, a tab, just snapped off.
Now the question : Is there some trick to fitting these awkward little spring-clip fuckers, or was I just unlucky (again)?
(I've actually got a spare caliper with a spare spring clip, it is with ADpete who isn't using it.....)
Are you talling about item 3 @GodSilla:
On the caliper body side of those spring clips are a couple of tabs that should grab the caliper and hold them in place. The should mount fairly firmly. Gently bend them closer together if they are loose.
Edit: yes I think you were unlucky!
Yep, part number 3 is the culprit, it has tiny tabs that hold it in place, and one of them just broke. I reckon I was just unlucky too.
On another note, I drove to Melbourne and picked up some parts, many thanks to @tileman and @kveldulv for holding on to them. I was trying to fit a RallyRaid carbon-fibre front guard when I had this issue crop up.
I've got parts on order from Boltons to repair it, but over $30 for a pair of tiny spring clips is a bit rude.
@GodSilla ... we're talking about 'unobtanium' now... Such parts will not be avalialable from the mothership soon...
Shoulda called / dropped in here!! I have parts and pieces :) Am seriously thinking about releasing all my 640Adv stockpile to the winds...
I reckon I may have broken one of them in past doing the retension thing. Being spring steel maybe they get brittle with age.
Early 640's have same Caliper listed as all the EXC's, and the later ones are same Caliper as 690's and 990's, so there should be a supply for a while, and then a gradual increase in wrecked ones.
But $30 is still a bit steep. I see the pad retaining pin with 2 R Clips is $30 as well.
Speaking of overpriced bits, Needle and Seat for an FCR carb $116 !!
Does anyone know where I might be able to get an aftermarket kit?
Check the parts list for Jap MX bikes from around 2005 or so. Their parts prices vary greatly.
Prices for the slide plate and seal
Kawasaki: $90 for both
Suzuki: $160 for the plate, $17 for the seal
Honda: $252 for both
Yamaha: $137 plate, $39 seal
KTM: $365 plate $30 seal
I've used these blokes for local supply in the past. https://showandgo.com.au/carbie/carb.htm?carb_bf.html~mainFrame
If your using it on a bike with pump you may want to get a smaller unit.
Safari tank gravity fed, so no pump.
I have bought jets off motorcyclespareswarehouse before so have emailed them as well.
Guys, New OEM cush hub. How tight should the sprocket carrier be in new cush rubbers? I've been smiting it with a rubber mallet and it is very tight, and doesn't want to sit in far enough for the bearings to touch. Makes me wonder if it will actually do any cushioning On my DR they are firm, but the carrier can be pushed in by hand
Is this the correct fitment?