Went there, did this

[shoganai]

Steve and I tore into the KTM 9 fiddy's clutch.
It all started with a grindy-clattery sound.
Together we believed we had isolated the sound from around the clutch.
Earlier Steve found a fair amount metal shaving on the oil drain plug.

These pictures aren't really in any special order and this is not a "how to" thread.

Left side of bike.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05484/1246664907_WCamB-L.jpg

Right side and clutch just about apart.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05483/1246664747_soPeQ-L.jpg

The break up and make up table.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05492/1246665667_6ZCW2-L.jpg

Here you see the clutch booster resting in inner clutch hub.

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3418/1246641551_KLy6u-L.jpg

Clutch booster pulled out.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05486/1246665168_hUb5x-L.jpg

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3414/1246640617_vJMzf-L.jpg

In the pic above you can see 2 notches on the bottom...

This is the very bottom of the inner clutch hub and mating surface for those notches.

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3415/1246640756_wzCkB-L.jpg


http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3416/1246640843_dhSRi-L.jpg

This was a pretty disturbing find on the inner face of the outer clutch hub.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05487-1/1246665199_tjDKQ-L.jpg

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3413/1246640465_X9Vng-L.jpg

Some scoring/gouging seen here along the toothed side. (The bright ring)

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3419/1246641739_ptCdz-L.jpg

And on the clutch plates.

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3420/1246641930_uSZeh-L.jpg

The oil filter.

http://shoganai.smugmug.com/Motorcycles/KTM-950/IMG3424/1246642991_KziPG-L.jpg

We did a valve adjustment while in there.

This is me torquing the down the cam shaft bracket / top of the cylinder head.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05481/1246664501_G8uj3-L.jpg

And zip tying up wires.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05485/1246665028_vXk4M-L.jpg


It was a GREAT time in the garage with my husband. Perhaps the best ever!

Anyway, we’re now waiting for a little over $600 in parts.




.

[Luna Tique]

Great title for this one :rofl:

The break up and make up table.

http://shoganai.smugmug.com/Motorcycles/KTM-950/DSC05492/1246665667_6ZCW2-L.jpg

.

My husband and I work together every day.
It is great to bring a project together and being able to enjoy the satisfaction of knowing you each had a part in it. :thumbup:

:chin:Just curious: What causes that kind of damage.? Is it weak metal?

[msyzf2u]

How did I miss this great thread ?

More Please!

I'd also like to know what caused this to go wrong

Also... loving all the pictures!

[Cyclone67]

I missed it too somehow -- thanks for the bump!!

I need to get down and dirty like this with my bikes!!

[msyzf2u]

Shoganai.... How did this all turn out ?


:popcorn1:

[BlueLghtning]

pretty cool jumping into that together. Sarah and I have done projects together, but usually she kicks me away and attacks them herself!

That is pretty strange it did that? Did you find a reason why it gouged the metal in those places?

[shoganai]

Ok to the best of our knowledge this is how it we got to that point.


1. Bought it from a friend as a favor with a cracked engine case. He had tried to patch it with JB Weld, which will not work in the presence of that much oil.


2. We slit the cases, and had it welded.


3. After putting it back together, it started making a bad sound.


4. Open the cases up, found some damaged bearings, most likely caused from the welding of the crack.


5. Bought a 20 ton press and replaced the bearings, all but two which looked good.


6. Put it back together and found a part was left out.


7. Opened up the cases, put missing part in, damages gasket, ordered gasket.


8. Put it back together ran it a while, and oil was gushing into the air box (a tiny bit is normal) It was also making a bad sound from the clutch cover side now.


9. Removed the clutch, found scoring on the plate and a bad needle bearing, ordered new bearings and plates, replaced they all put it back together.


10. Ran it a short while, oil still gushing into the air box and engine sounded worse.


11. Opened the cases again, found large amounts of metal shavings in there and clogging the oil filter. Found one one bearing we didn't replace failed, consumed itself and damaged the other bearings, the rings, pistons, and timing chain rails.


12. We found some heads used and in very good condition, complete with good pistons, cams and valves. We replaced the rings and adjusted the valves. We replaced ALL the bearings and took the clutch apart fro cleaning and inspection. It looked good. All the oil jets were also replaces.


13. Put it back together and ran it a while. It ran and sounded great, but was still dumping oil in the air box. Discovered there was one more seal that was bad, replaced it and as of two days ago we has declared the KTM CPR was a success!!!


The bike runs and sounds great!
And we both learned a lot, and that is beyond price.

[zee]

Wow, sounds like quite the ordeal. Glad you figured it all out!! :thumbsup:

[Cyclone67]

Shogani -- you Rock!! I hope to be able to do a project like that some time in the future!

[msyzf2u]

:wootrock::clapping::wootrock::clapping::wootrock: :clapping:


Shogani, that is one heck of a story!

[shoganai]

Thanks, however this was Steve's project, I just helped out and learned a lot.

And it's Shoganai or Gwen if you like :D (not that it matters, most people spell it wrong just like that)

Shogani -- you Rock!! I hope to be able to do a project like that some time in the future!

[Luna Tique]

Shogani -- you Rock!! I hope to be able to do a project like that some time in the future!


I would hope to be able to be patient enough to attempt a project like that.:D:

My tendency is to :ohsnap: when things get complicated and keep going wrong.:mgbanghead: