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  #1  
Old 17 Jul 2010
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HELP! KTM LC4 Expert needed in Darwin!

Hi,

I've just arrived in Oz with my bike and need a local expert who can help/lend me some tools and workspace in exchange for so I can ride into the desert of your stupidly large country with less fear or dying.

I need some work doing on my 2006 KMT 640 Adventure. It's a simple job really which I would like to do myself, but nobody seems to have the tool available. Basically I need to replace the starter sprag clutch, which I have.

I have borrowed under threat of death a flywheel puller - possibly not the right size, from NT motorcycles, however they do not have any means of holding the flywheel whilst the crank nut is untightened. Alternatively I could use an air gun but am not sure if this might cause damage.

Is there anyone around who can help please? I've not yet been able to try AliMoto in Winellie but as I mentioned would prefer to do the work myself - I learn more that way.

Cheers

Duncan
0422458655
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  #2  
Old 17 Jul 2010
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Have you tried contacting the Communities?
If all else fails - KTM Australia site has a dealer search facility here
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  #3  
Old 18 Jul 2010
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NT Motorcycles - the only nearest dealer for over 1000km, doesn't have the tools for the repair.

What Communities?
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  #4  
Old 18 Jul 2010
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Communities is on the left hand side here is a short cut http://www.horizonsunlimited.com/com...tEnglish.shtml

you could also try Advrider in the Aussie section Australia - ADVrider
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  #5  
Old 18 Jul 2010
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Have sent a community message and will post on ADV now. Thanks!
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  #6  
Old 18 Jul 2010
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I know they are in Alice Springs but they may have a contact
Finke Desert Race

OR-
N.T. Motorcycle Centre
Stuart Highway Service Rd
Darwin NT 0800, Australia
(08) 8939 0390

other general one
Norm's Motor Cycle Repairs
436 Stuart Hwy
Winnellie NT 0820, Australia
(08) 8947 2011
Home - Precision Honda

Motorcycle Territory
1/53 Hickman St
Winnellie NT 0820, Australia
(08) 8947 0042
Motorcycle Territory - Servicing Harley Davidson, Trumph and Ducati


Holeshot Kawasaki
2/53 Hickman St
Winnellie NT 0820, Australia
(08) 8984 4388

one of those hopefully has a contact for you / the ability to help?

Last edited by Bertrand; 18 Jul 2010 at 10:10. Reason: added info
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  #7  
Old 18 Jul 2010
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I don't know anyone in Oz, but still:

- I'm told that on certain KTM models, one can lock the crank with the crank shaft screw (KTM special part, but can easily be self-made). Basically if you have a Kokusan 4k-3 or a SEM rotor, the torque is "only" 60 NM so this works. If your bike has a Kokusan 4K-2, the torque is a whopping 150 NM and you will ruin your crank if you block it with the screw. The easiest way to find out which one you have, is to look at the hex nut of the flywheel. If it's M16 x 1.25, then it's the Kokusan 4K-2 with 150 NM, so the screw is a no-go. However, if it's M12 x 1 with 60 NM you can lock the crank with the screw. My parts manual says the 2006 Adventure has the 4K-2, so this won't work for you unless someone put a different stator in there, but I'm still putting it here for future reference.

- If you can't find the KTM wrench (584.29.012.000), I suppose you could order it through KTM, it should get there quickly, but it's about 70 EUR, so probably not. You can however use a generic flywheel holder as used by non-brand specific automotive mechanics. Look at the pic below, you'll get the idea. They should be available, or can be improvised if neccessary (as the one below is).



Finally, re the flywheel puller, if you can't get the right size, this one is cheap (<15 EUR), so ordering it through KTM is a viable option. The puller ought to be 584.29.009.000 for your bike, best to get the protection cap too (584.29.031.000). Oh and the thread is left-handed, so watch out for that!


Edit: here's a pic of a non-self made flywheel/rotor/clutch holder, this one is a honda tool, maybe you have a Honda dealer nearby?


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Old 18 Jul 2010
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Good advice above.

I used a 3/4" air impact gun, tightened it with a light touch on same & red loctite, 40 000km later no problems. (usually I use a torque wrench on such things but I didn't have a left hand one) You will certainly not damage anything taking off the nut with a rattlegun & the average 1/2" drive air impact gun is probably not capable of damaging it during tightening.

Cheers
Clint
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  #9  
Old 19 Jul 2010
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Thanks for all your advice guys. I popped down to Territory Motorcycles who were ridiculously helpful and we managed to remove the crank nut without drama with an impact gun.

The remover I had was also the wrong size so we tried to create one without success. I then measured the thread size and ran round other shops to see if they had one, also without success so bit the bullet and ordered the (hopefully) right one from KTM which should be here in a few days.

Sadly a 2 hour job turned into a bit of a nightmare and I got rather stressed not being able to find the right tool. Hopefully everything should be straightforwards once the puller arrives.

Thank you all!
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Old 19 Jul 2010
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I have heard of people removing the flywheel with a basic combination puller like this one:



I tried one on mine but it didn't work, mine was too tight - you really don't want to put too much stress on the flywheel. Might be worth try though. My local KTM dealer didn't even have the proper puller so I decided to just spend the $50 & now I own one.

Cheers
Clint
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  #11  
Old 21 Jul 2010
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We tried the combination puller too, but due to only having two points of support also didnt work - we were unable to remove some of the bolts holding the flywheel to the freewheel.

Just a bit miffed that I had to buy the tool for one time use. Anyone want to buy one?
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Old 21 Jul 2010
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Dude the flywheel puller is like 10 quid - get over it :P

If on the other hand, you also bought the holding wrench thing ... I'd be interested.
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  #13  
Old 21 Jul 2010
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95AUD here... and it has to come all the way from western Oz...that's a lot of !
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Old 21 Jul 2010
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Quote:
Originally Posted by DuncanCarwright View Post
95AUD here... and it has to come all the way from western Oz...that's a lot of !
Crikey, the ozzies get a bit raped on KTM parts prices. Mine has just about paid for itself in s from the people I have lent it to.

Now that it is too late I just remembered how you loosen/tighten that flywheel nut without a crank holding tool or an air impact wrench: You need a 1/2" socket to fit & a 1/2" drive t-handle adapter thingy that you slide a short (about 150mm) socket extension through, so its kinda like this but with a shorter handle:



Wrap some tape aroung the extension & adapter to keep them together, then put it on the nut & whack it with a BF Hammer = poor mans impact wrench / Flogging spanner. Having the bike in gear with the rear brake ziptied on helps too.

Don't do this with someone elses tools without asking

Cheers
Clint
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  #15  
Old 21 Jul 2010
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I tried something along those lines, however knocking it into gear didnt work. I think this is because the sprag clutch is going it doesn't engage and the engine just turns freely and is disengaged from the gearbox until the engine fires up and centrifugal force causes the freewheel to be engaged. I could be wrong though...

When my tool comes I ill steal someones impact gun as an easy solution.
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