crank rebuild kit - KTM Forums: KTM Motorcycle Forum
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post #1 of 8 (permalink) Old 10-06-2016, 04:15 AM Thread Starter
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crank rebuild kit

i have stripped the engine out of my 2002 lc4 640, im fairly good with a set of spanners, is pulling the crank apart something i can do in my shed, also would a 2006 crank fit into a 2002, any advice is most welcome, someone said change the crank bearings while im at it because the old ones tend to let go i decided as im pulling the engine out i might as well dismantle the entire bike powdercoat the frame, polish the swingarm the whole lot, will be lovely when done, im in surrey england, any decent powder coating around here?
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post #2 of 8 (permalink) Old 10-06-2016, 08:04 AM
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Welcome Spongebob, cool user name. My kids love spongebob.

Splitting the crank is very tricky and I would recomend getting an expert to do it. There is a fair bit involved. Sometimes the crank journals have to be heated to a specific temp and when assembling back together the crank pin has to be lined up very precisely with oil galleries as well as not creating to much run out on the crank journals + keeping within specs with axial clearance.
If milltech tags in, he will be a lot more knowledgeable than me in this area.
I have rebuilt many engines and the 2 things I don't attempt is re-coating cylinders and splitting cranks.

I don't know if an 06 crank will bolt in. I think they are different part numbers which usually means that it probably won't.
I am an aussie, so I can't answer your powder coating question sorry.
I will try to help with any other questions you might have.

Good luck with it.
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post #3 of 8 (permalink) Old 10-06-2016, 08:24 AM
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Welcome to the forum SB.

I'd concur with DW about the level of expertise required for
working on crankshafts. You may have the experience.

The 02 640 used to use this crankshaft 58430018200, which is now
superseded by 58430018300.
58430018300 is used by the following bikes (so you can do what you ask):

2005 625 SMC CRANKSHAFT, KOLBEN 625 SXC (Item Number 1)
2005 640 ADVENTURE CRANKSHAFT, KOLBEN 625 SXC (Item Number 1)
2006 625 SMC CRANKSHAFT, PISTON (Item Number 1)
2006 640 LC4 ADVENTURE CRANKSHAFT, PISTON (Item Number 1)
2007 640 ADVENTURE CRANKSHAFT, PISTON (Item Number 1)

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2008 KTM 950 Super Enduro R
2008 Husqvarna 610 TE

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'14 Honda NC700X
'11 Husaberg TE 300
'06 Ducati 1000S Multistrada DS
'04 BMW 1150 RT
'03 KTM 450 EXC
'02 KTM 640 LC4e
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'00 KTM 520 EXC
'98 Honda XR600R
'95 KTM 620 RXC
'90 KTM 500 MX
'88 Yamaha TT600
'86 Yamaha XT 350
'84 Yamaha IT465 (STOLEN)
'83 Kawasaki KDX 450
'83 Honda CB1000 Custom
'82 Kawasaki KDX 400
'77 Yamaha DT200
'70 Honda CT70

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post #4 of 8 (permalink) Old 10-06-2016, 08:32 AM Thread Starter
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thanks very much for your input , i like to know what im letting myself in for lol
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post #5 of 8 (permalink) Old 10-06-2016, 08:41 AM Thread Starter
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thanks Bajadog, thats good information, i bought this ktm knowing it had a dodgy engine, a really bad knocking sound, i presume its the big end going gone, the bike ran and looks like its been well cared for in the past, has taken me a day and a half but totally stripped the bike down to bare frame, and start over, guess i will take the head off and see, but definitely metal fillings in the sump plug, somethings gone, :-)
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post #6 of 8 (permalink) Old 10-06-2016, 09:08 AM Thread Starter
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Hi Bajadog, i just watched a youtube video called ktm main shaft bearing replacement, it might be just that, that has gone, fingers crossed, i will take the clutch cover off and give it a rattle, if its that then happy days i think :-)
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post #7 of 8 (permalink) Old 10-06-2016, 09:25 AM
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Baja is right on (as usual) with his parts information. I am a HUGE advocate of doing everything you can by yourself. This is not a crank rebuild I recommend attempting on your own. That being said, if you were to call KTM they will NOT rebuild this crank. You will also be hard pressed to find any reputable shop that will attempt to repair. Without getting too technical, the problem is the webbing at the counterweight is prone to breaking during disassembly and re-assembly. We have just spent a huge amount of time making a fixture and process that will allow us to perform the rebuild. We will begin testing this in mid-October. I'm not sure why more people don't rebuild their own cranks. (I'm also glad they don't, because this is how I pay the mortgage!) I applaud your thought process and would encourage you to attempt if this were another model.

Unsolicited sales plug here: We rebuild all 125cc and smaller cranks for $84.95. 150cc and up are $109.95
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post #8 of 8 (permalink) Old 10-07-2016, 06:49 AM
DW
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The knock may not be the big end. I have had the crank main bearings make a a bad knocking noise due to pitting on the inner races especially if the engine had been sitting or had a bit of moisture in it. I don't think it happens on the lc4 but I have also come across bad knocking noises on the rfs engines which has sometimes been a loose primary drive and or worn woodruff key.
I suppose when you pull it all down you will find out. Just check your radial free play in the big end.
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