Major service

I know this has been covered before.

But tomorrow I'm Going to start my major service myself.
Having read up on this with alittle due care and attention I should be ok. To be honest only thing I'm worried about is if the shim do need replacing making that calculation to get the right ones.

I've seen a table that's available. So fingers crossed.

What I'm after is other than feeler gauges are any other special tools do I require?

Also and hot tips to make this job a little stress free

Thanks guys/girls

Another member just did his first valve check, here is his thread on it:

Besides the normal tools I'd recommend getting there things:

2x KR8DI iridium plugs.

Anti-seize for the plugs.

Blue loctite.

You can purchase a Hotcams shim set if you think you'll be keeping the bike for while part number is HCSHIM31.

This sparkplug tool works and is cheap:

0113 080802 Crankshaft locking bolt.



There's a couple other things but it's all listed here as well as the excel document for figuring out what shims you need:

Thanks for that. I shall get them ordered!

So I will do the service once this arrives.

Bike done 14k I'm hoping that im not going to need shims just yet! Only time will tell

well i started it today.

so far no real big issues.. my only thing so far that took the most time was pulling the grey connector in half... did they glue it shut

ive drained all the oil and removed the radiator. (i know this is not required) but i wanted to change the coolant plus gave me the opportunity to clean a few bit up...

so unable to continue as my Local Dealer said my parts would arrive on TUE when i ordered them on friday.. But still waiting

so this is my current situation Bike looking extremely sorry for itself



my clutch cover looking real bad but ive ordered a new one so gave me a reason to inspect the clutch







well as im waiting on parts i decided to remove the black strip on the tank (it was all chipped and made the bike look ruff) the pic shows me half way through removing it



and how it looks currently



so thats me all done for today.. fingers crossed my local dealer have my parts in tomorrow

Presumably your local dealer i s L****a, as per your other thread - recommend contacting Darren @ Redline for parts in the future.

yes No.47 it is.

I did look at redline site and was going to order them.. saw that the clutch cover was a 5-7 day wait.. so thought i would give the local a try and they said "yep we can have these to you for tue"

i thought win win! ill get started on the job by the time the parts arrive all i would need to do is check my clearances.. (praying shims are within spec and dont need changing)otherwise its more waiting then its all back together.

Always best to call them to check.

After today experience I definitely will..

Shall post more pics once done

Well today I had to pop to halfords to buy some feeler gauges as Laguna still haven't received my stuff.

Checked clearance and all are within spec. (Winner)

Bikes all back together Laguna did have my filter pack and plugs so as soon as my clutch cover arrives with my other little bits I shall get it started up..

Getting withdrawal now

My valves were also within specs at the first 10k mile service. Nice!

Are you doing the water pump rebuild? I did mine just in case. I know I have peace of mind for the next 10k or more miles.

No I've not done it.

Are they prone to failure then?

You'll find different answers to that question. Some say ... (Sounding like Jeremy Clarkson here) better safe than sorry, others say, if it ain't broke don't fix it.

Since I had half the bike apart, I ordered the parts and did it at the same time. Here in the US, I ordered a $90 kit from ktm-parts.com. I know CJ Designs sells the kit for $160 and they guarantee the shaft for 30k miles. That's a good warranty.

Thanks for that.

Mmmmmm not sure what to do now!!

Does the bike need to be stripped again? If so I'll leave it til it breaks!

Not the top end. The water pump is in the right side of the engine. See links in my original post.


Sarasota_Steve
Black 08 990

I did have a little sand like residue (black)

but other than that coolant looked fine. oil looked fine.

i have bike back together now minus oil,coolant as im waiting on my new clutch cover to arrive before i put these in..

what you think? leave it til it goes or wait a few more days and get water pump sorted.. either way not buying from Laguna waited nearly a week now..

The little sand residue is the casting sand that remains and usualy makes the wear faster on seals and shafts.

It's your choice, I changed mine when I got it and since you're going over everything just take care of it now and sleep at rest

You may get a lot of problem free miles/km's from it and have it done next service...or not

I've had a good look into this.

And your right I should do it while it's being serviced.

But I was too keen to get the bike out on the road.
So I'm going to risk it for a chocolate biscuit. If it goes just means I need to buy more oil and filters again.

But thank you for the input I appreciate it

Bike is all up and running now. Took bike out for a sneaky test ride