Dirk
Puppy
Hi All,
I just joined here. I happened on the site while searching for info, parts and replacement bikes lol.
My 690 recently had a camshaft failure of sorts, around the 55k km's mark. It has a full dealer service history, and the rockers were replaced 2 years prior under warranty at KTM. The camshaft bearing broke, disintegrating it inside the head, along with the rocker arm rollers (rockers are fine, rollers pitted) and the camshaft itself was destroyed. On the other side of the larger bearing, the camshaft retaining hanger snapped off on one side, dropping into the bottom. I attached some pics of the ordeal - ignore the dirt, cleaning is still due.
I have since disassembled the top engine assembly. I managed to remove the leftover needle sleeve of the smaller camshaft bearing without damaging the head further. I tried checking whether it was warped oval, but couldn't get my vernier scale in there to confirm all edges. It appears round enough from sight, but ja...
Anyhow, I've also started disassembling the bottom, when the other half of the needle hanger drained out with the remaining oil. The hanger bit seems unscathed, and I did not notice metal filings in the drained oil (drained it onto cardboard for the oil to soak in and particles to remain behind), making me wishful that it didn't come into contact with anything. I don't have a case splitter or harmonic puller, so I may be in for those tools if opening the bottom takes place (alongside the expensive case gasket). For surety and safety's sake I should, but I'd like to avoid splitting the bottom, as that's an expensive gasket to replace, and with my riding frequency, may be worth the savings risk. I'm wishful that cleaning the un-split but open bottom with carb cleaner will reveal any metal filings, and if none are found, reassembly can commence.
Knowing the risk I'm taking with the bottom, I'd appreciate hearing some opinions on the potential repair.
I'm in for several pricey gaskets so far (unless cutting them from gasket paper using my templates would suffice for some), alongside a new head small bearing, new camshaft, new intake rocker and new exhaust rocker. This is besides other sundries like oil. The KTM dealer initially quoted R30k to open it up and repair, which was without checking apparently, and after charging me for a new battery, despite the old one working. Nonetheless, seeing the damage now, I'm in for around R15k in these parts, without replacing anything in the bottom. I may get flamed for this, but after my frustrations, I have half a mind of modifying it to take an 8kw electric motor, batteries and a charger.
Anyhow, do I risk sunk costs and attempt the repair? Do I pay KTM R30k or more to repair a bike that I could probably only sell for R30-40k? Does anyone have a private mechanic in Pretoria that could possibly carry out the repairs reliably and affordably? Do I part out? Do I forego the engine and apparent respect, and stuff an equivalent 8kw electric motor in there and aim for 150km range?
I just joined here. I happened on the site while searching for info, parts and replacement bikes lol.
My 690 recently had a camshaft failure of sorts, around the 55k km's mark. It has a full dealer service history, and the rockers were replaced 2 years prior under warranty at KTM. The camshaft bearing broke, disintegrating it inside the head, along with the rocker arm rollers (rockers are fine, rollers pitted) and the camshaft itself was destroyed. On the other side of the larger bearing, the camshaft retaining hanger snapped off on one side, dropping into the bottom. I attached some pics of the ordeal - ignore the dirt, cleaning is still due.
I have since disassembled the top engine assembly. I managed to remove the leftover needle sleeve of the smaller camshaft bearing without damaging the head further. I tried checking whether it was warped oval, but couldn't get my vernier scale in there to confirm all edges. It appears round enough from sight, but ja...
Anyhow, I've also started disassembling the bottom, when the other half of the needle hanger drained out with the remaining oil. The hanger bit seems unscathed, and I did not notice metal filings in the drained oil (drained it onto cardboard for the oil to soak in and particles to remain behind), making me wishful that it didn't come into contact with anything. I don't have a case splitter or harmonic puller, so I may be in for those tools if opening the bottom takes place (alongside the expensive case gasket). For surety and safety's sake I should, but I'd like to avoid splitting the bottom, as that's an expensive gasket to replace, and with my riding frequency, may be worth the savings risk. I'm wishful that cleaning the un-split but open bottom with carb cleaner will reveal any metal filings, and if none are found, reassembly can commence.
Knowing the risk I'm taking with the bottom, I'd appreciate hearing some opinions on the potential repair.
I'm in for several pricey gaskets so far (unless cutting them from gasket paper using my templates would suffice for some), alongside a new head small bearing, new camshaft, new intake rocker and new exhaust rocker. This is besides other sundries like oil. The KTM dealer initially quoted R30k to open it up and repair, which was without checking apparently, and after charging me for a new battery, despite the old one working. Nonetheless, seeing the damage now, I'm in for around R15k in these parts, without replacing anything in the bottom. I may get flamed for this, but after my frustrations, I have half a mind of modifying it to take an 8kw electric motor, batteries and a charger.
Anyhow, do I risk sunk costs and attempt the repair? Do I pay KTM R30k or more to repair a bike that I could probably only sell for R30-40k? Does anyone have a private mechanic in Pretoria that could possibly carry out the repairs reliably and affordably? Do I part out? Do I forego the engine and apparent respect, and stuff an equivalent 8kw electric motor in there and aim for 150km range?
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