Front base gasket replacement - Guidance/Advice wanted

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limeyduffa
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Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Tue Apr 10, 2018 11:11 am

Hello all. I'm a return user who used to own an 06 SD. I brought a 2012 990 SMT back in 2012, and have had that ever since. I've been lurching on the ktmsmt.com forum since then (and haven't returned to this site until last week). My problem appears to be rare for SMT's (by theory is that SMT owners don't ride their bikes nearly as hard as SD owners, but don't tell them I said that ! :P), so I got no response with my questions on the SMT forum. So, I have come here for tips/advice.

Anyway, by bike has developed a front cylinder base gasket leak (it has 38700km on the clock). I am investigating either doing the job myself, or taking it to the dealer. My city is a fairly dusty place, and I will be working under a pergola. So, if I do the job myself, I really need to have the engine reassembled within 3-4 days. Parts take 1-6 months to order through KTM Australia (which I avoid doing), so resort to overseas orders in Europe and US which I pay a bomb for, but arrive a reliable 3 weeks. So, I also want to have all the tools and spares needed to do the job without having to order new bits.

I have spent a night reading through this forum and the ADV forum, and the plan is to remove the front retaining engine bolts, drop the engine out of the frame, while leaving the swing arm bolt in place, allowing access to the front cyl (thanks Col Klinck for this tip) and then replace the following parts:

1 x 600 30 035 000 CYLINDER-BASE GASKET FR 0,35MM
1 x 584 30 074 000 CIRCLIP 22 X 1,6
4 x 600 30 043 100 STUD M10X161 06
4 x 600 36 078 050 SHIM 10,2X19X1,5MM 05
4 x 600 36 078 200 COLLAR NUT M 10 WS=13 05
1 x Rocker cover gasket ???

The $165AUD torque bar extension special tool, I'm planning to substitute for a $21AUD locally purchased extension - with a different torque correction of course !

Regarding the rocker cover gasket, is this reusable ?. It looks like I can't buy this individually and it comes in a $379AUD gasket kit.

I'm a bit nervous taking it into the dealer, because the last time I did three years ago (for leaking coolant hoses), the bike was sitting in the dealer workshop waiting for KTM Australia to pull their thumb out of their arse and order my parts. I ended up cancelling OEM order and ordering Samco after market parts. At least if I do it myself, I'm in full control and no infinite waiting period.

Anyway, these are my thoughts and questions. Any tips/advice will be muchly appreciated. Cheers :)
2012 990 SMT

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Aphex
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby Aphex » Tue Apr 10, 2018 2:23 pm

Can't be of much help since I've yet to have to do this myself.

But the valve cover gaskets can be reused. I've done three valve checks/adjustments with 40,000+ miles on the bike and I'm still using the OEM gaskets.

Just make sure the mating surface is clean and you torque it back down in an alternating pattern like you would lug nuts on a car wheel.
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No. 47
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby No. 47 » Tue Apr 10, 2018 3:38 pm

If you haven't done so already, download the workshop repair/rebuild manual from here viewtopic.php?f=18&t=16897
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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Motogoon
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby Motogoon » Tue Apr 10, 2018 7:30 pm

I did front and rear, how to further down the page here viewtopic.php?f=5&t=27648

Was no need to tilt the engine for replacing the front one, I assume it would be the same for the SMT. Should be ok to do in one day, it was the extra disassembly for the rear that took a lot of time.

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limeyduffa
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Thu Apr 12, 2018 11:35 am

Motogoon wrote:...


"stinking hot weather", would that be 13C or something in NZ ? hehe :P (just kidding). Good read, thanks :)

Thanks for the tips all. Just one more question. It's just me doing it. Would job require two people at any point in the repair ?

J
2012 990 SMT

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Motogoon
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby Motogoon » Thu Apr 12, 2018 7:34 pm

Haha no probs, easy one person job for the front cylinder, only the rear required some help to jack the engine up while I lined up the swingarm axle (thanks my 9yo daughter!)

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limeyduffa
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Fri Apr 13, 2018 10:58 am

Thanks Motogoon

This is probably a silly question, but does gasket fit over the piston and rings ?. If so, could a short piston ring compressor be used like this Subaru jobbie ?

https://www.iagperformance.com/Company2 ... -p/516.htm
2012 990 SMT

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Motogoon
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby Motogoon » Fri Apr 13, 2018 10:11 pm

Make sure you leave the piston in the barrel, you have to lift the head/barrel/piston off as one unit after you've lifted it just enough to remove the piston clip and pin. That and putting it back on are the worst part of the job.

You'll be in trouble if the piston comes out of the barrel from what I've heard (broken rings etc!)

Make sure to read through the procedure in the workshop manual a few times to familiarize yourself before starting.

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limeyduffa
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Sat Apr 14, 2018 1:03 am

ok. Thanks mate. Will do.
2012 990 SMT

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limeyduffa
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Mon May 07, 2018 1:39 pm

Does anyone have a side view photo of a 990 piston ? (looking directly into the gudgeon pin hole ?). I can't find any on the net. Cheers :)
2012 990 SMT

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No. 47
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby No. 47 » Mon May 07, 2018 2:58 pm

Image

Image
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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limeyduffa
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Re: Front base gasket replacement - Guidance/Advice wanted

Postby limeyduffa » Tue May 08, 2018 10:33 am

Thanks mate :)
2012 990 SMT


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