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2009-05-09T13:13:31Z

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2009-04-24T05:03:35Z

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2009-04-24T04:55:10Z

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2009-02-10T12:23:04Z

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2009-02-05T07:09:26Z

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2009-01-23T12:51:31Z

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2008-10-19T02:51:32Z

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2008-10-19T02:51:29Z

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Super Enduro Oil Lines Red arrow = pressure pump outlet inside filter housing Blue arrow= Pressure pump inlet line at terminal

2008-09-02T14:59:45Z

cpmodem
Super Enduro Oil Lines Red arrow = pressure pump outlet inside filter housing Blue arrow= Pressure pump inlet line at terminal

Clutch Hub needle bearing

2009-11-12T16:29:45Z

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Clutch Hub needle bearing

Outer Clutch Hub Removal

2008-09-02T15:51:39Z

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Outer Clutch Hub Removal

Oil Pressure Bypass Valve

2008-09-02T15:51:39Z

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Oil Pressure Bypass Valve

Oil Filter Removal

2008-09-02T15:50:15Z

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Oil Filter Removal

Oil Pressure Pump

2008-09-02T15:51:39Z

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Oil Pressure Pump

Oil line terminal

2008-09-02T15:51:39Z

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Oil line terminal

Oil pump drive gear

2008-09-02T15:51:39Z

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Oil pump drive gear

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2008-09-02T15:51:39Z

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2008-08-23T07:44:14Z

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2008-08-23T07:44:13Z

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2008-08-23T07:44:13Z

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2008-08-23T06:06:48Z

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2008-09-02T15:51:39Z

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OLYMPUS DIGITAL CAMERA

2008-06-12T06:15:27Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2008-06-12T06:14:43Z

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OLYMPUS DIGITAL CAMERA

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2008-06-08T11:34:43Z

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2008-06-06T03:01:06Z

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2008-06-06T03:01:07Z

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2008-06-06T03:00:59Z

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2008-06-06T03:00:59Z

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2008-06-06T03:00:55Z

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2009-06-22T08:15:08Z

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2009-06-22T08:47:40Z

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2009-06-22T08:22:02Z

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2009-06-23T06:08:46Z

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2009-06-23T11:42:08Z

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2008-12-28T21:25:38Z

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2008-12-30T05:23:33Z

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2009-01-02T18:32:50Z

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2009-01-07T04:38:34Z

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2009-01-07T04:38:06Z

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2009-01-07T04:39:57Z

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2009-01-07T04:39:20Z

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2009-01-09T05:31:38Z

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2009-01-09T05:30:32Z

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OLYMPUS DIGITAL CAMERA

2009-01-10T16:26:48Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2009-01-10T16:26:50Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2009-01-10T16:28:37Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2009-01-10T16:27:09Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2009-01-10T16:29:28Z

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OLYMPUS DIGITAL CAMERA

OLYMPUS DIGITAL CAMERA

2009-01-28T01:25:40Z

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OLYMPUS DIGITAL CAMERA

cpmodem's photo

2009-01-12T16:46:46Z

cpmodem

This is the tool of choice for removing the valve buckets. This one has a handy LED light in the tip, but the strong wide magnet is the essential part.

2009-01-12T19:46:30Z

cpmodem
This is the tool of choice for removing the valve buckets. This one has a handy LED light in the tip, but the strong wide magnet is the essential part.

Check the clearance between the cam lobe and the valve bucket when the engine is cold. As things warm up, the clearances tighten up. If you take your measurements when the engine is warm, ...

2009-01-13T16:41:19Z

cpmodem
Check the clearance between the cam lobe and the valve bucket when the engine is cold. As things warm up, the clearances tighten up. If you take your measurements when the engine is warm, ...

Here's how the rear cylinder cam lobes should be positioned when the rear cylinder is at TDC. To remove the cams, first remove the spark plug tube from the cam bridge. A pair of flat blade ...

2009-01-13T16:40:38Z

cpmodem
Here's how the rear cylinder cam lobes should be positioned when the rear cylinder is at TDC. To remove the cams, first remove the spark plug tube from the cam bridge. A pair of flat blade ...

This is what I use, but any non flaking paint will work as long as it will stick to the oily surface. This product rubs off easily, so take care not to inadvertantly remove the marks during ...

2009-01-13T16:40:03Z

cpmodem
This is what I use, but any non flaking paint will work as long as it will stick to the oily surface. This product rubs off easily, so take care not to inadvertantly remove the marks during ...

Mark the rear cylinder cam gears from the outside on the tooth closest to the cylinder head surface. This makes it easer to replace them properly on reassembly, as the factory "X" marks on ...

2009-01-13T16:40:55Z

cpmodem
Mark the rear cylinder cam gears from the outside on the tooth closest to the cylinder head surface. This makes it easer to replace them properly on reassembly, as the factory "X" marks on ...

Turn the locking tool in until the pointed end is snug into the recess in the crankshaft. The top will be flush or slightly recessed as shown in this photo.

2009-01-13T16:38:55Z

cpmodem
Turn the locking tool in until the pointed end is snug into the recess in the crankshaft. The top will be flush or slightly recessed as shown in this photo.

This is the official KTM crankshaft locking tool (0113 080802). You can make one with an appropriate sized bolt, but this part is pretty inexpensive (~ $6 from KTMworld.com). A pointed too ...

2009-01-13T16:38:47Z

cpmodem
This is the official KTM crankshaft locking tool (0113 080802). You can make one with an appropriate sized bolt, but this part is pretty inexpensive (~ $6 from KTMworld.com). A pointed too ...

As you turn the engine in a CCW direction on the left side, insert a small diameter tool into the crankshaft locking tool hole on the right side (easier than it sounds) to feel the TDC inden ...

2009-01-13T16:39:52Z

cpmodem
As you turn the engine in a CCW direction on the left side, insert a small diameter tool into the crankshaft locking tool hole on the right side (easier than it sounds) to feel the TDC inden ...

This bolt on the right side (clutch side) of the engine is removed to access the indent in the crankshaft for the crankshaft locking tool.

2009-01-13T16:41:23Z

cpmodem
This bolt on the right side (clutch side) of the engine is removed to access the indent in the crankshaft for the crankshaft locking tool.

This is how the KTM tool looks in the sparkplug hole.

2009-01-13T16:37:20Z

cpmodem
This is how the KTM tool looks in the sparkplug hole.

Here is the sparkplug too that was included in my owner's tool kit. Later years are said to not include this very useful tool. If you didn't get one, a standard sparkplug socket with the r ...

2009-01-13T16:37:57Z

cpmodem
Here is the sparkplug too that was included in my owner's tool kit. Later years are said to not include this very useful tool. If you didn't get one, a standard sparkplug socket with the r ...

Here's all the room needed to do a valve check/adjustment. Note the bottom is pulled away about 3 1/2 inches.

2009-01-13T16:40:20Z

cpmodem
Here's all the room needed to do a valve check/adjustment. Note the bottom is pulled away about 3 1/2 inches.

The front SLS block off plate. Tight, but still reachable without removing anything nearby, once the carbs are removed.

2009-01-13T16:39:17Z

cpmodem
The front SLS block off plate. Tight, but still reachable without removing anything nearby, once the carbs are removed.

The rear SLS block off plate. I made mine with simple hand tools from some scrap 1/4" aluminum plate that I had laying around in the shop. Cost $0.00. No need for anything fancy here. They ...

2009-01-13T16:41:38Z

cpmodem
The rear SLS block off plate. I made mine with simple hand tools from some scrap 1/4" aluminum plate that I had laying around in the shop. Cost $0.00. No need for anything fancy here. They ...

Once the oil tank vent lines are removed, a 10mm gear wrench makes quick work of removing the valve covers. The covers should come off the cylinder heads with very little trouble. If they ...

2009-01-13T16:39:20Z

cpmodem
Once the oil tank vent lines are removed, a 10mm gear wrench makes quick work of removing the valve covers. The covers should come off the cylinder heads with very little trouble. If they ...

You can uplug the radiator cooling fan for less clutter. Just remember to reconnect it before installing the carbs afterward. A few folks (including some dealers) have forgotten this step.

2009-01-13T16:39:39Z

cpmodem
You can uplug the radiator cooling fan for less clutter. Just remember to reconnect it before installing the carbs afterward. A few folks (including some dealers) have forgotten this step.

Remove the 4 bolts (2 on each side) holding the radiator to the frame, and gently pull the radiator forward for enough clearance to access the front vealve area. Some folks remove the radia ...

2009-01-13T16:38:32Z

cpmodem
Remove the 4 bolts (2 on each side) holding the radiator to the frame, and gently pull the radiator forward for enough clearance to access the front vealve area. Some folks remove the radia ...

Remove the oil tank vent hoses from the front valve cover by loosening the hose clamps and carefully removing the hoses. Note: The "L" into the valve cover is plastic and easily broken. Ta ...

2009-01-13T16:38:08Z

cpmodem
Remove the oil tank vent hoses from the front valve cover by loosening the hose clamps and carefully removing the hoses. Note: The "L" into the valve cover is plastic and easily broken. Ta ...

After disconnecting the low voltage wire connector from each coil, remove the sparkplug coils from the sparkplug tubes with a twisting motion. When you reinstall them, insure they are fully ...

2009-01-13T16:39:38Z

cpmodem
After disconnecting the low voltage wire connector from each coil, remove the sparkplug coils from the sparkplug tubes with a twisting motion. When you reinstall them, insure they are fully ...

Reinstall the cam bridge, insuring it is flush with the head surface all of the way around. Torque the 8 bolts holding the cam bridge to an initial 10nm using a diagonal pattern. Tighten t ...

2009-01-13T16:40:56Z

cpmodem
Reinstall the cam bridge, insuring it is flush with the head surface all of the way around. Torque the 8 bolts holding the cam bridge to an initial 10nm using a diagonal pattern. Tighten t ...

Now insert the sparkplugs. A dab of anti-sieze makes remove next time a breeze.

2009-01-13T16:40:50Z

cpmodem
Now insert the sparkplugs. A dab of anti-sieze makes remove next time a breeze.

Rear cylinder cams are set back into place with the paint marks aligned with the edge of the head (just like they were when removed).

2009-01-13T16:42:02Z

cpmodem
Rear cylinder cams are set back into place with the paint marks aligned with the edge of the head (just like they were when removed).

The other side (engine side) of the rear cylinder intake cam gear has the "X" mark indicating the proper position at TDC of the compression stroke.

2009-01-13T16:38:28Z

cpmodem
The other side (engine side) of the rear cylinder intake cam gear has the "X" mark indicating the proper position at TDC of the compression stroke.

If you get the cams mixed up, don't worry, they are marked with their proper positions. ie: EXhaust FRont in this image.

2009-01-13T16:40:24Z

cpmodem
If you get the cams mixed up, don't worry, they are marked with their proper positions. ie: EXhaust FRont in this image.

Torque each plug to 12nm. Then reassemble everything in the reverse of disassembly. Take care that the rubber vacuum lines are in good condition and that the rubber carb to manifold boots a ...

2009-01-13T16:38:51Z

cpmodem
Torque each plug to 12nm. Then reassemble everything in the reverse of disassembly. Take care that the rubber vacuum lines are in good condition and that the rubber carb to manifold boots a ...

A file may need to be used to remove a tiny bit of material from the toolkit adapter, as shown.

2009-01-13T16:39:24Z

cpmodem
A file may need to be used to remove a tiny bit of material from the toolkit adapter, as shown.

Likewise INtake FRont here. The rear cylinder cams will be marked IN RR and EX RR respectively.

2009-01-13T16:38:08Z

cpmodem
Likewise INtake FRont here. The rear cylinder cams will be marked IN RR and EX RR respectively.

Next, remove the cylinder locking tool (or back it out so it doesn't interfer with engine rotation) and rotate the engine CCW 75 deg to TDC on the compression stroke for the front cylinder. ...

2009-01-13T16:41:34Z

cpmodem
Next, remove the cylinder locking tool (or back it out so it doesn't interfer with engine rotation) and rotate the engine CCW 75 deg to TDC on the compression stroke for the front cylinder. ...

And the "+" mark on the rear cylinder exhaust cam gear on the inside.

2009-01-13T16:42:35Z

cpmodem
And the "+" mark on the rear cylinder exhaust cam gear on the inside.

One of the outside head nuts is in a recessed area of the head and requires an adapter. The factory lists 600 29 081 000 (~$55) for this job, but the tool shown above, found in the owner's t ...

2009-01-13T16:41:22Z

cpmodem
One of the outside head nuts is in a recessed area of the head and requires an adapter. The factory lists 600 29 081 000 (~$55) for this job, but the tool shown above, found in the owner's t ...

Here's what your beloved Lippizaner will look like when stripped for access to do the valve job. It looks like a lot of disassembly (especially to BMW owners, but really isn't any worse tha ...

2009-01-13T16:42:37Z

cpmodem
Here's what your beloved Lippizaner will look like when stripped for access to do the valve job. It looks like a lot of disassembly (especially to BMW owners, but really isn't any worse tha ...

The cam lobes should face away from each other as in this image. Note: The valve cover bolts make great handles for R&R'ing the cam bridges. Now just repeat the measurement, adjustment, and ...

2009-01-13T16:43:26Z

cpmodem
The cam lobes should face away from each other as in this image. Note: The valve cover bolts make great handles for R&R'ing the cam bridges. Now just repeat the measurement, adjustment, and ...

Remove them one at a time and clean the threads and lube with assembly lube. I use a product made especially for the job by ARP. Then torque to a priliminary 25nm, doing one nut at a time i ...

2009-01-13T16:43:30Z

cpmodem
Remove them one at a time and clean the threads and lube with assembly lube. I use a product made especially for the job by ARP. Then torque to a priliminary 25nm, doing one nut at a time i ...

Here's a photo of the "round circle" mark on the front cylinder cam gear. Note that the front cams use the marks on the outside of the gear, whereas the rear used the marks on the inside. ...

2009-01-13T16:44:11Z

cpmodem
Here's a photo of the "round circle" mark on the front cylinder cam gear. Note that the front cams use the marks on the outside of the gear, whereas the rear used the marks on the inside. ...

A laptop computer is real handy to have around the shop nowadays. Here is a handy spreadsheet from one of the OC Inmates that you can use to record your valve clearances and shim sizes as yo ...

2009-01-13T16:44:52Z

cpmodem
A laptop computer is real handy to have around the shop nowadays. Here is a handy spreadsheet from one of the OC Inmates that you can use to record your valve clearances and shim sizes as yo ...

These are the two external cylinder head nuts.

2009-01-13T16:44:20Z

cpmodem
These are the two external cylinder head nuts.

Re insert the sparkplug tube. It pops in with just hand pressure if aligned properly. Don't get it cockeyed.

2009-01-13T16:45:03Z

cpmodem
Re insert the sparkplug tube. It pops in with just hand pressure if aligned properly. Don't get it cockeyed.

It's also handy if you have Internet access in the shop for those times when you need to figure something out. WiFi is a great invention.

2009-01-13T16:43:25Z

cpmodem
It's also handy if you have Internet access in the shop for those times when you need to figure something out. WiFi is a great invention.

These are the two inside cylinder head nuts that the cams must be removed to get at, Sorry 'bout the focus, but the point is to show the location of the two head nuts.

2009-01-13T16:46:57Z

cpmodem
These are the two inside cylinder head nuts that the cams must be removed to get at, Sorry 'bout the focus, but the point is to show the location of the two head nuts.

With the carbs and airbox removed, you engine bay should look something like this.

2009-01-13T16:45:13Z

cpmodem
With the carbs and airbox removed, you engine bay should look something like this.

Remove the airbox cover and filter and you will see this view of the Ninefiddy's CVRD 43 carbs.

2009-01-13T16:44:11Z

cpmodem
Remove the airbox cover and filter and you will see this view of the Ninefiddy's CVRD 43 carbs.

Remove the front fairing, seat, glove box, and fuel tanks and you will see something like this. The red pre-filter is aftermarket.

2009-01-13T16:44:41Z

cpmodem
Remove the front fairing, seat, glove box, and fuel tanks and you will see something like this. The red pre-filter is aftermarket.

Otoscope. A handly tool for working on small parts and essential for "reading" sparkplugs properly.

2009-01-13T16:44:21Z

cpmodem
Otoscope. A handly tool for working on small parts and essential for "reading" sparkplugs properly.

Here's a closeup of what the stop tool looks like when not in the TDC recess.

2009-01-13T16:46:10Z

cpmodem
Here's a closeup of what the stop tool looks like when not in the TDC recess.

This is what it looks like when seated properly in the TDC recess.

2009-01-13T16:46:19Z

cpmodem
This is what it looks like when seated properly in the TDC recess.

OEM radiator cap circa 2003. Still functions in spec.

2009-01-13T18:29:47Z

cpmodem
OEM radiator cap circa 2003. Still functions in spec.

36" of AN-3 (3/16" I.D.) stainless steel braided high pressure hose was used for safety and durability. This tap in point also allows me to easily keep the OEM "idiot light" for those time ...

2009-01-14T15:05:48Z

cpmodem
36" of AN-3 (3/16" I.D.) stainless steel braided high pressure hose was used for safety and durability. This tap in point also allows me to easily keep the OEM "idiot light" for those time ...

The factory spec also prescribes a range for oil pressure at 6000 rpm (again at 60 deg C). 3.0 - 4.0 bar (44 - 58 psi) This image shows I have 51 psi at 6000 rpm at 100 deg C. Right in the ...

2009-01-14T15:08:13Z

cpmodem
The factory spec also prescribes a range for oil pressure at 6000 rpm (again at 60 deg C). 3.0 - 4.0 bar (44 - 58 psi) This image shows I have 51 psi at 6000 rpm at 100 deg C. Right in the ...

The factory oil pressure specification for the LC8 engines is: Minimum of 1.5 bar (22 psi) @ 1500 rpm taken at 60 deg C (140 deg F) As you can see, this KTM 950 has 32 psi at 1400 rpm (idle) ...

2009-01-14T15:08:53Z

cpmodem
The factory oil pressure specification for the LC8 engines is: Minimum of 1.5 bar (22 psi) @ 1500 rpm taken at 60 deg C (140 deg F) As you can see, this KTM 950 has 32 psi at 1400 rpm (idle) ...