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  #1  
Old 28-02-09, 10:18
Kev's Avatar
Kev Kev is offline
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Rattle in my motor

Since I bought my bike & before I did the Raptor 700 conversion I always had a small rattle in the motor on start up from cold.

Of late it has started to bug me & has got worse, so I had a look into the problem. What I found was the oil was draining back into the motor when it stood for a few days & would rattle until it had oil pressure. I removed the oil filter & found the oil was draining back through a oil gallery that has a one way valve in it, this gallery should always be full of oil no matter what.

I ordered the parts a few weeks back from Japan & removed my clutch cover, to replace the ball, spring & seal that hold the oil in the gallery. I retested for the oil draining back & it has stayed full after the repair, so I am happy again.

As you can see I always full the oil tank with 1500ml of oil & the remaining 1200ml I full through the engine breather. Start the bike then adjust the level as needed. Much easier this way, no messing around.















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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

  #2  
Old 28-02-09, 10:31
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CaptMoto CaptMoto is offline
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Excellent work as usual Kev!!
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  #3  
Old 28-02-09, 11:10
Worry Brother Worry Brother is offline
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Nice one Kev,

So wish you lived in the UK mate!!!

Cheers

WB
  #4  
Old 28-02-09, 19:21
NickW909 NickW909 is offline
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Great work Kev.

I hope you washed that Pyrex dish before you gave it back to the wife.......



Nick.
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  #5  
Old 28-02-09, 21:46
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Kev Kev is offline
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As any good mechanic knows, make sure you use your wifes best Pyrex jug in the house she won't mind. One needs to measure things correctly, I best put it back before my wife fines me using it.
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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946


Last edited by Kev; 21-08-09 at 08:07.
  #6  
Old 10-03-10, 08:21
Piipz Piipz is offline
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Ok, found the thread myself (already sent a message to Kev about where did it go :P)

About those parts - do I have the part numbers correct:
583-13113-00 SEAT, CHECK BALL
93503-08007 BALL
90501-04X01 SPRING, COMPRESSION
  #7  
Old 10-03-10, 09:02
gianni1951 gianni1951 is offline
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Great Kev,

I also full the oil in two step,like you, 1500 in the reservoir and 1200 always from the cover distribution chain. I never thought to fill the oil by engine breather !!!!!!!!

Also the wife's tool is a great idea........

Thank you Kev.
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  #8  
Old 10-03-10, 09:47
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Kev Kev is offline
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Quote:
Originally Posted by Piipz View Post
Ok, found the thread myself (already sent a message to Kev about where did it go :P)

About those parts - do I have the part numbers correct:
583-13113-00 SEAT, CHECK BALL
93503-08007 BALL
90501-04X01 SPRING, COMPRESSION
The oil runs back into the sump when the one way valve leaks, when you start the bike it takes 30 second to blead all the air out & the motor has a cold start rattle. Mine rattle went away when I replaced the one way valve.
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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

  #9  
Old 10-03-10, 17:08
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J_maker J_maker is offline
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excellent work Kev! Thanks for the photos and tips mate!
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My Mods
Kev's Fork Spacers - DNA stage 1 filter - Kev's O2 eliminator - Denso Iridium Spark Plug - AFAM XBAR - HEL brake line - Pirelli Diablo Rosso II Tires - Acerbis handguards

XTX - Better than SEX





  #10  
Old 14-03-10, 17:08
gianni1951 gianni1951 is offline
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[quote=Kev;84279]Since I bought my bike & before I did the Raptor 700 conversion I always had a small rattle in the motor on start up from cold.



ote]
Hi, Kev,

a question. What is the insert in the water tube upper water pump. It's seems like a radiator. Is a commercial part, or you have done by yourself ??

Thank you. Ciao.
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