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Fixing gearbox - specialist parts? - 950 sm 2007

4K views 78 replies 6 participants last post by  claudiop 
#1 ·
Hi Guys,
Thanks to @charlie264 and @KevInYorks I have made the decision to sort the gearbox out from my new bike. Long story to get to this point but the work is underway. (See image below.) Note that the adjustable spanner is just for effect :) !
Making good progress. I have only bought a full gasket set and the engine locking bolt.
In getting to the clutch booster I realise I am going to need to buy some more parts - the Clutch locking bracket p/n 60029003000 for example.
Can anyone give me a list of the minimum specialist tools I will need? Or means to work around their use?

I know that for example when I need to torque the head bolt I can use a spanner and use a torque wrench at 90 degrees to it rather than buying that specific part.
I am hoping to order the extra parts on Tuesday.
Now its started it actually quite good fun and with taking some time on a sensible labelling approach does not seem too difficult (not yet anyway).
Thank you for any help you can give.
Kindest regards,

Nicholas
 

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#66 ·
I have left my state of denial. Head buried in sand and have finally, with the help of a KTM garage made some progress.
I took it to a garage to get it going. With lock down etc they have only just managed to get it started.
Of all things it appears to have been simply the fuel pump!!
And started it is, going it is not. AND only then with a full battery with a few mis-fires!
I drove it home after the engineer said it was running weak and it just needed a good run.
Its starting really poorly and seems to only run on one cylinder! Managed to keep about 70mph but not any faster, clearly its not right.
I have spoken to the manager of the garage and she offered me a refund of the cost of the labour....!
They don't want any more to do with it so now its time to get it going properly.
So, my own sweet little project has returned to me :)
S***.
 
#67 ·
At least it is all zipped up and in one piece. I would say that your 950 is suffering from the usual '950 blocked jets after a lay-up' problem. Get some fresh petrol in there and chuck in a tub of "petrol magic" and ride it. It will clear itself - it might take a fair few miles, but the p.m will sort it out. It works - l have that T-shirt, as do a few others on here.
 
#70 ·
I used it after 2 winters before l started using ethanol free fuel for storage.

The first winter was the worst as l didnt drain the carbs. With a bottle full of PM in a fullish tank (overdosed) it took about 30 miles ...... better than stripping the carbs.
 
#72 ·
Ah. Very remiss of my to not report back.
The petrol cleaner made no difference.
Replacing the petrol - no difference.

When I dropped the bike off to KTM I said that I thought is was the signal pulse generator. They did not think this likely as they did not do anything about it.

With further thought I could not conceive that it could be anything other than that - or at least as it seemed to be timing based and all the other options checked.

I put it on its side stand and started stripping. Got to the generator and sure enough it was closer to 1.6mm than 0.6mm. Adjusted it and stuck it all back together again and it started first time.
What a relief!

Full power, easy start. Finally the job is complete.

Now, I am simply enjoying the bike.

Thank you everyone who has contributed and helped me though this ordeal.
 
#74 ·
I replaced all the bearing in the gear box and in all relevant places.
With everything apart it would have been short sighted of me not to.
I now have a new engine 😊.
There was nothing obvious though. There were some bearings that seemed a tiny bit rougher than others but that could have simply been my imagination!
I did not find any silver bullets for the gear box / final drive noise.
 
#75 ·
OK good to know....

my 2010 SMT 990 has 75,000km and recently completed a grand tour of 3,000km flawlessly...on another recent ride at around 60kmh my gearbox suddenly lost drive and making rough scraping noise and not able to properly engage any of the gears...ruled out input shaft/clutch....the output shaft sprocket and nut are fine....something has failed inside the gearbox eg the selector forks/drums etc

thanks for the very informative thread and sorry that you had so many starting issues....I replaced all the valve shims recently and was very careful to mark/align all components and follow manual meticulously and had no problems and the motor just burbles beautifully now

cheers, Claudio
 
#76 ·
Before starting the work I found a second hand gear box on eBay. The box said it's for the 990 even though I got it for my 950. Would it be of any value to you? It's cost was less than a single replacement spindle!
Or have you finished that job now?
 
#78 ·
It's just the internals, the case is the actual engine casing.
It's heavy as you would expect so you might be better off if you can find something more local but let me know if you want me to price it up with the postage for you.
(I'm happy to sell it for what I paid for it and it was a good price.)
 
#79 ·
OK that's what I thought....i'm considering all options including scrapping the bike....I've got it booked in at local KTM service centre next couple of weeks and will get a quote from them but suspect it's going to be very expensive.

I'll keep you in mind and will let you know, thanks and cheers
 
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