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Discussion Starter #1 (Edited)
The backgroùnd:
I bought this 2009 RC8R in May last year, one previous owner and very much cared for by its previous owner.

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Bike was originally registered in Japan where previous owner lived but he imported it into the UK when he moved here in 2013 or so.

It had just over 11,000 miles on the clock when I bought it and I took that to just over 12k during the course of last year. During that time it went in to have the ECU flashed to match the akrapovic and sort the dreadful fuelling. While it was in being dyno'd the valve clearances were checked and the alarm went off. There was wear to both intake camshafts (both exhaust cams ok though)

It wasn't possible to replace them at the time but over the winter I decided to set to and replace the cams. I've done valve clearances on both my previous bikes (4xv R1 & GSX-R 1000 K6) so I know what's involved in terms of checking and adjusting shims by getting the cams out, but this would be my first experience of a non Japanese inline 4cyl engine.

I like working on bikes and do all my own work, apart from fitting tyres (I take the wheels to my local man) and bleeding brakes (same, he does it far better and quicker than me. I know my limits). Oh, and my suspension gets done by a specialist.

So I also wanted to service the chassis: clean and re-grease the headbearings and rear suspension & swingarm pivot.
I'm a great believer in preventative maintenance where chassis bearings are concerned and a regular greasing is better than having to replace worn or seized bearings.

So here goes, this is a record of what I've done and discovered along the way....
 

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looking forward to hearing about the valve clearance job, it's something I may have to tackle myself at some point. My bike as spent most of its life in the Dubai and didn't come with a service history so what's as been done (or indeed not been done) is a bit of an unknown. Although I'm told that it may be possible to get hold of a copy of the S/H if it was serviced by an authorised dealer out in the middle east, apparently main dealers keep a online record of work done, recalls etc, so I'm hoping my local KTM dealer (Craigs of Dewsbury) can check and see if there is any record of my bike on the KTM system. I'm assuming that it will have had the valves checked at the 9K ml service but as it's now coming up to18K it's very unlikely it as been looked at since which makes it due about now...
 

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Discussion Starter #3
looking forward to hearing about the valve clearance job, it's something I may have to tackle myself at some point. My bike as spent most of its life in the Dubai and didn't come with a service history so what's as been done (or indeed not been done) is a bit of an unknown. Although I'm told that it may be possible to get hold of a copy of the S/H if it was serviced by an authorised dealer out in the middle east, apparently main dealers keep a online record of work done, recalls etc, so I'm hoping my local KTM dealer (Craigs of Dewsbury) can check and see if there is any record of my bike on the KTM system. I'm assuming that it will have had the valves checked at the 9K ml service but as it's now coming up to18K it's very unlikely it as been looked at since which makes it due about now...
Any work done at a ktm dealer will be on record with ktm.
I contacted ktm about the wear to my cams and they knew it had been a jap market bike, it was serviced there when new and then again at a ktm dealer in the Midlands in 2013 when it came into the uk.
I think the valves are due their first check at 12k miles and then every 12k.
I've got mine to the point the valve covers are next to come off but I'm waiting on some parts before I delve any further...
 

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I'm sure I read somewhere th valves were every 9k but 12 is better, if they were done on schedule (@12K) then they won't need doing for another 8000 mls, which is about 2 yrs for me ?
 

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Discussion Starter #5
I'm sure I read somewhere th valves were every 9k but 12 is better, if they were done on schedule (@12K) then they won't need doing for another 8000 mls, which is about 2 yrs for me ?
According to the factory workshop manual, valve clearances are due every 20,000km / 12.5k miles. Same interval as changing the spark plugs, conveniently ?
 

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According to the factory workshop manual, valve clearances are due every 20,000km / 12.5k miles. Same interval as changing the spark plugs, conveniently ?
that's good to know, so mine is either due in around 7.5K or overdue by 5K :rolleyes:
 

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Discussion Starter #7
that's good to know, so mine is either due in around 7.5K or overdue by 5K :rolleyes:
No worries.

while you've got yours in bits, and the airbox is off, I'd say probably a good idea to check them if you're not sure if they've been done or not.

If they're ok, then happy days. If not, well better to know that now
 

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Discussion Starter #8 (Edited)
Part 1:

So I made a start by removing the side fairings and belly pan on both sides, all pretty simple.

Then tank up to disconnect it. Note powerparts tank prop - available from your local KTM dealer

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And tank off, this is the underside which shows how little of the tank is actually for fuel - mostly it's space for the airbox

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The side panels under the seat were a bugger because of the (hidden) lug at the bottom that fits tightly into the hole with the grommet.

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Airbox lid open to reveal filter & throttle bodies

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And airbox lid off and filter out (it's a k&n so will get a clean and re-oi)

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The gloves are off... I mean on
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Once you've f*cked about moving some electronics from the right side of the airbox you get access to a small hatch in the side - this allows you access to the clamps on the bottom of the airbox

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But they are a bugger to get to and need a 3mm hex. I ended up having to make up a Frankenstien tool to get to them:

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And after some swearing, quite a lot of swearing, success!

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Discussion Starter #9
Part 2:

But then I got stuck. I couldn't get the lower airbox off the top of the engine, it was stuck fast and wouldn't budge at all.

In the end I borrowed the Mrs' hair dryer and warmed up the intake rubbers and bottom of the airbox and that made all the difference - it came off pretty easily.

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I've read lots about the oem plastic fuel line coupler failing so I'm going to replace it with a metal one, so I got some single use oetiker clamps to keep it factory.

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and that's as far as I've got with the engine as I'm know waiting on KTM for some parts which are on back order....
 

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looking good I wish you'd written this post 2 weeks ago I would have had some reference then instead of trial and error. And yes you're right it would have been the sensible to check the valves with the bike stripped, unfortunately it's all back together now so they will have to wait.
 

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Discussion Starter #11
looking good I wish you'd written this post 2 weeks ago I would have had some reference then instead of trial and error. And yes you're right it would have been the sensible to check the valves with the bike stripped, unfortunately it's all back together now so they will have to wait.
Well it's funny you say that but all of this has been happening in the last two weeks so it's all new to me as well, not really time to put it down here though until now.

I've got a copy of the favtory workshop manual if you want to pm me your email address I can ping it over to you mate
 

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Discussion Starter #15
Hi.

Can you please tell me where you got the metallic fuel line couplers?

Thank you in advance.
Sure, it's these


 

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Sure, it's these


(y)(y)(y)(y)
 

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Discussion Starter #17
wow, time flies, i haven't updated this for a while as I've been busy working and working on the bike.

anyway, it's now all sorted and yesterday was the first start up of the engine with new cams and it all seems fine.

had some highs and lows along the way but got there in the end. I'll add more details shortly
 
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