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View Full Version : Outlaw 450, common loose countershaft nut fix. ( w/pics)



TheLane
03-19-2012, 12:17 AM
****UPDATED****



I did this today, and figured it would be a nice write up to have on here, so here it goes!

Inherently the SOHC KTM 450 motor is a very noisy motor straight from the factory, and over time can become noisier. Throughout the course of time the motor can develop a very loud “chatter” “slap” or inconsistent ticking that sounds like it is coming from the clutch side of the motor. A lot of people say that it can almost sound like you forgot to put the cam chain tensioner back in and it sounds like cam chain slap.

One of the primary causes for this noise could be the well known problem of the crankshaft nut to become loose and try to back itself off.

If this happens it shouldn’t cause any immediate damage to any of the internals of your motor due to the fact that the shaft sits right up against the case and so the nut cannot completely back itself off. Since the nut is aluminum it can however create unwanted aluminum shavings in your motor and essentially trash its own threads. Also, over time your primary gears that this nut is used to tighten down, can become a bit loose and cause premature wear ( not to mention its just loud an obnoxious). So I have here written up a step by step instruction manual for doing this job and have included pictures.

PS: SORRY ABOUT THE DIRTY BIKE! I just went on a ride earlier that afternoon and was going to be spilling oil everywhere anyways so I didn’t want to do a full wash.

NOTE: It can be assumed unless noted that any and all pieces do not need to be put on in a particular manner for timing.

You will need: A set of Allen keys. A socket set. KTMs clutch locking tool, part no. PA-48685. (or a penny). A jack.


Step 1: Thoroughly clean the area around your clutch side of your motor using a degreaser of carburetor cleaner and if you have access to compressed air try and blow away any debris that might be lurking in hard to see spots. Then if you quad has oil in it and you want to minimize the overflow, get a jack and put the quad so it is leaning slightly on its side. If not, just drain the oil completely.


Step 2: Remove the 6 bolts that hold your clutch case on, remove the cover slowly as there is a rubber gasket attached to it and you do not want to cause any damage.



http://img215.imageshack.us/img215/3107/img0744vx.jpg



























NOTE: in this process my clutch is removed, yours may look different if you left the clutch in.


Step 3: Remove the 10 bolts that hold on the clutch side engine case. Make note of the order and position of which they came off. One bolt is longer than the rest, so it is important to remember which go where. I personally started at the top right and went clockwise, then put my bolts in order. After the bolts are off there are two tabs on the top left and the bottom right of the case that you can use to get a grip and pull the case off. Be careful, there is a gasket on the inside of the case that you CAN tear if you are not.


http://img62.imageshack.us/img62/2174/img0761ew.jpg

Shot at 2012-03-18


http://img823.imageshack.us/img823/3497/img0765q.jpg

Shot at 2012-03-18


Step 4:NOTE: Take note that the countershaft nut is a reverse thread setup. Righty loosey and lefty tighty on this one folks!!!

Using your KTM Clutch locking tool, or alternate means, lock the crankshaft gear. Pull the nut off and clean the threads and the bolt itself, then apply loctite to the threads, and tighten the nut down to 150nm or 110lbs of torque. ( or just as tight as you can get it in my situation)

We did not have the fancy KTM tool so we used a nickel that we wedged inbetween the gears to somewhat lock them and then tightened the bolt. I have heard of other people using other means to lock these gears, so if you have a suggestion please post it.


http://img843.imageshack.us/img843/43/img0768re.jpg

Shot at 2012-03-18

http://img62.imageshack.us/img62/5038/img0767yc.jpg


Shot at 2012-03-18





After your nut is tight, Rinse wash and repeat in reverse!!



A few reassembly notes: You may need to use a rubber mallet to get the clutch side engine case back on. Line up the case and then lightly tap and it should slide on easy.

As per some of the comments below, you should allow 12 hours for the loctite to cure before putting oil back in the motor.