KTM 990 Adventure engine rebuild in Thailand

KTMphil

Senior member
Joined
Jan 11, 2011
Location
Chiang Mai, Thailand
Bikes
2007 KTM 990 Adventure Suzuki DRZ 400
Lots & lots of hard Km's, starting to use lots of oil, fuel economy down, time for a full engine rebuild in Thailand. Getting the parts together took 3 months, all here now, so finally under way



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LUFC

Senior Member
Joined
Jun 21, 2011
Bikes
Berg 300, KTM 350, Trials Scoot
I'm no expert but I'm fairly sure cleaning the engine before a total rebuild is near the top of the "to do" list.
 

jkrfjessjess

Senior Member
Joined
Nov 10, 2011
Bikes
Honda Wave
I'm no expert but I'm fairly sure cleaning the engine before a total rebuild is near the top of the "to do" list.

Depends if there is a warranty on the work done and also how hard the KM's were
 

LUFC

Senior Member
Joined
Jun 21, 2011
Bikes
Berg 300, KTM 350, Trials Scoot
Depends if there is a warranty on the work done and also how hard the KM's were
Ah now I get it, if it's not been ridden hard but is covered in shit it doesnt't need cleaning. I've lucked out, no need for LUFC to clean another motorcycle.
 

KTMphil

Senior member
Joined
Jan 11, 2011
Location
Chiang Mai, Thailand
Bikes
2007 KTM 990 Adventure Suzuki DRZ 400
I went down there and the "mechanic" wasnt there, I havnt seen him yet since he started working on it, was a little horrified too.





LMAO...good point

When I saw the pics I was going to ask why it is that, here in Thailand, asking a mechanic to actually clean everything before starting to disassemble is like asking them to eat shit or something worse...then they wonder why new seals leak?

No insults intended Phil but when you took those pics I hope you told the "mechanic" that you expect to see shiny metal components before he starts to reassemble? I was going to pick up my truck on Friday...but noticed oil leaking and after closer inspection, every seal they changed and including the connections to the oil cooler were leaking...and this in a Toyota garage who's been redoing the repairs of the shady garage my insurance chose. Another lesson learned for me, I hope you do not have to go through the same...Cheers mate
 

KTMphil

Senior member
Joined
Jan 11, 2011
Location
Chiang Mai, Thailand
Bikes
2007 KTM 990 Adventure Suzuki DRZ 400
Final stages of getting the KTM 990 rebuild all finished at Sa Moto in Chiang Mai











Sa is probably one of the most knowledgeable mechanics regarding re-mapping the ECU in Chiang Mai, he's done 100's & one of the few that knows his way around a KTM (KTM Chiang Mai aren't set up to do it).










Still some slight problems with an erratic idle, Sa thinks it's the throttle sensor motor or the oxygen sensor, so some minor kinks still to get out



WP_20140904_17_39_27_Pro.jpg by Triangle Golden 007, on Flickr




Total bill came in, labor charge for this big, complex job - just 10,000 Bht (plus parts) , great value


WP_20140905_14_11_26_Pro.jpg by Triangle Golden 007, on Flickr
 

bsacbob

Administrator
Joined
Jul 1, 2012
Location
Chiang Rai
Bikes
Honda CRM-AR 250, Honda CRF 250-L, Suzuki V Strom XT 650 Honda XR250 Baja BMW F650GS
looks like a pretty capably mechanic Phil, do you have the co-ords and number for the shop ?
 

KTMphil

Senior member
Joined
Jan 11, 2011
Location
Chiang Mai, Thailand
Bikes
2007 KTM 990 Adventure Suzuki DRZ 400
looks like a pretty capably mechanic Phil, do you have the co-ords and number for the shop ?


Sa Moto's location in Chiang Mai is:


N18.77878

E98.97690


Off of the SW corner of the moat square (headed south on Mahidon (l) Rd/ R 1141), go 100 meters under the first pedestrian overpass, take the u-turn immediately after the pedestrian overpass, once u-turned (now heading north on Mahidon(l) Rd/ R 1141), Sa Moto is 50 meters on your left (western side of Mahidon (l) Rd/ R 1141)



Bing Maps:




Bing Maps - Driving Directions, Traffic and Road Conditions





Thai Nostra Map below:



Sa Moto




Nokia Here Maps:


http://here.com/l/18.77869,98.97682,16/Mahidon Road





Google Maps:



https://www.google.com/maps/dir/18....22,98.9427076,13z/data=!4m3!4m2!1m0!1m0?hl=en





sa moto with txt.jpg






This is Sa below:


/
 

Davevb

Senior Member
Joined
May 26, 2011
Bikes
2010 Triumph Thruxton
Remapping a KTM is relatively easy with some free software called Tune ECU. Just need to buy a cable and get the map from somewhere, most are on the net already. Just save your original map and then upload whatever map you want. All the settings are configurable if you want to play.

I did it on my Triumph, both KTM and Triumph run Keihin EFI. The hardest part was having to carry my desktop PC out to the shed as Tune ECU is only comparable with windows and I have a MacBook....
 

LUFC

Senior Member
Joined
Jun 21, 2011
Bikes
Berg 300, KTM 350, Trials Scoot
Remapping a KTM is relatively easy with some free software called Tune ECU. Just need to buy a cable and get the map from somewhere, most are on the net already. Just save your original map and then upload whatever map you want. All the settings are configurable if you want to play.

I did it on my Triumph, both KTM and Triumph run Keihin EFI. The hardest part was having to carry my desktop PC out to the shed as Tune ECU is only comparable with windows and I have a MacBook....
Be a lot easier to load Parallels to run windows!
 

Algarve Nick

Senior Member
Joined
Oct 1, 2013
Location
Lagos, Portugal
Bikes
Suzuki B-King & Buell Ulysses
Be a lot easier to load Parallels to run windows!
Nice pics, Phil. 90,000 km isn't so much, though, is it? When I had my 950 Adventure in London the KTM head mechanic at Bracken (now sadly closed) told me the engine was only good for 80,000 miles (128,000 km) of normal road use. I take it you've been off-roading a lot, which I suppose must be much harder on the engine. Good to see it back on the road.
 
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