Like I have mentioned in the Preflight check, I had a busted hard parts air filter cover on my KTM, and I had replaced it with a OEM plastic sealed cover. It worked OK but the bike was getting to much fuel and when you opened the throttle quickly, it got flooded. So instead of getting the carbs re-jetted I have decided to fix the mesh on the filter cover.

Busted cover

So after getting a suitable mesh, I have been thinking of how should I fix it. I thought about welding, soldering, drilling&screwing,… None of those options as easy to do with my time frame.

So after turning the basement up side down, I found some JB weld and decided to give it a try. New mesh cut to size.

Adding the JB weld.

This version of JB weld is supposed to cure for 24h on 20 degrees Celsius or 80min at 80 degrees Celsius. Luckily my mother wasn’t home and I could use her oven.

After baking it came out well done and smelling like chicken.

Back on the bike.

Now time will tell how long this will last.

Stay safe!

From the time I first took my LC4 on a gravel road, I didn’t like the standing position on it. It was to low and to far back for my taste. It felt like I am going to tip over the bars. So I have decide to order a new set of bars. And with new bars, you also need new grips. And everything had to be orange.

I started working on a nice autumn evening. The disassembly went fast. When I took everything apart, I have decided to grind the locating pins on the controls instead of drilling in to the bars.

Looking at OEM Magura bars and Renthal RC High bars, there is quite a difference in the hight.

All the cables were luckily long enough, though not lone enough to use a bar pad that came with the bars. Putting everything back together went quite fast.

And while I was working on the bars, I went ahead and mounted the Barkbuster handguards I had taken from my KLE when I sold it. But with the KTM using fatbars, I had to get a new mounting kit. I got their new BTC-06 kit, I must say that it is a nicely made product, like their guards.

Here is how those look mounted on the bars. They don’t fell as solid as the straight mounts on the 22mm bars, but they clear the cables nicely.

Here are the guards on the bike.

A side view of the guards. I have tipped them a bit downwards to clear my wrists in case I fly over the bars. I don’t want to break my wrists.

Now I only need to wait for good weather to test out the new set up. It felt great on the stand in the garage, but we will see how it turns out in the field.

Stay safe!

Marathon ride

Posted: 30/09/2014 in Ride reports archives

Today was a sunny day, and supposedly the last one for a while. So in the morning I saddled up my LC4 and headed to the best mountain passes in the country. Now here are a few pictures from today.

First pass was Ljubelj pass

Descending from that pass, the bike turned 30.000km on the clock

The views were spectacular today

Here is the lake under Predel pass, mountain water only so it is cold as hell

On the Slovenian side of the Predel pass

On top of Slovenian highest road, Mangart pass

Taking a break on Vršič pass

Pass Korensko sedlo has a tank on the Austrian side of the border

I got back home with night fall after 371km in the saddle. It was a really good day riding.

A while back, my bike has developed a fault. While kick starting it, e-motor and all the gears were turning with it. It surely didn’t sound healthy.

So I have started investigating the problem. After talking to the guys at I have been advised that the sprag clutch is probably stuck in engaged position. So before we head into the process itself, lets look at the tools and parts you will need.

– 8, 19(puller screw) and 24 socket
– 32 wrench, at least for my custom magneto puller
– magneto puller, KTM part nr. 584.29.009.000

– new gasket, KTM part nr. 584.30.040.000

Here is the puller that they made for me

So we have started wrenching with the bike on its side. I have put a log under the handlebars. A fret taking 4 bolts (8 socket) out of the case you can simply lift the cover off. But be careful no to tear any of the cables.

Once the cover is off, this si what you will be looking at.

To undo the nut you will need a 24 socket. Also it is a right hand thread, so you un-tighten it with turning it right. After that you screw on a puller. At this time I have put the bike up on its side stand as it was easier to undo the nut, fortunately no oil got out.

After pulling everything off, I have found out that the spring was torn in a few places.

After cleaning the debris of the spring out of the bike and off the magnet, I have reassembled everything back in reverse. I kicked it a few times and it started up nicely. The only drawback of this is that I now don’t have a e-starter on my bike.

Stay safe!

After a slide

Posted: 28/09/2014 in Repair archives

So on Tuesday, I have taken the bike for a short spin after a workout session on the kick starter. It was one of the few days that we had sun this week, so I put my boots, helmet and gloves one. I pinned the throttle up the nearest hill that had just recently been paved, they ruined one of my favourite gravel roads in the area. So I got to the top, had a few minutes rest and than headed back down. On the way down I always go slow as you only have your brakes and railing to to stop you.

But today, going down, was a bit of a problem. In one of the turns, at 20-30 km/h, I have hit a patch of some lose gravel/sand on the pavement and lost the front end of the bike. It was like I have hit a ice patch no chance to keep the bike up.

So after sliding on the pavement for around 15m in jeans and a long sleeve shirt I have come to a stop with the bike upside down, leaking fuel and me leaking blood.

A quick check of myself, and other than being peeled like a banana on my left knee, both elbows and right hip, I checked the engine for any cracks in the sump guard and any other major damage and luckily the worst damage was a broken shifter lever.

Before the pain sets in, I kicked the bike and rode to the garage, took a few pictures and went home to take a shower and clean the wounds. In the end I ended up at the ER and on the pills for a week…

Lets focus on the bike. Here are are a few pictures of the bike

Luckily for me the KTM dealer here is fast and I got the new shifter lever in 3 days, but the price really high a 54€+ delivery. New and old. I will get the old one welded to have it as a spare.

I won’t bother with the rear plastic as it will get even more scratches as I start ridding off road, as for the handguards I have a set of Barkbusters from my KLE ready to go on.

Ow well, I think I will be going on a rides from now on in full riding gear.

First good ride

Posted: 26/09/2014 in Ride reports archives

It was a nice, beautiful, partly cloudy Saturday. It showed like it could start raining, but I didn’t care. I have saddled up my bike and went for a few hour ride. I have set off towards Pavličevo sedlo, through Austria. This route would give me the best conditions to test the bike out on twisty pavement and some gravel roads.

The view from behind the bars

A lonely rode in a lonely world

Taking a break on the way up

It was a good ride up, but as always, what goes up must come down. So I have started my descent towards the border and Solčava valley.

I have taken a quick look into Logarska valley, but the view isn’t that great as it was really cloudy.

In a small town of Solčava I have stopped for a quick cup of tea as it was really cold on the KTM. They have a really nice tourist centre called Rinka, it is worth a visit.

After getting my core temperature back up, I headed back up in to the hills, over to Črna. In a few kilometres out of town I have spotted something interesting just by the road. It looked like someone was carving a bear out of the log.

When I have got on the gravel it quickly got really interesting. I thought I knew how to ride off-road but my beast has quickly proved me wrong. But I have to say that the bike has a used Metzeler Sahara front tyre, to low bars for sanding and it is much lighter than KLE, so I guess it rides differently that what I used to from KLE.

With a few more minutes back to the house I have looked up and didn’t like what I saw.

Hopefully the weather has held up until I got to the garage. It was a nice day for riding and I really had a good time. Riding really is the best medicine for clearing your head.

Preflight check

Posted: 16/09/2014 in Repair archives

Hey all!

As I have stated in the my bikes post, I have recently bought a KTM LC4 640 Enduro. And like with all second hand motorized things I buy, I always preform a complete check of the bike and do a service on it. So after having a bike for 2 weeks, I have done the following things:

Changed the brake pads, as the ones on the bike were under the service limit, and brake fluid…IMAG0308

…next on the list was the radiator hose that was leaking, and it still leaks after the change, and coolant…IMAG0304

…also the battery needed to be changed…


…I have found a broken KTM Powerparts filter cover, so I ordered a new one, but instead I got a OEM gasket and plastic cover…



There are a few more things to do, I still have to clean the air filter, I am thinking of just getting a new one as this one might still be the OEM one installed 12 years ago…


… and get a new tachometer cover (those things are really expensive), as the buttons are chewed up and water can get inside..IMG_4509

Also I have a new spark plug ready to go in as soon as I get a proper tool to remove the old one.

Stay safe and keep an eye out on the blog as I have quite a few things to post up!