It seems somehow impossible that after this many weeks, I could still be struggling my way through this refresh/tune up on my 990, but I am not the speediest wrench on the planet. I generally take my time and if I get to a point where I'm confused, I will take a step back and figure things out. Also, I tend to redo jobs whenever I'm not satisfied with something I've done. I have a lot of sources for knowledge when it comes to working on motorcycles in general and this particular bike specifically. I apprenticed for a year at a motorcycle shop when I lived in Maryland, which has given me a good basis for working on bikes. Then I also have my owners manual along with a pdf of the shop manual. Then there is the KTM 950/990 Halls of Wisdom resource at http://www.ktm950.info/ which has a ton of great walk throughs of a lot of the jobs I am doing. I would be remiss if I didn't mention the people at https://advrider.com/f/ as well. In fact, that was the place I saw this bike for sale. It's a great place to find all sorts of help, some of it is even good. I'll also cruise YouTube for videos of some of the jobs I am doing. That can be a big help to see things first hand. Anyhow, back to reality. I needed to drain the oil to access the coolant hoses that I need to replace. Normally, I would run the bike to bring it up to temp before draining the oil, but that's not possible right now. No biggie, I will do another oil change soon enough. The 990 has both an oil tank that needs to be drained as well as the engine sump. Then there are 2 oil screens as well as the oil filter. It's usually a pain to get to the sump since it sits in between the two fuel tanks, but having everything apart made it job a breeze.
First I drained the oil tank and then the sump...I managed to hit the drain pan both times too...
Very few metal shavings on the oil tank drain bolt...good sign.
None on the sump bolt
Clean
New crush washer...you can see the old one is noticeably thinner than the new washer, that's why they should be replaced.
Now to remove the oil tank...there are 4 hoses that need to be disconnected.
Three
and four
That last hose has an oil screen above it...
Then I just removed the three bolts holding the tank on and it falls right off.
Wow...more dirt...who could have imagined that??
Then I removed and cleaned the sump oil screen
Of course, I had bought a replacement, but there is nothing wrong with this one, so now I have a spare. I also cleaned and bagged the oil tank sump until I need it again. Finally, I removed the old filter and installed a new one. Of course I had already cleaned and put away my drain pan, so I used a tiny bit of Tupperware and made a new mess....
Finally I wheeled everything outside and did another cleaning. Will it be the last one? Who knows? I'm sure the bike will still be dirty. That's a constant.
Some hot water and scrubbing later....
I need to clean out the oil tank to remove any dirt that has settled over the years, but that can wait until tomorrow. I am sure I will have more spot cleaning to do, but I won't have to wash the bike any more. I have gotten all the dirt off that matters at this point (famous last words).
From here on out, I should be mostly doing the actual tune up/refresh. I think I will do all the lower electrical connections next. They need to be cleaned and greased with dielectric grease. Then I should be able to attack the shift shaft and clutch.
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