Sportbike Addicts | Two Wheels... Our Drug of Choice
Page 2 of 3 1 2 3
Show 40 post(s) from this thread on one page

Sportbike Addicts | Two Wheels... Our Drug of Choice (http://sportbikeaddicts.com/forums/index.php)
-   Two Smokes (http://sportbikeaddicts.com/forums/forumdisplay.php?f=72)
-   -   KTM rebuild (http://sportbikeaddicts.com/forums/showthread.php?t=6670)

carl_g 06-09-2008 09:58 PM
Quote:
Originally Posted by Ant (Post 86872)
why are the rear cylinder bolts corroded?
Good question... I have no idea. I have seen pictures of other people's ktm's torn down and noticed similar corrosion on the rear bolts as well :huh:
I will clean them up but I am not going to replace them.

carl_g 06-09-2008 10:20 PM
Cleaned the head up tonight.. it was too damn hot to do anything else...

http://www.ism409.com/images/ktmrebuild/rebuild_19.jpg

John712 06-09-2008 10:47 PM
Damn looks nice and new, what did you use to clean it?

carl_g 06-10-2008 07:30 AM
Quote:
Originally Posted by John217 (Post 86882)
Damn looks nice and new, what did you use to clean it?
Elbow grease, carb cleaner and a couple of scotch brite pads. :)

FigNewTon 06-10-2008 08:20 AM
Quote:
Originally Posted by ism409 (Post 86877)
Cleaned the head up tonight..
Nice work man. Damn thing looks new.

carl_g 06-18-2008 09:33 AM
New main crank bearings installed
 
Was able to remove the old seals and bearings for the crank and replace them with new ones. I had to heat the case halves to about 150 degrees with a propane torch.. after that, the original bearings fell out. I then took the new bearings which were in the freezer overnight and they dropped right into place :ride:

http://www.ism409.com/images/ktmrebuild/rebuild_20.jpg

http://www.ism409.com/images/ktmrebuild/rebuild_21.jpg

Cranks comes back today.. I should have the bottom back together tonight. ;)

NYCSTRIPES 06-18-2008 10:22 AM
I used a similar trick when putting on the timing chain or my 66 Mustang...cool.


Nice and clean...looks ready to get it dirty again. do the bearings require grease or will the gear oil suffice?
Ken

carl_g 06-18-2008 10:46 AM
Quote:
Originally Posted by NYCSTRIPES (Post 87295)
I used a similar trick when putting on the timing chain or my 66 Mustang...cool.


Nice and clean...looks ready to get it dirty again. do the bearings require grease or will the gear oil suffice?
Ken
No I don't have to grease them.. they get their lubrication from the oil in the premix. I might put some 2 smoke oil on them before I put it together so when I first start it there is already some oil down in there... the other bearings towards the back of the case get lubed by the gearbox oil. :)

carl_g 06-18-2008 03:15 PM
Got the crank back!!!!!!
 
new crank is all fresh thanks to MR. Crankshaft
http://www.ism409.com/images/ktmrebuild/rebuild_22.jpg

another crank shot
http://www.ism409.com/images/ktmrebuild/rebuild_23.jpg

This is the old rod.. you are not supposed to see any gap there.. this thing is toast.
http://www.ism409.com/images/ktmrebuild/rebuild_24.jpg

You can see the bearing was starting to attach to the rod.
http://www.ism409.com/images/ktmrebuild/rebuild_25.jpg

I'll be putting this in tonight! :nod2:

bondo 06-19-2008 11:18 PM
the pic of the mushed needle bearings is cool :roflmao:

more pics!

carl_g 06-20-2008 08:45 AM
Quote:
Originally Posted by bondo (Post 87349)
the pic of the mushed needle bearings is cool :roflmao:

more pics!
Here is a couple more.. ;)
I got the crank back into the cases and put the bottom end back together.
Before mounting the engine back into the frame, I fixed my outer clutch basket. It was grooved pretty bad which would catch the clutch plates and never let it fully disengage. For example, it would slightly creep on me in 1st gear with the clutch pulled in and it was also hard to kick over while in gear.

I have to mill off a couple .001" or so to get the basket all smooth again.
This should be good for another season or two. For now, it also saves me $200 (price of a new one)

Here are the pics of the refreshed basket.

http://www.ism409.com/images/ktmrebuild/rebuild_26.jpg

http://www.ism409.com/images/ktmrebuild/rebuild_27.jpg

SAXON117 06-20-2008 08:48 AM
Quote:
Originally Posted by ism409 (Post 87354)
Here is a couple more.. ;)
I got the crank back into the cases and put them back together.
Before mounting the lower end of the engine back into the frame I fixed my outer clutch basket. It was grooved pretty bad which would catch the clutch plates and never let it fully disengage. For example, it would slightly creep on me in 1st gear with the clutch pulled in and it was also hard to kick over while in gear.

I have to mill off a couple .001" or so to get the basket all smooth again.
This should be good for another season or two. For now, it also saves me $200 (price of a new one)

Here are the pics of the refreshed basket.

http://www.ism409.com/images/ktmrebuild/rebuild_26.jpg

http://www.ism409.com/images/ktmrebuild/rebuild_27.jpg

don't know it its my computer but I can't see those last 2 pix :(

lol must be my computer after I quoted your entry they showed! :LOL:

carl_g 07-14-2008 01:29 PM
It Lives!!!!!!!!!!!!!!
 
I totally slacked on taking pics of putting it back together but it is back together and on Saturday it started up 2nd kick!!!! :drink:
I rode it the piss out of it on Sunday!

- new parts/crank rebuild = $600
- new tools = $50
- hours spent working on it..I lost count
- paying ZERO for labor and rebuilding the whole engine by myself....PRICELESS!!!!! :nod2:

duc748pilot 07-14-2008 04:34 PM
good job dude! glad everything worked out!

NYCSTRIPES 07-14-2008 04:44 PM
cool!


All times are GMT -4. The time now is 12:18 PM.
Page 2 of 3 1 2 3
Show 40 post(s) from this thread on one page

Powered by vBulletin® Version 3.8.2
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.