KTM rebuild - Page 2 - Sportbike Addicts

***carl_g*** · 06-09-2008, 09:58 PM

Quote:

Originally Posted by Ant

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

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...

**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

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

Cleaned the head up tonight..

Nice work man. Damn thing looks new.

***carl_g*** · 06-18-2008, 09:33 AM

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

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

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

new crank is all fresh thanks to MR. Crankshaft

another crank shot

This is the old rod.. you are not supposed to see any gap there.. this thing is toast.

You can see the bearing was starting to attach to the rod.

I'll be putting this in tonight!

bondo · 06-19-2008, 11:18 PM

the pic of the mushed needle bearings is cool

more pics!

***carl_g*** · 06-20-2008, 08:45 AM

Quote:

Originally Posted by bondo

the pic of the mushed needle bearings is cool

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.

SAXON117 · 06-20-2008, 08:48 AM

Quote:

Originally Posted by ism409

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.

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!

***carl_g*** · 07-14-2008, 01:29 PM

I totally slacked on taking pics of putting it back together but it is back together and on Saturday it started up 2nd kick!!!!

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!!!!!

duc748pilot · 07-14-2008, 04:34 PM

good job dude! glad everything worked out!

NYCSTRIPES · 07-14-2008, 04:44 PM

cool!