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KTM rebuild |
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05-15-2008, 08:42 AM
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#1
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carl_g is offline
Join Date: May 2005
Location: nj
Posts: 1,947
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KTM rebuild
I know it is not a sportbike, but nonetheless it is my bike and 2 weekends ago I blew up the bottom end during a race.
I need to split the cases and replace the crank. I will also replace the piston and rings while I have it all apart.
Here is my progress so far of taking off the top end.
Head (needs to be cleaned up)
Engine
Cylinder & top of piston
Power valve actuating arm
Cylinder - doesn't look bad at all!
Another cylinder shot.
This weekend I will split the cases so stay tuned for more..
oh yeah wish me luck ![Emot LMAO](images/smilies/emot-LMAO.gif)
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RIP AJ600M
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05-15-2008, 08:55 AM
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#2
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Throttle Lock
ronin_01r1 is offline
Join Date: Jun 2005
Location: south jersey
Posts: 1,105
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take lots of pics! GL.
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SONG
2007 Kymco Grand Vista 250
2006 KTM 950 Supermoto
2001 Yamaha R1
1976 Honda CB360t
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05-15-2008, 11:14 AM
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#3
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Meatball's Daddy
NYCSTRIPES is offline
Join Date: Oct 2005
Location: Queens, NY
Posts: 1,754
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What controls the power valve?
The head gasket design is very similar to the TZ50 I have. Personally I wish it was something more substantal than these little o-rings.
__________________
2003 TL1000R #489
1998 Valkyrie cruiser
No man's life, liberty, or property are safe while the legislature is in session....-Mark Twain
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05-16-2008, 08:39 AM
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#4
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Short Shifter
bondo is offline
Join Date: Dec 2005
Location: wrong island, ny
Posts: 170
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Looks good Carl.
I guess you could consider it a little "unplanned maintenance"
There's a lot of hours on that bottom end and a fresh engine will be nice to have next time you are 20-30miles into the woods.
I think I might start carrying a buddy tow rope too.
The guy who parked next to us at the Curly Fern was the owner of powerseal. They did my cylinder.
Behold ![Roflmao](http://sportbikeaddicts.com/forums/images/smilies/roflmao.gif)
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- john
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05-16-2008, 08:44 AM
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#5
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Short Shifter
bondo is offline
Join Date: Dec 2005
Location: wrong island, ny
Posts: 170
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Quote:
Originally Posted by NYCSTRIPES
What controls the power valve?
The head gasket design is very similar to the TZ50 I have. Personally I wish it was something more substantal than these little o-rings.
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Hey Ken,
Centrifugal force and 3 different springs with a screw adjuster. You can adjust the power/exhaust valve to operate any way you'd like. Tune the power so it's just right.
O-rings are simple and it's all you need with relatively low cylinder pressure/heat. I like 'em! If it was a turbo I-4 drag bike, then some nice copper/bronze head gaskets with metal o-rings machined into the block are necessary.
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- john
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05-16-2008, 01:43 PM
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#6
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Meatball's Daddy
NYCSTRIPES is offline
Join Date: Oct 2005
Location: Queens, NY
Posts: 1,754
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Quote:
Originally Posted by bondo
Looks good Carl.
I guess you could consider it a little "unplanned maintenance"
There's a lot of hours on that bottom end and a fresh engine will be nice to have next time you are 20-30miles into the woods.
I think I might start carrying a buddy tow rope too.
The guy who parked next to us at the Curly Fern was the owner of powerseal. They did my cylinder.
Behold ![Roflmao](http://sportbikeaddicts.com/forums/images/smilies/roflmao.gif)
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Powerseal does nice work. They replated the barrels on my TZ250 this spring. I am pretty happy with the quality of the work.
Ken
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2003 TL1000R #489
1998 Valkyrie cruiser
No man's life, liberty, or property are safe while the legislature is in session....-Mark Twain
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05-19-2008, 10:06 PM
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#7
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Kung Fu Panda
Ant is offline
Join Date: May 2005
Location: NJ
Posts: 2,049
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Yeah Carl!
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Quote:
Originally Posted by mike295
i figer i got about 20 more pounds till i can't see my dick
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Quote:
Originally Posted by Cakes
That'll make ya crap where ya stand
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Quote:
Originally Posted by Jimmy
gixxer...cage....it's like kicking me in the balls
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06-06-2008, 08:44 AM
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#8
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carl_g is offline
Join Date: May 2005
Location: nj
Posts: 1,947
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I have been sort of lagging on this project while waiting for parts to come.
I made some good progress last night.
Here you can see I took off the main clutch case cover and took apart my autoclutch.
I also pulled the flywheel and stator off..
I will have an impact wrench tonight to get the primary gear off and then I will finally be able to split the cases and send out the crank to be rebuilt.
Thank god for friends having extra bikes with the willingness to let you beat on them ![Ride](http://sportbikeaddicts.com/images/smilies/ride.gif)
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RIP AJ600M
Last edited by carl_g; 06-06-2008 at 08:46 AM..
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06-06-2008, 11:30 AM
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#9
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Meatball's Daddy
NYCSTRIPES is offline
Join Date: Oct 2005
Location: Queens, NY
Posts: 1,754
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who's rebuilding your crank? Local?
With the TZ250, all you need to do is wedge a penny into the primary gear and you can use standard tools to loosen the nut. From the angle of the picture I can't tell if that's possible with your bike.
Ken
__________________
2003 TL1000R #489
1998 Valkyrie cruiser
No man's life, liberty, or property are safe while the legislature is in session....-Mark Twain
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06-07-2008, 12:37 AM
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#10
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carl_g is offline
Join Date: May 2005
Location: nj
Posts: 1,947
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Quote:
Originally Posted by NYCSTRIPES
who's rebuilding your crank? Local?
With the TZ250, all you need to do is wedge a penny into the primary gear and you can use standard tools to loosen the nut. From the angle of the picture I can't tell if that's possible with your bike.
Ken
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The crank is getting sent out to this guy in KY. He goes by the name of Mr Crankshaft and he has been super helpful and there has been excellent communication.
Here are some pics of my progress tonight.. finally the cases are split!
Engine out of the frame..
another engine pic...
Make sure you read the shop manual
BAM! Split cases.
Inside of left half of engine.
The reason for all this work..bad crank.
Inside of the right half of engine.
![](http://www.ism409.com/images/ktmrebuild/rebuild_18.jpg)
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OCCR
RIP AJ600M
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06-07-2008, 10:39 AM
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#11
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Meatball's Daddy
NYCSTRIPES is offline
Join Date: Oct 2005
Location: Queens, NY
Posts: 1,754
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looks like you're on your way. the mr. crankshaft website claims a quick turn around...hopefully you'll be back in business quickly. Question..the green stuff on the engine case...is that a rubberized or paper gasket ? or is that silicone?
Ken
__________________
2003 TL1000R #489
1998 Valkyrie cruiser
No man's life, liberty, or property are safe while the legislature is in session....-Mark Twain
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06-07-2008, 10:58 AM
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#12
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carl_g is offline
Join Date: May 2005
Location: nj
Posts: 1,947
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Quote:
Originally Posted by NYCSTRIPES
looks like you're on your way. the mr. crankshaft website claims a quick turn around...hopefully you'll be back in business quickly. Question..the green stuff on the engine case...is that a rubberized or paper gasket ? or is that silicone?
Ken
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paper gasket..
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RIP AJ600M
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06-07-2008, 10:52 PM
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#13
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Puke Boy
John712 is offline
Join Date: May 2005
Location: 6 Million ways to die, choose one!
Posts: 4,126
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oh man, and i though my bike was in pieces!
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06-09-2008, 09:49 PM
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#14
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Kung Fu Panda
Ant is offline
Join Date: May 2005
Location: NJ
Posts: 2,049
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why are the rear cylinder bolts corroded?
__________________
Quote:
Originally Posted by mike295
i figer i got about 20 more pounds till i can't see my dick
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Quote:
Originally Posted by Cakes
That'll make ya crap where ya stand
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Quote:
Originally Posted by Jimmy
gixxer...cage....it's like kicking me in the balls
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06-09-2008, 09:54 PM
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#15
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Meatball's Daddy
NYCSTRIPES is offline
Join Date: Oct 2005
Location: Queens, NY
Posts: 1,754
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probably from a coolant leak..just a guess.
Ken
__________________
2003 TL1000R #489
1998 Valkyrie cruiser
No man's life, liberty, or property are safe while the legislature is in session....-Mark Twain
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