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KTM rebuild
Old 05-15-2008, 08:42 AM   #1
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Default 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
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Old 05-15-2008, 08:55 AM   #2
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take lots of pics! GL.
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Old 05-15-2008, 11:14 AM   #3
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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.
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Old 05-16-2008, 08:39 AM   #4
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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
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Old 05-16-2008, 08:44 AM   #5
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Quote:
Originally Posted by NYCSTRIPES View Post
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.

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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Old 05-16-2008, 01:43 PM   #6
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Quote:
Originally Posted by bondo View Post
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
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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Old 05-19-2008, 10:06 PM   #7
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Yeah Carl!
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Old 06-06-2008, 08:44 AM   #8
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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
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Old 06-06-2008, 11:30 AM   #9
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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
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Old 06-07-2008, 12:37 AM   #10
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Quote:
Originally Posted by NYCSTRIPES View Post
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
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.
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Old 06-07-2008, 10:39 AM   #11
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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
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Old 06-07-2008, 10:58 AM   #12
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Quote:
Originally Posted by NYCSTRIPES View Post
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
paper gasket..
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Old 06-07-2008, 10:52 PM   #13
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oh man, and i though my bike was in pieces!
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Old 06-09-2008, 09:49 PM   #14
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why are the rear cylinder bolts corroded?
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Old 06-09-2008, 09:54 PM   #15
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probably from a coolant leak..just a guess.
Ken
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