KTM Maintenance Part II, Revenge of the Tard

[shilka99]

Considering that I cant ride the 1.3 on Sunday, and even if I could the 4-speed would make it impossible, I decided to get started on the transmission transplant.
I started this evening around 10, and just finished the initial tear-down.

Before:


After:


Thank god for the new work bench. Its a nice change finishing a job like this without a terrible back ache.
Considering that my office in New Jersey is underwater right now, I'll have a few days to work on this. And there was a reason I stripped it down to the frame, I have some special powder coating ideas that I hope to experiment with. Here's hoping it doesn't end up looking like a bike with a sunburn...

[milesmiles]

I'm taking bets on how many bolts are left over when this is put back together!!!

[Rhino]

Put me down for zero. I've got faith in Shaun's skills.

[DarcShadow]

I'll say -1, meaning one is going to get lost some place along the line and he'll have to dig out a spare.

[milesmiles]

normally i would agree, but the new work bench would seem to keep things more organized. +1 for me

[shilka99]

Actually, being a 10 year old dirt bike there are a lot of rusted bolts and stripped nuts, and I've already found several empty holes. There's a small pile of metal shavings on the table where I had to drill out a bunch of bolts.
The new bottom end will donate several fasteners that are in very good shape. (the owner of that motor rode it very little, cleaned it constantly but never changed the oil)

[WillK675]

Put me down for 2 trips to go buy new bolts.

[shilka99]

Put me down for 2 trips to go buy new bolts.

I'd take that bet if I could...

[shilka99]

The frame is ready. The orange is a little brighter than I expected!
Just need to finish the motor now...

[Rhino]

That's a sexy orange.

Paint or powdercoat?

[shilka99]

Powder. I dont think paint would last long. I'm hoping powder coat will resist abuse for a while.

[shilka99]

It took a while but the parts finally came in. I started with the engine tonight and what fun, the cylinder is worn out and needs a re-plate.


The piston is also worn beyond spec so looks like another weeks delay while I get an exchange cylinder and new piston.

[shilka99]

I had a few hours to work on the KTM tonight.

Thats a 6-speed gear cluster in place of the original 4-speed.

Heres a closeup of the fun stuff;


With all new gaskets and seals the cases are together. axial play in the transmission shafts is 0.5mm


Working hard to keep everything clean, assembly went well;


Ready to be buttoned up;


This motor now has a new clutch, new stock size piston, and the new cylinder arrives thursday or friday. Once that gets here it should take no more than an evening to finish the motor. Then the installation into the pretty new frame begins.

[DarcShadow]

very cool.

[U-Turn]

Interesting to see. Beyond my mechanical skills.

[shilka99]

Forged goodness.


When the new cylinder arrives (tomorrow hopefully), I hope to get the bike up and running over the weekend.

[shilka99]

Everything is coming together now.

Ready for the new cylinder


Heres the replated cylinder. Notice the honing scratches in the Nikasil? These are needed to retain a microscopic oil film after the ring scrapes most of it off.


Sizing the rings


Cylinder installed with the new piston/rings.


Top end with new seals and o-rings for the water pump. The previous owner dunked the entire assembly in liquid gasket. It was blocking coolant lines, oil feed lines and the coolant drain. I even found a big chunk of silicone that had been pumped down to the transmission and was blocking the oil jet over the transmission input shaft. How it survived without that oil flow I will never know.



That cam chain is a pain. It has to be riveted, so getting the sprocket 1 tooth out of alignment requires a new link to be riveted. I miss the gear driven cams of my VFR's and VOR.


Almost done


Ready to go in the frame

[shilka99]

Its starting to take shape.

[Striple]

Looking awesome! I'm gonna have to swing by and check it out in person.

[DarcShadow]

Impressive is an understatement.

[shilka99]

Done. Just need to get a new chain and fill with coolant and I can go riding.

[shilka99]

Here's a little experiment I tried with the GoPro:

[Rhino]

I like the time lapse Shaun! Did you have the camera plugged in so it didn't lose power, or did you do that on one battery charge?

[shilka99]

Thanks Rhino. It took 3 battery charges to film the reassmbly. only having 2 or so hours at a time to work on it made it easy to charge the battery between sessions.

[Polokid69]

excellent video!