KTM Maintenance Part II, Revenge of the Tard
- shilka99
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KTM Maintenance Part II, Revenge of the Tard
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...
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...
Shaun in McKinney
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- milesmiles
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Re: KTM Maintenance Part II, Revenge of the Tard
I'm taking bets on how many bolts are left over when this is put back together!!!
The world needs Miles
Sometimes you gotta draw the line, but that doesn't mean it can't be squiggly-miles
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Sometimes you gotta draw the line, but that doesn't mean it can't be squiggly-miles
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Re: KTM Maintenance Part II, Revenge of the Tard
Put me down for zero. I've got faith in Shaun's skills.
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Re: KTM Maintenance Part II, Revenge of the Tard
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.
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- milesmiles
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Re: KTM Maintenance Part II, Revenge of the Tard
normally i would agree, but the new work bench would seem to keep things more organized. +1 for me
The world needs Miles
Sometimes you gotta draw the line, but that doesn't mean it can't be squiggly-miles
"it's not a stupid dirt bike, it's a supermoto!"-miles
Sometimes you gotta draw the line, but that doesn't mean it can't be squiggly-miles
"it's not a stupid dirt bike, it's a supermoto!"-miles
- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
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)
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)
Shaun in McKinney
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- WillK675
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Re: KTM Maintenance Part II, Revenge of the Tard
Put me down for 2 trips to go buy new bolts.
-Will
'07 Daytona 675
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When it comes to addiction Motorcycles are worse than crack.
"Brake fade is God's way of telling you to quit squeezing the coward lever and carry more corner speed, you pussy." - Rhino
'07 Daytona 675
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When it comes to addiction Motorcycles are worse than crack.
"Brake fade is God's way of telling you to quit squeezing the coward lever and carry more corner speed, you pussy." - Rhino
- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
I'd take that bet if I could...WillK675 wrote:Put me down for 2 trips to go buy new bolts.
Shaun in McKinney
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
The frame is ready. The orange is a little brighter than I expected!
Just need to finish the motor now...
Just need to finish the motor now...
Shaun in McKinney
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Re: KTM Maintenance Part II, Revenge of the Tard
That's a sexy orange.
Paint or powdercoat?
Paint or powdercoat?
- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
Powder. I dont think paint would last long. I'm hoping powder coat will resist abuse for a while.
Shaun in McKinney
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
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.
The piston is also worn beyond spec so looks like another weeks delay while I get an exchange cylinder and new piston.
Shaun in McKinney
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
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.
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.
Shaun in McKinney
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- DarcShadow
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Re: KTM Maintenance Part II, Revenge of the Tard
very cool.
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Re: KTM Maintenance Part II, Revenge of the Tard
Interesting to see. Beyond my mechanical skills.
Sitting on the couch, watching TV, isn't living.
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txt 8..223.0762 to ride.
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Triumph 955
txt 8..223.0762 to ride.
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
Forged goodness.
When the new cylinder arrives (tomorrow hopefully), I hope to get the bike up and running over the weekend.
When the new cylinder arrives (tomorrow hopefully), I hope to get the bike up and running over the weekend.
Shaun in McKinney
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
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
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
Shaun in McKinney
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RGV250|520SX/SMR|RSV4 Factory
- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
Its starting to take shape.
Shaun in McKinney
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Re: KTM Maintenance Part II, Revenge of the Tard
Looking awesome! I'm gonna have to swing by and check it out in person.
Current: 10 Triumph Street Triple | 08 Kawasaki Concours 14 | 07 Yamaha YZF-R6 (Race) | 05 Suzuki DR650 SE | 04 Yamaha TT-R 125LE
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- DarcShadow
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Re: KTM Maintenance Part II, Revenge of the Tard
Impressive is an understatement.
I Refuse to Tiptoe Through Life...Only to Arrive Safely at Death.
Attack Life! It's gonna kill you anyway.
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
Done. Just need to get a new chain and fill with coolant and I can go riding.
Shaun in McKinney
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- shilka99
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Re: KTM Maintenance Part II, Revenge of the Tard
Here's a little experiment I tried with the GoPro:
Last edited by shilka99 on Mon Apr 28, 2014 4:47 pm, edited 1 time in total.
Shaun in McKinney
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Re: KTM Maintenance Part II, Revenge of the Tard
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
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Re: KTM Maintenance Part II, Revenge of the Tard
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.
Shaun in McKinney
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- Polokid69
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Re: KTM Maintenance Part II, Revenge of the Tard
excellent video!
Current Bike:
KTM RC390
Previous Bikes:
2007 Kawasaki ZZR600
2012 Kawasaki Ninja 250R
2002 Kawasaki Ninja ZX6
2000 Kawasaki Ninja EX250
1983 Kawasaki GPZ550
1980 Yamaha RD400
1978 Yamaha DT 125
1978 Yamaha YZ 125
1975 Yamaha DT 100
KTM RC390
Previous Bikes:
2007 Kawasaki ZZR600
2012 Kawasaki Ninja 250R
2002 Kawasaki Ninja ZX6
2000 Kawasaki Ninja EX250
1983 Kawasaki GPZ550
1980 Yamaha RD400
1978 Yamaha DT 125
1978 Yamaha YZ 125
1975 Yamaha DT 100