Mid-80's KTM 2-Stroke

Discussion in '2 smokers' started by CrazyD2.0, Feb 1, 2013.

  1. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    Nice looking machine! When I get to the frame on this one, I know there's going to be some welding to be done - there's been some previous frame breaks/bad re-welds, as well as some rusted holes that need to be addressed, plus some much needed paint. In the end, I'm hoping to get this thing to approximately 75% new-looking.

    Now that I think about it, I believe you are correct kellymac - on that PentanPartsUsa site there was an exploded diagram of the main case clutch/crank with that lever extending into the clutch pack. Off the top of my head I wondered if it was that de-compression lever I've heard about, used to kick-start bikes easier - but no, it must be clutch-related.
    #21
  2. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    I obtained the critical parts from PentonParts (thanks Alan, for having them!), so #2 Son basically did the remaining tear down of the main frame while I was working on a commisioned job.

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    While we were doing the forks, I noticed that the rubber o-ring had broken (dried out, whatever the case) and saw the bearings visible - I trust this is normal? I would have thought the bearings for the steering head would have been better sealed. Strangely enough, the movement of the forks left/right was smooth enough - but I think I'd look into replacing them when I get to servicing the forks and seals.

    I also found that one of the clutch actuator/cover capscrews had been stripped out once apon a time, so after taking a closer look found that the threads extend right into the transmission cavity, so any thread tapping is going to put metal into the gear set. Not good. so I figured I'd pull that side of the engine housing off. Turns out the sprocket output shaft seal took a hit and is deformed, so have to add a seal for that, gasket for the housing and a seal for the end of the crankshaft too...PentonParts to the phone please... one of the machine screws that holds the ignition system to the crankshaft cover sheared off too - sigh. Better take an inventory on what small drill bits I have available.

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    There were some previously repaired cracks that need to be cleaned up and I wanted to get the frame cleaned and painted, so in the event the engine comes together nicely, I can basically continue with the rest of the restoration without having to pull the engine off again.
    #22
  3. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    I was able to successfully drill out and heli-coil the bolt hole for the clutch release lever cover on the right hand engine case, as well as drill out and extract the broken #4 machine screw that was sheared off in the crank seal cover/ignition adapter. :rillaThat was a bit of a worry. I'm starting to run into issues with parts availability - more on that later...

    As it were, I'm just waiting for the remaining gaskets and seals to show up so I can start reassembly of the engine. In the meantime, my boy Wesley had ground off the excess welds from previous repairs - not a complete job, only half of each of the cracks were done, so he ground of the blobs of weld, and I finished welding the remaining cracks (forgot to bring camera, so no pics...). Today, cleaned off old dirt/mud/oil, and primed the main frame.

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    So I have a question. It is my intention to sell this bike after I get it restored. Provided everything goes to plan, I was going to get it to as near new condition as possible, given its age and availability of parts, and once completed, take it on our annual camping trip, which involves lots of mountain logging roads and trails, so I plan to bring the bike with me to make sure all goes well and bike performs as best as it can. But ultimately, I don't want a 2-stroke, so the outcome is that it will go up for sale. Which brings me to ask: Do I paint the frame to match original KTM colours, or do I take this opportunity to bring in a personal touch. Would any prospective buyers prefer sticking to original in every way or would there be room for change where paint is concerned. This would also apply to getting new fenders and tank, where colours other than white are (supposedly) available. Please chime in, it doesn't matter to me either way, I haven't bought the paint yet, but I'd like to have an idea from those that do have an opinion (me, I like modern/custom looks...)

    And finally - I've been in touch with pentonparts and vintagedirtbikeparts - does anyone else know of others? I've signed on to KTMtalk as well, so I'll post there as well...but like a good fisherman, cast as many lines wherever I can.... I'm finding that some parts are not available from the above mentioned sources, so would like to find more possibilities.
    #23
  4. Scootern29

    Scootern29 Been here awhile

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    Crazy,

    You would be better off doing it in the original factory colors. If you customize it, it is not a true restoration and it will take away from the value to a serious collector.

    Whatever you do, you will never get the $$$ from your labor out of it that you have put into it. So you are not going to make any profit by restoring it on the vintage/classic/evo market unless it is a full on concourse restoration or a very rare bike, and then that is if you can find someone who truely has to have it. If you were keeping it for yourself then the bike is well worth your time.

    Hope this helps
    #24
  5. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    I hear you about the cost factor - I'm not doing this with the expectation of a big $$$ sale - more like a "never-done-this-kinda-thing-lets-see-how-it-goes" project. Of course I would like to cover my parts, maybe couple hundred extra to give to the boys for their help (and a case of beer for me). But you probably are right - return it to original as possible. After all orange is a cool colour anyways, right?
    #25
  6. Bill-66

    Bill-66 Hencho in Kansas

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    Try LETKO Cycles..Shawnee Ks..Jim Letiller raced Pentons forever and has had this shop since KTM was importing as Penton..new location on the highway, but Jim knows his stuff.
    #26
  7. buls4evr

    buls4evr No Marks....

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    It is a 1980 MX bike so will not be too fun for trail riding. It has large ports. They vibrate a lot and suck fuel like mad. They are sudden. Not exactly a good recipe for trails. The tank is not original. Probably came with a 2 gallon tank or so. Without a GS type cylinder and a lot of flywheel added & smaller carb it would be a handful. Likely why it was parked to begin with as much as needing a ring job. I would just make a crosser out of it as this is the cheaper way to go and follows the original intent of the bike anyway.
    #27
  8. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    You'll have to explain the term "crosser" - don't know what you mean by that. As to the bike's characteristics, I guess I'll find out when I'm done what this thing is all about. I've been told by my friend who owned it before, he rode it like he stole it, hence the repairs needed. Plus he says no one liked to ride behind him because it was so noisy :lol3.
    #28
  9. buls4evr

    buls4evr No Marks....

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    "crosser"= a pure motocross bike. Not a trail bike or enduro bike. Perhaps useable in the desert by some. A racing machine. The lines were drawn much more clearly in the 80s than they are today. No power valves to re-adjust. Huge ports and a big carb. Loud as all heck.Arm straightening acceleration....like that.
    #29
  10. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    Ok, I get it. Note to self: increase life insurance...

    Actually looking forward to completion of this thing - I hear about how these machines behave, Its going to be interesting to experience them first hand...
    #30
  11. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    One whole can of orange. Actually its original Kubota orange, but close enough..:evil

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    I pulled the clutch housing/cover off to reseal and discovered the main crankcase drive gear nut was loose - you can see the gouge in the cover from the nut. Good thing I decided to reseal everything, woulda missed that...

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    #31
  12. craydds

    craydds Long timer

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    Going to be a sweet bike! I rode my friend's KTM back in the early eighties and it was an great machine. My brother had an old KTM which he loved, then sold it. Now he wants another one. Went to the dealer yesterday to pick up some parts for my old YZ - was drooling all over the new KTM's. They still make some AWESOME 2-strokes. Does YamaKawaHonSuki even make 2-strokes any more?
    Taking my bike apart I found a loose front sprocket, probably wouldn't have been a disaster, but I put the torque to it with some blue locktite, too:
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    #32
  13. PSchrauber

    PSchrauber Been here awhile

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    Very nice bike, looking forward for any progress.
    As already mentioned by the other member here, a rebuild as close as possible to the original condition is the best way to go.

    Sadly KTM's don't share the same price range when classic like Maicos.
    The next thing are spares, these are expensive.

    I aldo have just rebuild a KTM, still some work to do, ..., the higher costs didn't stop me rebuilding it, it's a passion. And if you don't get the money out now when trying selling it, you will get more in a couple of years. The selling and finding the right new owner will take some time.
    #33
  14. anonny

    anonny What could go wrong?

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    Whats the bar stock welded to the frame for?
    #34
  15. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    My friend Lenny, who owned the bike since he was a teen, says he beat the crap out of the machine, hence the weld repairs to the frame. He added those pieces for added strength, I'm assuming, so I decided to leave them on. So far I've got all that I need for the engine re-assembly, so time permitting this week, I should get that done. Then I'll give it a coat of aluminum etching primer and a silver coat of paint before I remount it to the frame. I'm working on positive thinking, that everything will go perfect and once stuff goes back together, I won't have to take it apart again...:freaky.

    Except for the rear suspension and front fork assy - I'll get that mounted to the frame so I can at least sit astride the bike and kick-start the engine and get it to run. As we all know projects always go as planned, once the motor shows its not gonna toss its cookies on me, then off come the suspension for some cleanup. Forks need new seals and oil, rear shocks need replacing, new chain and sprocket set - not sure about the brakes yet. Already got the carb together (still can't find an air filter tho), and of course new rubber. July 6th we go camping to Sugar Lake near Vernon, BC - That will be the week the KTM returns to life! :thumb:ricky
    #35
  16. buls4evr

    buls4evr No Marks....

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    Try UNI-Filter for a foam air cleaner. They make a heck of a lot of odd stuff:clap.
    #36
  17. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    Great - I'll check out that source. I'm also trying to find the rubber carb mount that joins the carb to the engine intake adapter - I might have to go to some custom hose for that....
    #37
  18. buls4evr

    buls4evr No Marks....

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    A piece of radiator hose or Sudco in CA.
    #38
  19. CrazyD2.0

    CrazyD2.0 We Havin Fun Yet?

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    I thought about using radiator hose - but was thinking that fuel/oil would deteriorate it in fairly short order. I was going to look into some low-pressure hydraulic hose, something that can be fairly flexible/easy to seal with hose clamps.
    #39
  20. Rot Box

    Rot Box Been here awhile

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    Love the updates. That frame is really cool looking :evil
    #40