My KTM 660 Rallye rebuild

Discussion in 'Thumpers' started by Pezz_gs, Jul 11, 2006.

  1. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    4,056
    Location:
    Sydney Skunkworks
    Well it starts like this . . .

    I bought this 1997 640 Rallye with the intention of converting it to electric start, running the 660 Rallye crank, 80mm stroke. This is finished now and runs like a train. I had a charging problems but it appears to be fixed.
    [​IMG]

    I was talking to the previous owner of the 640 and he had a 99 660 in bits he was going to sell. Actually he had a 1999 and a 2000 model 660 Rallye. The 99 frame was easily registerable in OZ (Compliance Plate) The 2000 frame wasnt. So he swapped the 99 frame and bolted his 2000 bits to it and he had this left over. He had the '99 head flowed and his Carbie oval bored and he wanted to keep them, so it was a 2000 model Frame, head and carbie with 99 everything else. I ask for 1st option on it . . .

    A deal was struck, where I would pay him once I sold the 640 Rallye, and I loaded the parts into my Discovery for the LONG trip home. 1500km's each way.
    [​IMG]
    [​IMG]
    [​IMG]

    I promised myself I would touch the 99 until I had sold the 640 Rallye, then buy the necessary parts, bearings Valves ect. So it sat in my garage for a number of months untouched. . . I ended up selling my R80G/s and then paid for the 660 :D Still trying to sell the 640 :ear.

    I moved it over to a good freinds workshop last week and I need to find out just what I have, and what I will need.

    So its Dry assembly time . . .
    [​IMG]

    Had a snapped off bolt in the bottom triple clamp, one of the 4 that hold the front guard on . . . its amazing how much time you loose on little things. About an hour later and it was out . . . .

    This will be a long project as I get about 3 hours a week on it.
    #1
  2. meat popsicle

    meat popsicle Ignostic

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    Is that a golf cart? I hear you can remove the voltage regulator and... :wink:

    Anyways, your garage is bigger than my entire lot. :fitz

    :lurk
    #2
  3. Trevor S

    Trevor S Cap'n Flatulence !

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    Off the Grid, Northern Rivers, NSW, Aus.
    I think he needs it to get around in that shed :eek1 Don't mind me, I have penis... err shed envy.. I have 2 SQ M or so in the corner of the garage I am allowed to use.
    #3
  4. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
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    Thats not my shed, it is the KTM "Bad Influence" workshop of Ian lovell. He led me over to the Orange side :D

    Ian builds and fabricates bikes. Mainly Classic Race bikes and he has a KTM LC4 609cc that he races in Bears racing :clap
    View attachment 77934
    #4
  5. Beez

    Beez Given to fly

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    Hey Pezz, this looks like a chance for a lot of us to see what goes into a real KTM rally bike. Please take lots of photos and explain all the details.

    Cheers :beer



    :lurk
    #5
  6. meat popsicle

    meat popsicle Ignostic

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    A mechanic who plugged my car tire said he used to work at a golf course, and they would remove the voltage regulator so that, well, he said they will reach 30mph w/out the regulator! :lol3 With those bouncy tires and being top-heavy they are unstable at their normal speeds; so he said they are a blast at higher speeds. Occasionally someone would forget to put the regulator back in and a customer would get one... usually ended up in a water trap. :eek1

    I think it would be a waste of time not to remove the regulator in this case. Just to get from one side of the shed to the other at normal golf cart speeds must be agonizing! :nod
    #6
  7. Young-Gun

    Young-Gun KTM Tragic

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    Hey Pezz,

    Looks like you're gonna have a lot of fun putting that all together! Mine's all in one piece now, except I have an issue with super-hot exhaust... check out my thread.

    Cheers,
    Ryan
    #7
  8. Arch

    Arch Incurable Gearhead

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    Looks like a fun project, Pezz. :thumb
    #8
  9. overlandr

    overlandr Dystopist

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    :lurk
    #9
  10. Loadedagain

    Loadedagain making chips

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    here we go... :clap
    #10
  11. ChrisC

    ChrisC Amal sex?

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    Good luck... pics, pics, pics :ear
    #11
  12. overlandr

    overlandr Dystopist

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    Hey John welcome ! Pls fill in your profile so we can see what wonder you ride with the 39mm!!
    #12
  13. Pezz_gs

    Pezz_gs Cant ride for crap

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    G'day John :wink:

    So whats the difference in the ride between the 41 Dellorto and the 39 FCR on ya 660 ??

    Pezz :)
    #13
  14. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
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    Slow progress last week. Basically cleaning and assembling the Rolling Chassis.
    Sorry about the poor pics. Left my digital camera at home so used the Nokia Phone .
    My Dad was in Hospital having a big operation hence the slow post.
    [​IMG]
    Basically put the tail and front fairing bracket on. Missing quite a few of the Bolts that hold the various brackets on . . .
    [​IMG]
    Cleaning the cases and getting ready to remove all the bearings. The cases look quite good inside and will happily house the NEW 660 crank :D
    [​IMG]
    This is my mate Ian working on his supermono. This bike is about 5 meters from my bench . . . Very Distracting :lol3
    [​IMG]
    Photo's dont do this bike Justice . . . . .
    #14
  15. kres

    kres Arrrrrrrrr!

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    :lurk

    [​IMG]

    That SM is SICK :eek1

    {Be sure to include progress on that puppy as well! I'm only just understanding how versitile the LC4 platform really is!}
    #15
  16. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
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    Well I got a bit distracted this week and bought a 98 Adventure R with a blown gearbox.

    It has a few parts I need to finish the 660 Rallye.
    Mainly the frame which is complied and currently registered.
    The frame is nearly Identical to the 660 and has the tree mount for the Road book.
    View attachment 80289

    I am also looking for a LC4 5 speed gearbox as it is totally shagged due to the bearing failure.

    Pezz :)
    #16
  17. Pezz_gs

    Pezz_gs Cant ride for crap

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    The Gear Cluster.
    You can see the hardening missing from the teeth.
    Sorry about the blurry pic.
    View attachment 80290
    #17
  18. rapiti

    rapiti IOR Veteran

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    On the island
    Onya Pezz. Good to see the late 90s represented so well. If you stumble across a source for .50 or .52 fork springs for the WP 5060, let me know. If they happen to be stateside, I will help.

    Many happy mammaries of Sydney. Is the Neutral Bay groin exchange still full of posers? :1drink

    Cheers,

    Paolo
    #18
  19. Pezz_gs

    Pezz_gs Cant ride for crap

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    With OldDog just finishing his 660, I should give you an update on mine.

    Me mate Ian has sold up and moving to Queensland :huh

    So moved the bike home & I now have an overcrowded shed again!!!

    View attachment 97971

    Its now on my bench I am starting to prepare a new parts list.

    I will lay the whole thing out again and take lots of pics

    Okay Satisfied Bill!!!!!!!!!!!!!!!!!!!! :dood
    #19
  20. OldDog

    OldDog aka Hugh Jarse

    Joined:
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    Mudgee, Australia
    Well, yes ...for now:rofl

    So what are we going to call that BMW? the /6? the /5?
    #20