Olddogs 660 Rallye Rebuild

Discussion in 'Thumpers' started by OldDog, Nov 10, 2006.

  1. OldDog

    OldDog aka Hugh Jarse

    Joined:
    Feb 20, 2005
    Oddometer:
    5,330
    Location:
    Mudgee, Australia
    G’day Everyone,
    A few weeks ago I had the questionable :huh good fortune of picking up a ’99 KTM 660 Rallye, thought you guys might be interested in seeing it's rebuild. To the best of my knowledge this bike was raced in 2 Paris – Dakar’s and was raced here in the Australian Safari by Tim Fitzhardinge and then several times by Craig Hartley, heres some pics of him in action
    [​IMG]
    [​IMG]
    It's 1 of 3 660 Rallye’s in Australia which has compliance for road registration. Craig sold the bike to Shane Martin (aka Leglessone) earlier this year, heres a pic
    [​IMG]
    he in turn sold it on to me. For whatever reason, the bike has suffered some reliability issues recently and I picked the thing up in several large lumps and several boxes full of small pieces, queue more pics
    [​IMG]
    [​IMG]
    [​IMG]

    After close inspection I decided to strip the bike right down and start again, replacing any bits required.
    [​IMG]

    After disassembly the first thing I did was get some cans of crack test and go over the welds and joints on the frame and swing arm, all clear! Then the axles, gearbox shafts, swing arm pivots and triple clamps, all clear! Then I used a string line on the frame and again with the swing arm installed, plus checked the swing arm was true, those were all clear as well. Given that this bike would have copped a fair hiding from all those race miles I’m impressed that something isn’t bent. I noticed it’s had a hit in the front taking off the radiator mounts which were then welded back on but not painted so there was some rust there, also some rust inside the front frame brace as the drain holes were blocked, I’ve treated that. After a quick bead blast it’s received a few coats of some flash grey epoxy 2 pack wonder paint that a mate uses on mining equipment, I was a bit disappointed that it wasn’t the same shade of grey but what the hell it looks ok and the finish is tough. another pic or 2...
    [​IMG]
    [​IMG]

    So far i can see that it needs a new main wiring harness and a new suspension linkage. The harness is just old and a new one will make sure I don’t get any unexpected “surprises” The pin in the suspension linkage where it bolts to the swing arm was frozen due to worn out bearings….or so I thought, turns out the bore is stretched out of round, possibly due to a hard landing (?) anyway, Pezz the Rallye Guru happens to have a spare which saves me trying to source an “out of stock” part. Thanks mate:thumb

    The engine is in a bad way, the big end failed taking out the crank pin, conrod, piston and barrel. The scours in the barrel go deep so I dunno if it’s reusable although now that I think of it…. Pezz mentioned a 105mm piston kit :-0 so it may live again MMmmmmm big block!! Never mind though, it comes with a new barrel/rod/piston assembly ready to go in. There was an impressive amount of debris right through the motor so while it’s in bits I’ll replace all the bearings that would have been affected. I pretty impressed with this thing, it was still going strong despite the busted bottom end and still fired straight up, made a horrible racket though! The only other issue I can see so far is the gears in the gearbox, looks to me like 6 of the 10 gears have pitting, some of it pretty bad. Once I’ve saved up the $$$ for those puppies I’ll be able to get the engine nailed together and have the beast back on the road……errr tracks and see just what this things made of, well to the best of my ability I guess :lol3 I can’t see myself racing it so it will live a life of relative semi retirement, being mainly used to take me to those hard to get to places that I won’t take the GS, after my last accident that bike stays on the road or good dirt.

    #1
  2. doyle

    doyle RallyRaidReview-ing

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    24,788
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    :clap

    keep it coming!
    #2
  3. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
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    731
    Location:
    Hell-sing-land, Sweden
    I´m waiting.. :lurk
    #3
  4. Ignore Amos

    Ignore Amos bruised, dazed & confused

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    Aug 4, 2004
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    Tucson, Arizona
    This is worth waiting for...
    #4
  5. bugfnnuts

    bugfnnuts Somewhat Regrouped

    Joined:
    Mar 24, 2006
    Oddometer:
    956
    Location:
    Not the F'ing Canary Islands
    there lost boy :wave

    How ya been? You need a rallye project like this one. Would be perfect for your Baja trip.

    Tim
    #5
  6. Beez

    Beez Given to fly

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    Looking good! :thumb
    #6
  7. meat popsicle

    meat popsicle Ignostic

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    Location:
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    Frame on up restoration? :lurk
    #7
  8. Speaker

    Speaker Been here awhile

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    Mar 31, 2006
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    888
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    N. AZ
    Oh man, bookmarked.
    #8
  9. Hoder

    Hoder Card carrying greeny

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    1,019
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    Congrats on the cool new project :beer
    This is gonna be good :lurk
    #9
  10. AndyBee

    AndyBee Adventurer

    Joined:
    Aug 1, 2006
    Oddometer:
    42
    Location:
    Just North of Civilisation, UK
    Crikey, I'm excited! Once it's finished, I'm going to emigrate to Australia in case you ever sell it.:clap
    #10
  11. OldDog

    OldDog aka Hugh Jarse

    Joined:
    Feb 20, 2005
    Oddometer:
    5,330
    Location:
    Mudgee, Australia
    Thanks for the encouragement everyone! The pics will probably be a little slow as i'm stuck in the stone age and using a film camera.
    If anyone out there has information on these puppies don't hesitate to post it up, also if anyone knows how to get more on this bikes history let me know.
    Thanks heaps
    Bill
    #11
  12. sixer

    sixer I suffer from Ainrofilac

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    Very cool indeed. I'll be lurking in this thread.

    :lurk
    #12
  13. bmwktmbill

    bmwktmbill Traveler

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    5,600
    Location:
    Traveler
    Dog,
    Good work. Neat to see how the later machines followed from the early rally racers.
    I am interested in the airbox and airfilter configuration. KTM changed the airbox on later CV carb models.
    Any chance you could photograph the airbox cover and explain what the dohicky is on the side of your airbox?
    What carb is you machine set up with?
    Thanks, Bill.
    #13
  14. OldDog

    OldDog aka Hugh Jarse

    Joined:
    Feb 20, 2005
    Oddometer:
    5,330
    Location:
    Mudgee, Australia
    G'day Bill, Below is a pic of the airbox showing the valve thingy on the side, sorry i have no idea what it does, it's just an alloy plate with a hole behind it leading into the airbox, the plate is a bit flexible so may let air in at some point, maybe theres someone out there can help? Filter is just a normal foam one, the airbox itself is much larger than a normal 640's, also see the holes drilled at the back, they're normally covered by mesh as is the top but the material is unavailable. The carb is a Dellorto PHM 40
    [​IMG]

    Hope that helps
    Bill (the other one)
    #14
  15. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    <TABLE cellSpacing=1 cellPadding=1 width="100%" border=1><TBODY><TR><TD vAlign=top noWrap align=middle width=500 bgColor=#ffffff rowSpan=17>[​IMG] [SIZE=+1]320475 - FILTER BOX 660 RALLYE `99[/SIZE][SIZE=+1]
    [/SIZE]Copyright ©2002 by </I>KTM Sportmotorcycle USA. All rights reserved.
    Powered by </I>KTMWorld.com®
    </TD></TR><TR align=middle bgColor=#999999><TD width="3%">[SIZE=+1]#[/SIZE]</TD><TD width="32%">[SIZE=+1]Description[/SIZE]</TD><TD width=11>[SIZE=+1]Number[/SIZE]</TD></TR><TR><TD width="3%" bgColor=#ff6600>10</TD><TD width="32%" bgColor=#ff6600>SPLASH PROTECT.FOR FILTER BOX</TD><TD width="11%" bgColor=#ff6600>54606010000</TD></TR><TR><TD width="3%" bgColor=#cccccc>15</TD><TD width="32%" bgColor=#cccccc>FILTERELEMENT 125/550/LC4/DUKE</TD><TD width="11%" bgColor=#cccccc>56506015100</TD></TR><TR><TD width="3%" bgColor=#ff6600>16</TD><TD width="32%" bgColor=#ff6600>FILTER CARRIER `97</TD><TD width="11%" bgColor=#ff6600>58306016100</TD></TR><TR><TD width="3%" bgColor=#cccccc>17</TD><TD width="32%" bgColor=#cccccc>HOLDING HANGER FOR FILTER `97</TD><TD width="11%" bgColor=#cccccc>58306017100</TD></TR><TR><TD width="3%" bgColor=#ff6600>18</TD><TD width="32%" bgColor=#ff6600>HOOK FOR FILTER BRACKET</TD><TD width="11%" bgColor=#ff6600>58306017050</TD></TR><TR><TD width="3%" bgColor=#cccccc>19</TD><TD width="32%" bgColor=#cccccc>CLAMPING DISK KS4</TD><TD width="11%" bgColor=#cccccc>54606019004</TD></TR><TR><TD width="3%" bgColor=#ff6600>20</TD><TD width="32%" bgColor=#ff6600>AIR FILTER BOX BLEEDING</TD><TD width="11%" bgColor=#ff6600>50206020000</TD></TR><TR><TD width="3%" bgColor=#cccccc>27</TD><TD width="32%" bgColor=#cccccc>AIR FILTER BOOT 540/620/640</TD><TD width="11%" bgColor=#cccccc>58006026500</TD></TR><TR><TD width="3%" bgColor=#ff6600>28</TD><TD width="32%" bgColor=#ff6600>HOSE CLAMP 60-80MM</TD><TD width="11%" bgColor=#ff6600>55006028000</TD></TR><TR><TD width="3%" bgColor=#cccccc>29</TD><TD width="32%" bgColor=#cccccc>HOSE CLAMP 50-70MM</TD><TD width="11%" bgColor=#cccccc>51006027000</TD></TR><TR><TD width="3%" bgColor=#ff6600>38</TD><TD width="32%" bgColor=#ff6600>HH COLLAR SCREW M 6X15 WS=8</TD><TD width="11%" bgColor=#ff6600>0014060153</TD></TR><TR><TD width="3%" bgColor=#cccccc>39</TD><TD width="32%" bgColor=#cccccc>HH COLLAR SCREW M6X10 WS=8</TD><TD width="11%" bgColor=#cccccc>0014060103</TD></TR><TR><TD width="3%" bgColor=#ff6600>40</TD><TD width="32%" bgColor=#ff6600>BUCKET</TD><TD width="11%" bgColor=#ff6600>72210079000</TD></TR><TR><TD width="3%" bgColor=#cccccc>44</TD><TD width="32%" bgColor=#cccccc>FILTER BOX CPL. WITH VLIES `98</TD><TD width="11%" bgColor=#cccccc>58506001044</TD></TR><TR><TD width="3%" bgColor=#ff6600>45</TD><TD width="32%" bgColor=#ff6600>VLIES CUT RALLYE `98</TD><TD width="11%" bgColor=#ff6600>58506099000</TD></TR></TBODY></TABLE>

    vlies means fleece in German, don't know why they call it that though
    #15
  16. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    #16
  17. OldDog

    OldDog aka Hugh Jarse

    Joined:
    Feb 20, 2005
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    5,330
    Location:
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    #17
  18. Hoder

    Hoder Card carrying greeny

    Joined:
    Mar 15, 2006
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    1,019
    Location:
    Buckley, Washington
    Hey OldDog, did you happen to get any pics of the instrument bracket before you removed it?
    #18
  19. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    4,059
    Location:
    Sydney Skunkworks
    Bill
    The 660 Rallye's run an overbored 40mm carbie which takes it out to 41mm.
    The body says PHM40, so get the Verniers out and have a measure.

    Great thread, I will get some good info for rebuilding mine :wink:

    Hey have you thought about Painting it GS 'Ewan' Silver :rofl
    #19
  20. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    http://www.ktm-sommer.de/Seiten_06/f_start_06.html

    http://216.165.194.66/munnracing/catalog/catalog.cfm?theirgroup=15
    #20