Birth of a rallye bike

Discussion in 'Some Assembly Required' started by Mudguts, Oct 30, 2008.

  1. Mudguts

    Mudguts when in doubt GAS IT

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    Stage 2 525-540 kit rebuild by a noob
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p> </o:p>
    , I have had the 540 kit sitting in my bedroom for few weeks now
    <o:p> </o:p>
    And it time to install having never done a top end on 4\St just want to know the tricks of the trade as some you seem to pull you bike down because you think it is funn
    ‘
    1) I have the thumper 540 kit with gaskets
    2) I have the cam chain tool
    3) Have all new cam chain & guides
    4) Head will been sent out for new valve and seats
    5) I have check ring gaps) all good
    6) I have the service manual .
    7) Have a 3 torque wrenches ¼ 3/8 ½ inch.
    <o:p> </o:p>
    What other things do I need to know , tip and tricks
    <o:p> </o:p>
    My plan is get the head & barrel off tonight , drop the head off tomorrow
    Pick up head and cam chain & guides weds and reassemble.
    <o:p> </o:p>
    Disassembling is the easy part , putting back together is tricky bit ,
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    I’ll need to check the deck hight , don’t know how to change it if I needed to thou
    <o:p> </o:p>
    I think I’ll be fine up until the cam and TDC I know the theory just need the practice. I suppose it is just a matter of lining up all the indicators and going for it . and to double checking my work.
    #61
  2. Mudguts

    Mudguts when in doubt GAS IT

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    So i got home and got right to it

    a quick pressure wash before pulling the motor down
    [​IMG]


    start stripping parts off
    [​IMG]

    some springy bits that go up and down
    [​IMG]



    and a shiny new thing that goes up and down

    [​IMG]

    and this it where it stops for tonight, gotta drop the head off in the morning for new valves



    old V New
    [​IMG]
    #62
  3. Mudguts

    Mudguts when in doubt GAS IT

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    Well got pick the head up last night then hurried home , to start reassembling , 3 hours later she was together , after checking and double check valve gap , & cranking the motor by hand , i felt it was time to drop the spark plug in , and her a kick ( battery is rooted )

    so wheeler outside flip out the kick starter , and give a boot full
    the first thing i thought was ......SHIT this has compression

    forgetting to turn the fuel on and 10 kicks later ,
    i turn the fuel on two kicks and she fired up Oh what a lovely sound
    of HI-comp 540 KTM EXC , big and meaty but sharp and crisp

    I excitited , I have to take her around the block
    #63
  4. OldDog

    OldDog non impediti ratione cogitationis

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    :clap Well done Mudguts, there are few things sweeter than the first bark out of a newly rebuilt motor, hope you enjoyed the ride.


    Oh and don't worry about the fuel thing, we all do that:rofl
    #64
  5. vallarian

    vallarian Position doubtful

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    Well done with kit install Mudguts. Must be satisfying seeing it come together. Can't remember which thread I read, but there is some good info around on running-in theory if u can find it (basically slowpoke vs WFO) J
    #65
  6. macuser

    macuser Been here awhile

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    next time u buy wheel bearings just get them from a bearing shop rather than a bike shop and you'll save lots of $.
    #66
  7. teti

    teti especie en extincion ®

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    mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

    cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

    saludos atte

    y gracias

    teti
    #67
  8. nevgriff64

    nevgriff64 .

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    So what`s your reply to this one Mudguts??

    :lurk
    #68
  9. teti

    teti especie en extincion ®

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    perdon pero no entiendo , yo uso google para traducir y algunas cosas las traduce mal,

    el q tenga las medidas si le las puede pasar

    gracias

    teti
    #69
  10. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Originally Posted by teti
    perdon pero no entiendo , yo uso google para traducir y algunas cosas las traduce mal,

    el q tenga las medidas si le las puede pasar

    gracias

    teti




    pardon but I do not understand, I use google to translate and some things translate them bad,
    the q has the measures if him teti can
    pass
    thanks
    #70
  11. Sylvia

    Sylvia vir sapit qui pauca loqui

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    Originally Posted by teti
    mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

    cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

    saludos atte

    y gracias

    teti



    mugguts good day, serious so amiable to pass the measures to me of the support of road book?
    whichever centimeters develop forwards, upwards, always taking like reference the pivot from the direction, I am about to to copy anchorage q tenes put in your moto, and if tenes a photo of how you anchored in the chassis
    greetings atte
    and thanks
    teti
    #71
  12. Mezo

    Mezo Banned

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    I think he`s saying,

    Hello Mudguts,

    Would you please pass the measurements of the support for road book.
    how many centimeters develops forward, upward, against the direction of the pivot, I am copying the anchor post in your bike, and if you got a photo as anclaste in the chassis.

    greetings and thanks atte Teti.

    Well thats how Google translates it, he basically wants to do the same as you i think, spanish is the language.

    Mezo.
    #72
  13. mookymoo

    mookymoo Mookish Mook

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    Correct.

    Hes after the measurements of the nav post, to copy it. (Teti is argentinian and imported stuff there is very expensive - so hes trying to do a DYI job)

    Mudguts, how did you get on with a possible clone of the fairing?
    #73
  14. Mudguts

    Mudguts when in doubt GAS IT

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    Yeah cool I'll get the basics .If any one has a CAD program they can lend me
    #74
  15. teti

    teti especie en extincion ®

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    no seria tan necesario la prolijidad , solo mas o menos con una regla cuanto desplaza hacia adelante y cuanto hacia arriba del eje pivote , yo saco mis propias conclusiones .

    mi idea es partir http://www.advrider.com/forums/showthread.php?t=400288 como este post , empezar por la torre o soporte de gps y q sirva para anclar el carenado ( fairing ) , tomar basicas ideas de mi 990 dakar , pero en otras dimensiones , me explico?

    agradezco un monton a todos ustedes por prestarme atencion a mis pedidos , espero en algun momento poder retribuir sus favores , lamento mucho molestarlos pero me facilitan en gran parte la tarea , y siempre una foto ayuda mas que los textos .

    no tengo a mano tantos elementos como ustedes pero tengo mucha conviccion de poder lograrlo con mis manos y su ayuda , de dejarla linda y conseguir el objetivo , una hermosa 530 exc RALLY

    gracias , gracias , gracias

    teti
    #75
  16. teti

    teti especie en extincion ®

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    nonserious so necessary the prolijidad, single more or less with a rule whatever moves forwards and whatever upwards of the axis pivot, I draw my own conclusions.

    my idea is to start off http://www.advrider.com/forums/showthread.php?t=400288 like this post, to begin by the tower or has supported of gps and q serves to anchor the fairing (fairing), to take basic ideas from my 990 to dakar, but in other dimensions, I explain myself?

    I thank for a pile to all you to pay attention to me to my orders, at some time hope to be able to repay its favors, moan to bother them much but facilitates I the task to a great extent, and a photo always helps but that the texts.

    I do not have so many elements by hand as you but I have much conviction of being able to obtain it with my hands and their aid, to leave it is contiguous and to obtain objective, beautiful 530 exc RALLY

    thanks, thanks, thanks

    teti
    #76
  17. mookymoo

    mookymoo Mookish Mook

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    este Traduccion de google es terrible :lol3

    Basically, what he is after is the height & fwd measurement of the nav post, measured relative to the stem.
    He'll work it out from there on.

    (I would suspect that the height/fwd measurement of the centre attachment point for the fairing is going to be useful too)

    Hes going to draw on this and other threads to work out the nav post, fairing etc.

    While he doesnt have the resources we might, hes going to build a sweet 530 Rally.
    #77
  18. teti

    teti especie en extincion ®

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    las lineas en blanco y negro son las medidas que necesito , y si tienen una foto como la amarran al chasis

    [​IMG]

    [​IMG]


    espero aclarar las medidas que necesito

    gracias

    teti
    #78
  19. Mudguts

    Mudguts when in doubt GAS IT

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    height 275mm
    length 290mm
    weight 35mm
    #79
  20. teti

    teti especie en extincion ®

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    manos a la obra , algo va a salir , enviare fotos del proceso

    gracias

    teti
    #80