KTM 660 Rally build (or is it Rallye, Ralleye :scratch)

Discussion in 'Thumpers' started by PASSMORE, Apr 27, 2007.

  1. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    I made a deal with lastplace for his 660:clap

    Problem is, it is in parts:cry

    Soooo.... This thread will serve to document the build as well as its trials and tribulations - not that there will be any issues, I am sure all will go tegether perfectly with no problems or otherwise:D

    The goal of this will be to build a like-new example of the 660. Might even do some fancy paint'n - we'll see how I feel... The bike will be built up for my needs and may differ from a classic example of the 660 due to those needs (not sure even what those are yet...).

    At the end of the day, it is a bike to ride wherever I please.

    If Charlie is nice, he gets to ride it:deal :rofl

    So the journey begins. Read on. Read on...
    #1
  2. backdrifter

    backdrifter Wannabe rider

    Joined:
    Jan 6, 2005
    Oddometer:
    1,369
    Location:
    Belleville, IL
    :clap:clap:clap

    Can't wait to follow this one!
    #2
  3. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    I will post a lot of photos during the course of this build, but should you wish to look at every buggin' one of them, go HERE:deal
    #3
  4. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    I had the motor gone through and everything looked good aside from the clutch hub being a tad worn, but I am going to run it as it is easy to get to with the motor installed. Otherwise, everything was cleaned, inspected, and ready for service. Carb too...

    [​IMG]

    [​IMG]
    #4
  5. commo_soulja

    commo_soulja Supa Thumpa Pilot

    Joined:
    Jun 19, 2005
    Oddometer:
    386
    Location:
    C-Ville
    :lurk
    #5
  6. doyle

    doyle RallyRaidReview-ing

    Joined:
    Jan 14, 2004
    Oddometer:
    25,084
    Location:
    Off Piste
    :lurk :ear
    #6
  7. Loadedagain

    Loadedagain making chips

    Joined:
    Jan 1, 2003
    Oddometer:
    26,763
    Location:
    West Vancouver, BC
    letter rip passy! :clap
    #7
  8. Beez

    Beez Given to fly

    Joined:
    Aug 20, 2004
    Oddometer:
    6,016
    Location:
    Framingham, MA
    :thumb :lurk
    #8
  9. Betelgeuse

    Betelgeuse Don't Panic

    Joined:
    Apr 7, 2005
    Oddometer:
    218
    Location:
    Central NH
    This should be good.:thumb
    #9
  10. Odysseus

    Odysseus Stoic Philosopher

    Joined:
    Jul 25, 2005
    Oddometer:
    4,161
    Location:
    Aurora, CO
    Really cool Passmore! I'll be sure to stay tuned to this same bat channel. :lol3
    #10
  11. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    6,840
    Location:
    Kalgoorlie, Western Australia
    Congratulations on the find Passmore:clap I had to assemble mine from pieces as well, dunno if i can be of much help as it's a '99 model, but if i can offer anything i will, i'll be putting this thread in my favourites:D

    Straight up i see that the water pump is mounted down low where my fuel pump is. Is that driven off the balancer shaft somehow?
    #11
  12. RallyKay

    RallyKay Adventurer

    Joined:
    Dec 2, 2003
    Oddometer:
    13
    Location:
    Uppsala, Sweden
    I used to have a 2001 of those, so i might be able to answer some Q:s that come up during the rebuild.

    I did a CrMo rear fender support and a luggage rack to go with that.
    Replaced the emergency beacon support with a scott oiler.

    REALLY fun bike. I miss it!
    #12
  13. Renazco

    Renazco Formerly AKA Boejangles

    Joined:
    Apr 17, 2003
    Oddometer:
    4,751
    Location:
    Santa Rosa, Ca.
    Yer gonna have fun Passy, what a sweet bike to begin with... :wink:
    #13
  14. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    Photos of yours?
    #14
  15. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    This is essentially what I wil be shooting for (thanks for the nice photo James - keep 'em coming, detail shots are great too!).

    [​IMG]
    #15
  16. RallyKay

    RallyKay Adventurer

    Joined:
    Dec 2, 2003
    Oddometer:
    13
    Location:
    Uppsala, Sweden
    I have at home. Vill post asap.
    #16
  17. PASSMORE

    PASSMORE Just the last name...

    Joined:
    Apr 9, 2004
    Oddometer:
    4,312
    Location:
    The Texas Embassy in Sloughhouse, CA
    I would very much appreciate that :thumb
    #17
  18. neduro

    neduro Addict

    Joined:
    Jul 8, 2003
    Oddometer:
    12,285
    Location:
    Colorado Springs, CO
    :tb

    :lurk
    #18
  19. Gwilli

    Gwilli "Life Behind Bars"

    Joined:
    Apr 15, 2003
    Oddometer:
    275
    Location:
    Canberra: -"The Ivory Tower"- Australia
    :lurk +1
    #19
  20. gaspipe

    gaspipe Wandering Soul

    Joined:
    Jul 12, 2004
    Oddometer:
    11,437
    Location:
    Pickwick Lake, Tennessippi
    Go Passmore!
    #20