KTM LC4 660 Rallye

Discussion in 'Some Assembly Required' started by mossawi, May 12, 2019.

  1. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    Hi guys,

    So I started working on rebuilding my Factory LC4 660 Rallye. The bike is now getting stripped and we will see how things go from here onwards :)
    #1
  2. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    Some more pics
    20190212_060331037_iOS.jpg 20190212_090128294_iOS.jpg 20190212_090128312_iOS.jpg 20190212_090128319_iOS.jpg 20190212_090128327_iOS.jpg
    #2
    OldDog, airgord, LC8TY and 3 others like this.
  3. plumer1kt

    plumer1kt Adventurer

    Joined:
    Feb 11, 2015
    Oddometer:
    1,327
    Location:
    Hellas
    I can't see your images.
    "
    Access to am3pap001files.storage.live.com was denied
    You don't have authorization to view this page.

    HTTP ERROR 403"
    #3
  4. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    Thanks for letting me know. Clearly pasting the images doesn't work. I uploaded some images now
    #4
  5. plumer1kt

    plumer1kt Adventurer

    Joined:
    Feb 11, 2015
    Oddometer:
    1,327
    Location:
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    Photos visible now.
    What's the plan for the bike?Restore or something else?
    #5
  6. Antti

    Antti Been here awhile Supporter

    Joined:
    Mar 14, 2003
    Oddometer:
    488
    Location:
    Finland
    Tell a bit about your plans? How is the history with the bike?

    I have 100% original Rallye with very very low kms at my carage. Never raced.

    784DCF4D-215B-4A04-9CD3-988FC57CAB04.jpeg
    #6
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  7. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    So here is the thing. I want to use the bike as intended so I am going all out mechanically.

    My view is, to leave the scratches and scruffs as they are as it shows the rally history of the bike.

    I have started stripping the bike and it doesn't seem to be too bad underneath. I managed to get the electrics sorted enough to get ignition and the engine turns over with no issues which is great news considering the last time this bike started was in 2005!

    Love the simplicity and the uniqueness of this bike
    . IMG_5463.jpg

    Needs a good clear to see whats going on but it seems quite solid.
    IMG_5456.jpg IMG_5460.jpg IMG_5505.jpg

    Carb is also out and cleaned
    IMG_5528.jpg IMG_5532.jpg
    #7
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  8. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
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    Dubai
    That is beautiful... Do you get to ride it much?

    As you are the only person I now know with the same bike, I will be asking you quite a few questions going forward :)
    #8
  9. Antti

    Antti Been here awhile Supporter

    Joined:
    Mar 14, 2003
    Oddometer:
    488
    Location:
    Finland
    I ride it only once or twice a year.. :hide
    But keep it fully serviced :)

    My bike has been imported as new for Finnish ex enduro and rally driver mr. Tiainen to be kind of
    training bike but he newer drove it. KTM Finnish import company had it for half decade and only rented
    it few times at that time. Then it was for fifteen years basicly standing until I bought it one and half year ago.
    And made a full service but things in suspension and so was like new so there wasn`t much to do.

    I`m planning to get navigation system dated and I`m getting glasfiber copy from original fairing as I want to save it from crashes.

    Heres something about these bikes:
    https://advrider.com/f/threads/ktm-660-rallye-questions-thread.915778/
    #9
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  10. JimmieDK

    JimmieDK Been here awhile

    Joined:
    Nov 27, 2010
    Oddometer:
    148
    Location:
    Copenhagen, DK
    May I ask how the Dellorto is setup with regards to jetting?
    #10
  11. Antti

    Antti Been here awhile Supporter

    Joined:
    Mar 14, 2003
    Oddometer:
    488
    Location:
    Finland
    Mine has:
    - main 195
    - pilot 45
    - needle don`t remember.

    I happen to have ex KTM mechanic Mr. Jarmo Toivonoja "Topi" living near me. He did work for KTM an decade as race mechanic at enduro
    and rally teams and also another decade for Honda and GasGas. He has been working at Dakars and so. He now runs his own shop and mostly
    works on suspension. When I took shocks from Rallye to him he took bunch WP charts from his race archives wich they made when setting up
    factory bikes and chose the one for hard terrain. I must say I`m pretty impressed with result. Can`t be compared to stock 640 or 1190 or what ever I have had :-)

    In the pics bike has fairing borrowed from Adventure as I`m trying to save the original..
    Now the bike has non golden front rim but I think it has rolled out from factory with golden one.
    When the bike was new there was introduction about the model and few pics of the bike at Finnish rally magazine and it had the golden rim already at then.


    20180815_150257.jpg 20180815_150244.jpg 20180815_150209.jpg
    #11
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  12. Antti

    Antti Been here awhile Supporter

    Joined:
    Mar 14, 2003
    Oddometer:
    488
    Location:
    Finland
    Looks like your bike has oilcooler, mine has third (!) oil filter at same place.
    Did you get roadbook holder with the bike?
    #12
    mossawi likes this.
  13. Wonkyconk

    Wonkyconk Adventurer

    Joined:
    Feb 26, 2012
    Oddometer:
    80
    Location:
    Coleford, glos, england
    How does the oil cooler get air to it up there? It's behind the fairing no?
    #13
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  14. Wonkyconk

    Wonkyconk Adventurer

    Joined:
    Feb 26, 2012
    Oddometer:
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    Location:
    Coleford, glos, england
    IMG_20180920_144517.jpg
    Mine is similar too.
    #14
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  15. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    I used the workshop guide to run the settings. To be honest because I still have not fired it up, I am not sure if my jetting is setup correctly or not. The guys from the local KTM dealer in Dubai will probably lend me a hand with this.
    #15
  16. mossawi

    mossawi Adventurer

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    Feb 17, 2019
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    Lovely bike... I wonder how many were actually made by the KTM factory
    #16
  17. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    On mine, the Peter had the fairing drilled through to get some air in. IMG_20190509_081349.jpg
    #17
  18. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    Yes the mounting bracket and the roadbook came with the bike. I have the roadbook holder and the ICO holder in the box full of all kinds of spares. I still need to work out how it is put together.
    #18
  19. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    I have now stripped the bike down ... Mechanical engine build will be done with the help of the KTM guys in Dubai.. I was amazed to find most of the parts available and reasonably priced through MSP in the Netherlands.

    IMG_20190513_115345.jpg IMG_20190513_115524.jpg IMG_20190513_115606.jpg IMG_20190428_153852.jpg
    I found a damaged cam bearing end but luckily I have 2 other spare heads to use. One is chipped in the same place but the other seems to be perfect.
    IMG_20190428_153839.jpg

    Attached Files:

    #19
    Antti likes this.
  20. mossawi

    mossawi Adventurer

    Joined:
    Feb 17, 2019
    Oddometer:
    26
    Location:
    Dubai
    Hi guys,

    Thought I give a quick update for those who are not on my instagram (@bike_tribe). https://www.instagram.com/stories/highlights/17998628278162822/

    I have now finished the frame, the engine is rebuilt and fired up, suspension is rebuilt. It is now time to put everything back together.

    Since I intend on road registering the bike, I have now purchased a TrailTech Voyager unit to give me some of the information I need (engine temp, rev counter, speed etc...).

    I hope to get the bike finished and registered ready for the season in October :)

    Attached Files:

    #20