My KTM 660 Rallye rebuild

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

  1. Pezz_gs

    Pezz_gs Cant ride for crap

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    Can you do another bearing order for me Bill???

    Im getting itchy palms . . . . . .

    Got to ring Prorider in the morning :ear
    #21
  2. Pezz_gs

    Pezz_gs Cant ride for crap

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    Well over the next 7 dyas I will have the 660 back together :evil

    I will hopefully have this space filled . . .
    View attachment 99502

    All the bearings and parts will arrive today, so here we go! :wink:
    #22
  3. Pezz_gs

    Pezz_gs Cant ride for crap

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    Tomorrow I will strip the cases and install the new crank bearings, assemble the cases without the crank and measure Between the bearings and the Crank and then shim for end float.
    View attachment 99503
    I will be taking quite a few pics on the way through. OldDog did a pretty good report so the gauntlet has been thrown down :lol3
    #23
  4. v8turbo

    v8turbo When in Doubt.... Gas it.

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    sweet. waiting for more.
    #24
  5. OldDog

    OldDog non impediti ratione cogitationis

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    :lurk come on, come on, come on, wheres the pics? :lol3
    #25
  6. davorallyfan

    davorallyfan Commonist

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    Almost a s good as OldDogs rebuild, but in a strange way, not. :jack
    #26
  7. overlandr

    overlandr Dystopist

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    Hmmm The pics are a whole lot better!
    #27
  8. OldDog

    OldDog non impediti ratione cogitationis

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    :dizave
    #28
  9. overlandr

    overlandr Dystopist

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  10. OldDog

    OldDog non impediti ratione cogitationis

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    Are there any pics yet?:ear
    #30
  11. Pezz_gs

    Pezz_gs Cant ride for crap

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    Well finally got to pulling the bearings out of the cases.

    Took a bit of heat and got em all but 1 :huh

    View attachment 99852

    This is a blind bearing so I cant get underneath it to lift it out.

    Back tomorrow with gas torch to get it really hot . . . and then it will fall out

    Apart from that I am having fun . . . . . :lol3
    #31
  12. Pezz_gs

    Pezz_gs Cant ride for crap

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    Left side case

    View attachment 99853

    Still to be cleaned before the crank bearings go in for assembly without the crank, to measure for shimming for the endfloat.
    #32
  13. OldDog

    OldDog non impediti ratione cogitationis

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    Yeah thats a bugger that one Pezz, you need a small puller for that. If the heat doesn't get it out then either an engineering shop or you freindly local KTM workshop should be able to get it out.
    I've been out on mine since dawn this morning playing on the tracks, you're gonna love that thing! And the seat softens up after a while.......:rofl
    #33
  14. Pezz_gs

    Pezz_gs Cant ride for crap

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    Study is finished, so back into it . . . .

    Did a bit of cooking last weekend . . . .
    View attachment 114139
    120 degrees C for 10 minutes, removed bearings from freezer and they just dropped in

    Measured the crank and have 24 thou worth of shims to press on the crank

    Gearbox over this weekend . . . . .
    #34
  15. R-dubb

    R-dubb Dubbious Adventurer

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    Nice to see you back on it. Very cool thread!!!
    #35
  16. Pezz_gs

    Pezz_gs Cant ride for crap

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    Thanks R-Dubb

    I now have to lay out the gearbox from box's and count teeth ect to make sure I got it all when I picked the bike up . . . It is harder when you dont pull them apart yourself . . . . . . . . . . . . . . . :evil
    #36
  17. OldDog

    OldDog non impediti ratione cogitationis

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    Thats the spirit Pezz, this puppy will be up and running short order!:clap
    I assume Jane was away when you cooked up those cases:rofl
    #37
  18. davorallyfan

    davorallyfan Commonist

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    :bore

    Something happening out there?


    Was that a blowfly Dad?


    Nah. It must have been a mosquito Dave.
    #38
  19. Pezz_gs

    Pezz_gs Cant ride for crap

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    Deal was Im supposed to clean the oven . . . . . .

    But I just havent found time yet . . . . . :lol3
    #39
  20. v8turbo

    v8turbo When in Doubt.... Gas it.

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    this rock..............
    #40