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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    Wife and Kids away next week.

    Im looking to convert the dining table to a Gearbox workbench :evil

    Should get the bottom end finished next week.
    #41
  2. rjf

    rjf SBS's #1 fan in January

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    Not if you spend all your time on here,



    get back in the shed!!!:whip









    And stay there till its ready for me and Bill to test ride:rofl
    #42
  3. srosa

    srosa Been here awhile

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    .:eek1 :tb :clap
    #43
  4. Pezz_gs

    Pezz_gs Cant ride for crap

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    #44
  5. Pezz_gs

    Pezz_gs Cant ride for crap

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    Well, this is going too slow isnt it . . . . . .

    Measured the crank for shims 0.012 thou each side.

    I am now up to assembling the gearbox. The LC4 Manual and parts book will be a great help. Im starting with this . . . . .
    View attachment 116863
    Just need to start counting teeth and work out what goes where :evil
    #45
  6. OldDog

    OldDog non impediti ratione cogitationis

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    Mmmmmm can't wait Pezz, it'ss be good to see an original one one up and running:thumb
    #46
  7. rjf

    rjf SBS's #1 fan in January

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    :hide
    #47
  8. Pezz_gs

    Pezz_gs Cant ride for crap

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    Well things have been progressing pretty slowly, with work and study. Last weekend OldDog was getting a bit tired of my SLOW progress and drove 9 hours to the big smoke to spend a few days in the shed.

    Things were all set ready for the assembly. I had the cases and the crank measured and the bearings and shims on the NEW 80mm crank. All parts available.
    Bill Arrived 4pm on Friday afternoon, wife had the kids at the inlaws for the night so we had a clean slate.
    First was a check fit with the crank installed in the cases . . . Unbolt the cases after the measuring.
    [​IMG]

    When we bolted the cases together and tried to turn the crank it was locked tight :eek1.

    I must say I was a little disappointed. We disassembled and decided to heat the cases gave the bearings a little TAP to see if we could steal a few thou, we reassembled and now the crank would turn but the tension on the bearings was way too much and stil no clearance.

    When the crank was measured it worked out that I needed 24 thou, 12 each side. I had 2 x .006" shims and 3 x .004" shims.

    I now had to remove the crank bearings and take out some shims. We calculated that removing 8 thou would be the best option. So I looked at the crank and decided to remove the bearing with the 3 shims. Tried gentle heat . . nope. More heat . . . . nope. The whole crank was getting hot now and we had no chance of getting the bearing off. Time for a beer and a break.

    I now had to grind the bearing off. Carefully covering the NEW crank I got on the angle grinder and started to grind away. Taking many light cuts. when I got to about 1.5 mm I was going to use a rotary tool but didnt have any suitable bits. As I didnt want to damage the crank we decided to leave it until Saturday Morning and contact the KTM shop to see if they had a bearing removal tool to finish the job.

    So we decided to get he gearbox back in . . . OldDogs healing hands and recent experience was invaluabe :clap
    [​IMG]

    [​IMG]

    The box all in and back together.
    [​IMG]

    We called it a night at about 2am after a few beers :freaky

    Next morning we called the KTM shop who were booked up, but asked me to call back and 11am. They would try to fit me in. I really appreciate the help offered by Prorider as I didnt expect them to drop everything. :clap

    A visit to the fellow who measured the crank and a look at his recently completed restoration of his BSA 350 Gold Star. He had a rotary tool and finished the grinding. 1 hit with the cold chisel and the bearing cracked with not a mark on the crank . . . .phew.

    I called Prorider and thanked them for the offer but we had it sorted.

    Wouldnt you know it . . . the side removed was the one with the 2 x 6's. A quick call around the Sydney KTM dealers for a 4 thou shim and no-one had any in stock. We were stumped. I ordered another on and had it on Wednesday for $1.60.


    I have fitted the new bearing race and I am about to bolt it up and check in about an hour. I will be back to you shortly.

    NOTE:
    OldDog, apart from being a great fella and co founder of the Australian 660 Owners Club - Cobar Branch, is typical of the guys I have met on Advrider. Always up for a chat, offer a hand, and the occasional sledge :lol3

    Bill, you are a Legend and thanks mate for the 18 hours driving to come to the city to see if we could get the 660 running. :clap:clap:clap:clap
    #48
  9. OldDog

    OldDog non impediti ratione cogitationis

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    Not a problem mate, it was a good laugh and i had a great time! I see you didn't mention the "easy listening" 70's disco radio station:rofl .
    So does the crank fit? It will i'm sure, then you can just button that puppy up. :thumb
    #49
  10. Pezz_gs

    Pezz_gs Cant ride for crap

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    Just slipped the crank in!

    Between 7 & 8 thou axial play. 8 thou is recommemded :clap:clap:clap
    #50
  11. OldDog

    OldDog non impediti ratione cogitationis

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    YES! That's great news mate! Now go and bolt that beastie together:D
    #51
  12. rjf

    rjf SBS's #1 fan in January

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    :clap
    #52
  13. Pezz_gs

    Pezz_gs Cant ride for crap

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    With life business this is taking quite a while
    I now have the bottom end in the frame.
    Should be finished by Christmas . . . . dunno which year :evil
    View attachment 131726
    #53
  14. BobCWNC

    BobCWNC Orange lithotripter

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    Nice Rally!! I hope it's this christmas:lol3 .

    Is the frame on your friends bears racer handmade? That thing is sweet.
    #54
  15. atgreg

    atgreg Africatwinarama

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    Hurry up Pezz, Im hanging out for a ride :whip :ddog
    #55
  16. Pezz_gs

    Pezz_gs Cant ride for crap

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    Yep Hand made. A replica of Max Biaggi's 250 GP Yamaha

    Ian, the owner, has carried out many modifications to it to strengthen it.

    Basically he has rebuilt it over again.

    I am sure you could imagine the vibration in a LC4 running no counter balancer in an alloy frame.

    I am hoping its this christmas too :wink:
    #56
  17. BobCWNC

    BobCWNC Orange lithotripter

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    You Aussies are a crazy bunch when it comes to modding bikes:clap . You should ask him to do a write up and post some more pics. I've always liked road racing singles- I can imagine a well set up LC4 with aerodynamics would be a ripper on a tight track, vibes be damned.

    Maybe I missed it, but how did you acquire your rally? Was it an ex racer or is it another example of the things we here in the states can't get?
    #57
  18. JAFO

    JAFO displaced Jeep guy.....

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    #58
  19. Loadedagain

    Loadedagain making chips

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    better getting it right than getting it done quickly. nice work so far mate.
    #59
  20. mars

    mars Starbucks anyone?

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    I loved the pictures, never having seen the inside of one. I rode one of the 620 rally bikes last year and it just kept pulling like crazy. It ran like it was a shorter stroke engine than my 640 and was much smoother. It ran more like my 400 lc4 but pulled much stronger.
    #60