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Olddogs 660 Rallye Rebuild

Discussion in 'Thumpers' started by OldDog, Nov 10, 2006.

  1. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    Whats GS 'Ewan' Silver look like ?








    Is that the colour of the bike used in "The wrong way Down".:evil


















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    Hi Bill:wave























    :hide
    #21
  2. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    *sigh* I guess it was only a matter of time wasn't it? You going to THE BEER NIGHT?
    #22
  3. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    G'day Hoder, no i didn't actually, i'm assuming you mean the whole cockpit includeing the ICO's and road book? I'll get a few pics when i get back and post 'em up for you. I'm heading off to get my GS which has just been repaired and it'll a long, slow ride home, should be back next Monday.:clap
    #23
  4. HighwayChile

    HighwayChile greetings from Wa state

    Joined:
    Aug 19, 2003
    Oddometer:
    5,004
    Location:
    Bow, WA USA
    good on ya for keeping a chunk of history on the road:1drink
    if you get stuck on parts post on ktmtalk.com:1drink
    thanks for keeping this out of the graveyard:1drink
    #24
  5. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    yep.:clap
    #25
  6. jfn68

    jfn68 Banned

    Joined:
    Aug 27, 2004
    Oddometer:
    620
    Make sure you flush out all the external oil lines and the frame,my bike had debri in both after its failure,just that nice frosty lapping paste stuff that would of taken many hours of engine life away if these were not flushed,also check the oil pumps,the pair of mine were no good,and also the most important thing is to make sure you set up the crankshaft end float to spec,get all your measurements correct!!!!!!,before installing the bearing inner race on the crank,check you got the shims in the parts you ordered,you will need them.
    #26
  7. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Thanks for the tip off's about the frame, it's probably full of junk too, and the crank float, just had a quick look at the crank and it's still got the old bearing inner races on there, i'll never get 'em off myself so it's going to the shop.
    #27
  8. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Okay folks, now it's time for the engine damage pics, get your tissues ready this is nasty stuff. I'm impressed with it though, this engine ran another 50 km's after the rider suspected a problem, and it started straight up the next day!

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    Hmmmm where did all this shrapnel come from?

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    Horrifying isn't it:eek1

    Once the rest of the "cosmetic" work is done i'll start putting it back together. Heres a few pics of the bike mocked up

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    [​IMG]
    #28
  9. The Misinformant

    The Misinformant What road?

    Joined:
    Jun 22, 2004
    Oddometer:
    350
    Location:
    Adelaide, Australia
    OldDog,

    The thing that looks like a needle roller bearing race without any needles?

    Is that the stuffed big end that caused the failure?

    If it is and it still ran that is absolutely bloody amazing!
    #29
  10. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Yeah it was the big end that caused all the trouble all right, i've got most of the needle rollers, looks like three were ground up:eek1 . I thought it may have damaged the head as well, but it appears fine, looks like all the damage as done on the power stroke which makes sense.
    #30
  11. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Well, heres the next instalment, the wiring. It was a bit dodgey (sorry Legless) and sported a fair few of those crappy crimp connectors which i figure will eventually loosen up and cause faults, so i went through and removed 'em all and soldered up the connections. This will do the job for the moment, i'll replace the harness at a later date as it's pretty easy to do but prefer to spend my $$ on engine bits for now.
    Anyway, hooked it all up last night, crossed my fingers and connected the battery, for a wonder, no smoke, no fire!! The second surprise, most of it worked!:rofl


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    #31
  12. Racketeer

    Racketeer Must escape......

    Joined:
    Sep 2, 2006
    Oddometer:
    898
    Location:
    Melbourne near the sshitty...I mean the City!!
    Well done Olddog...

    Lookin great.:clap
    #32
  13. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    Don't appologize to him, he's the heathen bastige :D that destroyed this example of KTM's finest. And rode it an extra 50 km to make sure it was stuffed good and proper.:deal

    And he stole your 200 MPH club ZX12R and dumped this box of stuff on ya to take its place:huh .

    no wonder he left town so fast. :rofl





    (admitedly, it would be hard to leave town slowly on a big blocked, nitrous fed zx12 :lol3 )
    #33
  14. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Heh i still got the Nitrous kit...............
    #34
  15. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
    Oddometer:
    4,378
    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    Look out Finke desert racer's, here comes old dog:freaky
    #35
  16. Chadleys1

    Chadleys1 working on it

    Joined:
    Sep 26, 2005
    Oddometer:
    565
    Location:
    Toledo Bend Country Louisiana
    I love this thread.
    Keep it up.!!!!!!!!!!
    #36
  17. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
    Gunnedah, New South Wales
    Evenin All,
    Time to clear up a few mistakes i've made regards the bikes history.
    I initially thought the thing had done 2 dakars and some Aus Safari's, well thanks to Craig Hartley of Dalby Moto and Woody at Race Motorcycles in Alice Springs i now have a better picture.
    The bike's complianced as a '99 but was more than likely built in '98 and was raced in the '99 Granada - Dakar by an un-named German. Didn't get a place as it didn't finish due to ummmm "operator error". The bike was imported into Australia with 2 others and used in the '99 Australian Safari, i was correct about the rider being Tim Fitzhardinge, he also rode this bike again in the 2000 Australian Safari. Dunno how he went. Anyway, Craig then bought it off Woody in '01 and used it for his adventure bike and was retired at the end of '03 when the new 950's came out. It was dragged out of mothballs for the '04 Australian Safari and it was still competitive even though it was suffering fuel pump isssues, Craig mentioned he got a 4th place in one 195km stage that was bloody rough. Anyway it ended up busting a crankcase so was retired from the race, rebuilt and put on display at Dalby Moto when Shane (Leglessone) bought it......and now it's mine, aaaaaallllll miiiiiiine !!!!:clap
    I don't have any plans to race it, i just don't have the skills.
    #37
  18. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    5,347
    Location:
    Sydney Skunkworks
    Hey I got one Just like it . . . . no Engine :lol3
    View attachment 93212
    :wink:
    #38
  19. OldDog

    OldDog non impediti ratione cogitationis

    Joined:
    Feb 20, 2005
    Oddometer:
    7,155
    Location:
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    I hope we ain't starting a trend here:rofl
    #39
  20. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    768
    Location:
    Hell-sing-land, Sweden
    Is that a common thing on that model?








    :hide Sorry,could not resist...:D
    #40