Olddogs 660 Rallye Rebuild

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

  1. Chadleys1

    Chadleys1 working on it

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    Excellent work olddog,
    I thoroughly enjoyed following your thread.
    :clap
  2. SamH

    SamH 90S on the bench

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    A new 690 engine no less. You probably don't want the old one. 5k race km's and a buggered gear box :puke1.

    Anyway. Great thread! Get that left leg beefed up, kickin's a bitch.
  3. rjf

    rjf SBS's #1 fan in January

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    Eh, those BMW's are a peice of piss to pick up.:deal

    View attachment 99296
    Although I must admit I haven't tried lifting one up after cartwheeling it down the deck at warp 1.5:eek1 ....:cry
  4. Pezz_gs

    Pezz_gs Cant ride for crap

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    Bill, Just found this pic of my Rallye in the hands of Andy Hayden :huh

    View attachment 99298

    I hope Rhys doesnt pick up on this :wink:

    FYI. Andy Haydon (AUS) was a privateer that finished Dakar in 3rd place outright in 1998.
    [​IMG]
    Andy Haydon's own achievement in the 1998 Dakar rally, an astonishing 3rd place on his first attempt, is yet to be matched.
    Read Here http://www.abc.net.au/southeastsa/stories/s1021025.htm
  5. Pezz_gs

    Pezz_gs Cant ride for crap

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    Final result :
    1. St├ęphane Peterhansel - F (Yamaha 850XTZ, Team Yamaha Motor France) 62h39'37''
    2. Fabrizio Meoni - I (KTM 660 LC4, Team KTM Austria) 63h10'06''
    3. Andy Haydon - A (KTM 640 LC4, Team Haydon) 63h59'19''</pre>
  6. OldDog

    OldDog non impediti ratione cogitationis

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    :rofl :rofl I ain't so sure about that Chris, i'm still riding like a Nana! I've already started praying though....please God don't let me do an Andy Hayden:lol3 From memory i think he rode through that endo didn't he Pezz? Bloody brilliant rider that fella. Oh, another lesson i've just learnt..........tyre pressure should be 20 psi.....not 30 psi :eek1 I'm such a noob :lol3
  7. v8turbo

    v8turbo When in Doubt.... Gas it.

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    sweet rebuild. now lets see some action shots.
  8. 9 Ribs

    9 Ribs Rocks?What Rocks?

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    Excellent rebuild Olddog. Fortunate to be busy on a 2000 Rally 660. your thread helped a stack. Thanks. Where did you get the Dakar Granada decal? Any help appreciated.
  9. Hambone950

    Hambone950 Mas Naranjas Por Favor!

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    A swift Google did not find much on Andy that is recent. What a story.
    Surely he is in the ADV Rider privateer Hall of Fame though along with Chris Blais of course. Is Haydon still racing? The Finke and other races seem every bit as tough and more than the US style BID including on the liver.
    A few write ups as these things come along would be great.
    Great photo btw.
  10. OldDog

    OldDog non impediti ratione cogitationis

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    Ribs, Glad it helped some :D i hope you got my PM reply ok?

    Hambone, I havn't heard of Andy racing for a bit now, the bloke is a dead set legend though, i've seen some spectacular shots of him in action. We have the Australian Safari back on again this year, maybe he'll be racing?
  11. OldDog

    OldDog non impediti ratione cogitationis

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    Evenin All, Just a bit of an update. Up until recently i've been having great time wandering about the bush on this thing, i think it's a bit too much bike for me but what the hell! Anyway, the other day the starter decided to seize on while i was riding:eek1 It'd been playing up on and off for a bit but this time it wouldn't free up. Once i got home and stripped it all down i found the starter was fried, it was old anyway so i'm not really surprised:pope , i ended up getting a new one from Chip at Munn racing for less than half i would've paid here,
    pic of nice new shiney starter motor
    [​IMG]
    while i was at it i bought a carb gasket kit and a fuel pump rebuild kit for the spare fuel pump. I suspected that the starter clutch bearing was a bit dodgey as well so i got a new one while i waited. Once i pulled the ignition off this is what i found..
    [​IMG]

    Turns out the circlip has come adrift from the bearing and slid down between the bearing and the starter wheel:eek1 . Originally i had pulled this bearing out to clean it, and i've stuffed up when putting the circlip back in, so with the help of KTMajor, this time i assembled it properly.
    At the first oil change at 50km's i noticed metal in the oil, at the time i was very worried that i'd somehow missed some from the original blow up, now i know better:lol3 While i was waiting for the starter i'd also popped the head off and checked the bore and big end, thankfully they are bedding in perfectly without a sign of abnormal wear.
    Another thing i did while waiting was to fit up a trailtech computer
    [​IMG]
    Crappy pic i know, but you get the idea, now i have a temp guage, tacho and odometer, which will make it easier to live with.
    The final thing i have to do to it is fashion up an oil pressure warning light......that works, the one in the pic is as supplied by KTM and is really just for show:huh . I'm going to fit up a double banjo bolt at the oil line coming into the crank, similar to the one at the oil filter cover, the extra banjo i'll modify to accept a small pressure switch and voila, low oil pressure warning system!
    And now i need a beer:1drink
    Later
    Bill
  12. OldDog

    OldDog non impediti ratione cogitationis

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    Howdy All,
    Just a quick update. I've had a few problems with water getting in the oil, which stoppedme from getting to the Condo as planned. I originally thought it was the water pump but after some testing, (thanks for the tips on that JFN68) it seems to be okay. It turned out to be a warped cylinder head. I originally straight edged it and it seemed okay, but on the mill we had to take off 8 thou:eek1 to get it straight. It all seems to be good now, i took it out for a spin in the mud on Sunday and it performed perfectly.
    [​IMG]

    Yeah yeah i know, thats not muddy by some peoples standards:rofl
  13. rjf

    rjf SBS's #1 fan in January

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    :thumb:clap :wings :rayof:rilla :drif :jive :super:strum :drums :kumbaya :marc:velvt:beer :slurp :dutch :loaded :webers :flug :kbasa :dg
  14. Pezz_gs

    Pezz_gs Cant ride for crap

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    What exactly are you saying RJF???
  15. OldDog

    OldDog non impediti ratione cogitationis

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    I think thats his way of saying....FINALLY!:lol3
  16. rjf

    rjf SBS's #1 fan in January

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    Yep, finally its party time for Bill and his Rallye:clap
  17. OldDog

    OldDog non impediti ratione cogitationis

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    Hmmmmm Nup, it's doing it again! What one earth could be the problem? I'll post up a seperate thread as i'm sure everyones tired of this one
  18. overlandr

    overlandr Dystopist

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    Errr no Bill you old dog you - we're certainly not fed up with this thread. We need to see the whole story warts 'n all!
  19. OldDog

    OldDog non impediti ratione cogitationis

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    Okay well it's time for an update on the Rallye saga:rofl . After much stuffing around i've discovered that the head has a serious crack in the top leading from the water jacket out into the rocker box under the cam:huh . It sounds a little odd until you dig a little deeper and find out that the 6D Rallye heads water jacket is cast deeper into the head to give extra coolant capacity, which leaves less meat in the head at the top. This head had about 8 thou of warp in it:eek1 and has suffered extreme heat damage. Remember how i kept discounting that the water pump could be causing the problem as it was brand new 600kms ago? well it leaks too and thats because the water pump seal is BAKED, parts of it had to be chipped out!
    So at present the hhead is up with a reputable head specialist and the crack has been repaired, he's talked me into getting the ports flowed while it's there.........for better fuel economy:lol3 . He's also putting in a set of new valves as the old ones were a bit hammered.

    I'm also sticking in a new set of rings as the original oil ring as supplied fitted to the new piston is way out of spec, the ring gap is huge! I think there may have been a manufacturing problem with this one as the bikes only done 1000 kms riding:eek1 and theres no way a normal ring would wear like that no matter how bad you stuffed up!

    Lesson learned? 1. These LC4 engines can take a licking and keep on ticking, but 2 when rebuilding a lunched engine, check everything no matter how good it looks.

    The devils in the details.
  20. Pezz_gs

    Pezz_gs Cant ride for crap

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    Its getting closer Grasshopper

    I know where there is another one being rebuilt too :evil

    Learning a lot from you :wink: