Olddogs 660 Rallye Rebuild

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

  1. OldDog

    OldDog non impediti ratione cogitationis

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    :rofl yeah mate....well at least this is helping someone! But hat one of yours is in much better condition too.
    One of the blokes at work has been giving me a hard time about it but sat down this morning when i was telling him about the rings and he told me that seriously i was being an idiot and that i should get rid of it.
    My reply to that is well, it's a bloody rare bit of kit with so much history that it's worth saving. Sure there'll probably be a few more issues but eventually i'll get every problem solved. The project only becomes a failure when my resolve fails and that ain't happened yet and theres been some shit to sort out!:lol3
  2. Gaup

    Gaup Adventurer

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    And i think this is a greate tread.. always wanted a Rallye 2000
    so i rebild a Adv 05 i no its not the same butt its close....
    and i can do pretty muths as i want to do...

    Keep front wheel spinning Kenneth

    Attached Files:

  3. Chadleys1

    Chadleys1 working on it

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    That is so bad ass.:eek1
  4. Gaup

    Gaup Adventurer

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    Bye the way... do some body have a rer shoch absorber to a 2000Rallye for sale? dont need to be new butt its nice if i dont have to rebild it..
  5. OldDog

    OldDog non impediti ratione cogitationis

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    Well now after much fartarsing about, the Rallye is back on the road!!! I got the heaad welded up, and the porting done, check out this bit of porn

    [​IMG]
    Opened up combustion chamber to increase flow around the valves

    [​IMG]
    raised floor on the intake port to increase flow

    [​IMG]
    welded head to decrease water getting into the f&*king oil:lol3

    I've put down about 500kms since the work with no signs of anything going wrong. It's a bit out of tune now due to the head work so i'll have to find someone who knows how to tune PHM dellorto's, but other than being a bitch to start, it's great! The powers now a bit smoother in the delivery, and it's maybe a bit faster. Okay, enough of this talking i'm off for a ride WOOOOOOOHOOOOOOO!

    [​IMG]
  6. Pezz_gs

    Pezz_gs Cant ride for crap

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  7. rjf

    rjf SBS's #1 fan in January

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    :clap :clap :clap

    Shit, I even feel motivated to put the adv back together tomorrow. It also has a slightly weeping base gasket. IIRC KTM went from a fibre one to a metal one. I might order in a gasket set and replace it soon.
  8. NordieBoy

    NordieBoy Armature speller

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    I want to do that to my XR250 but its intake ports are not roomy enough to get the damn stuff in there.
  9. davorallyfan

    davorallyfan Commonist

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    Dogs Rallye at the TTT Rally
    [​IMG]
    I heard it running... it horn. :thumbup
  10. nfranco

    nfranco over macho grande?

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    MMMMMM, Purty!
  11. Pezz_gs

    Pezz_gs Cant ride for crap

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    No the base gasket is still paper.

    The crankcase gasket (Between the Crankcase Halves) is available in Metal

    Come on RJF get the sliver thing going . . . .

    It should be in WA at the Safari . . . . . :evil
  12. JAFO

    JAFO displaced Jeep guy.....

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    let me know how this works ou for you. I am considering doing something much the same for my KLR.
  13. atgreg

    atgreg Africatwinarama

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    Great to see the rallye out on the road again !!!:clap
  14. OldDog

    OldDog non impediti ratione cogitationis

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    Thanks Greg, alli gotta do now is find someone who knows how to tune the bloody thing! I want to keep the Dellorto carb, and i think i need a "specialist" to get the best out of it.
  15. OldDog

    OldDog non impediti ratione cogitationis

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    Evenin all, Bit of an update. Following the repairs to the head i've been doing a fair bit of riding. I think the Rallye is probably a bit too "advanced" for a dirt noob like me, and i have the bruises to prove it :rofl . That doesn't mean i'll sell so get back you philistines!
    In late January i headed off to the Limeburners rally, about 800 kms of mostly dirt, but at Taralga the next morning doing my morning check....i found bloody water in the oil again! I limped the bike about 150 kms to Bathurst where a mates wife gave me and the "Tupperware Timebomb" a lift home
    [​IMG]

    I've stripped the engine down completely and found that the bloody water pump seal had blown again, thats twice now! I'm not sure whether it was a faulty seal, or me stuffing up when i rebuilt it last time. Either way, i'm a firm believer that coolant leaking past the seal should not end up in the engine oil! Bloody archaic design if you ask me, so i've done a little something about it, I've drilled a small 1/8 weep hole through the housing like so

    [​IMG]

    [​IMG]

    The opening inside sits between the sel and the face of the bearing. Under pressure coolant will come out here rather than get forced through the seal on the bearing. I'll plug the hole with a dab of grease to keep the dust out, This is purely experimental, i've tried it with the blown seal in and the cooling system pressurised. It worked ok, not as well as i expected but when hot maybe it'll work better. Anythings better than the other dumbass idea.:rofl
  16. bend27

    bend27 by hook or by crook

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  17. tHEtREV

    tHEtREV Encouragement award recipient. tEAM iDIOT.

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    I can't beleave he didn't finish this thread...

    All I will say is that he discovered why the water pump seal was failing, and it was aparenty running great when it was sold.
  18. OldDog

    OldDog non impediti ratione cogitationis

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    My goodness, I happened to wander past this thread to collect some info as I'm thinking about buying another Rallye and i see that theres been some activity on here!

    And yes to finish the tale off I found the problem (s), and its something other Rallye owners should take note of if they start having the same issues -

    1. The original water pump drive (which is the camshaft drive sprocket retaining bolt with a slot in it to drive the water pump tang) had been replaced with a normal bolt that had a slot hacksawed into it, looked like a makeshift "get it back in the race" repair. Anyway the slot was very slightly off centre so the pump shaft wouldn't run true and eventually wreck the bearings. and

    2. The repair manual has the water pump seal lips both facing the direction of the engine.....when one seal should face the water pump and the other face the engine.

    Lessons learned, and I'm happy to report that the bike is still racing. Shoulda kept that bike...
  19. rustaboy

    rustaboy n00b

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    G'day Bill Tobes here mate the big fella who bought the Rallye from you jeez was that in 2008? Well I think I spoke to you a few years ago when I killed the motor again at a Blinman. Well shame on me but I only just got her going again. Was a ceased main bearing God knows what went wrong but having replaced main bearing and oil pumps the beast Snorts again. In fact is going like a train. Hope your all good I recall you where going to build some crazy off-road Ducati. Would be good to catch up for bullshit session. Also put the other cam you gave me in and seems to have increased power nicely was wondering what the story was with the cams.
  20. OldDog

    OldDog non impediti ratione cogitationis

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    Well well, looky here! I've been lookin for you for ages...but did I think to come back to this thread and see if you'd posted? Nah.
    Just saw a pic of you and the bike of the Dakar thread in the Aussie forum. Will send you a PM.

    Cheers

    Bill