OzVMX Forum
Marque Remarks => KTM => Topic started by: brebel on March 11, 2010, 06:58:41 pm
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My KTM has been sitting in my shed for about 15 years with a broken crank case, I finally decided to do get it going again I had the engine done by Dean at track & trail ,
](http://i210.photobucket.com/albums/bb259/brebel327/ktm511.jpg)
](http://i210.photobucket.com/albums/bb259/brebel327/ktm522.jpg)
there was a small piece broken off the air box so I glued it back on and fibreglassed over it, after sanding and painting it looked a treat
(http://i210.photobucket.com/albums/bb259/brebel327/brownlowhill007.jpg)(http://i210.photobucket.com/albums/bb259/brebel327/brownlowhill008.jpg)
today I fabricated the front and top engine mounts because I couldnt find the originals
](http://i210.photobucket.com/albums/bb259/brebel327/brownlowhill017.jpg)(http://i210.photobucket.com/albums/bb259/brebel327/brownlowhill018.jpg)
heres the spring stripped and ready for paint while the shock body is at Shock Treatment being re-chromed and rebuilt
](http://i210.photobucket.com/albums/bb259/brebel327/brownlowhill019.jpg)
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Very nice, classic moto worthy of a good resto.
Andrew
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I have also started my resto here in Newcastle and keen to hear from any one who has any spares for these gems.
I'm chasing a rear brake lever, an air box, all the engine mounting bolts and the 2 rocker covers off the Rotax engine.
PM me if you have any ideas on where I should try for these and other bits.
I have tried Bolton's in Vic but they came up short
brebel your bike looks great, I'm looking forward to seeing your progress
Tim
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try this guy he might be able to point you in the right direction, tell him barry sent you. Steve Ling ([email protected]). he's been very helpful to me.
Barry
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Tossa - is it really wise to tell him Barry sent you????? ;D
luv ya bud!
Rossco
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Ha this from a man running back home on saturday night , using his wife as an excuse, so he doesn't get photographed being roosted by team Tossa!!lol
Think next time I'll see you it'll either be manjimup or August
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I have also started my resto here in Newcastle and keen to hear from any one who has any spares for these gems.
I'm chasing a rear brake lever, an air box, all the engine mounting bolts and the 2 rocker covers off the Rotax engine.
PM me if you have any ideas on where I should try for these and other bits.
I have tried Bolton's in Vic but they came up short
brebel your bike looks great, I'm looking forward to seeing your progress
Tim
They might not have all the bits you need but you're going to need them :
http://www.enduroklassiker.at/
I'm waiting for a heap of bits to arrive any day now
it felt like I won the lottery when I stumbled across that site, thank god for the internet ay!
got any pics of you're 83 GS?
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Are you sure this is an 84? I have the 560 drum brake upsidedown forks model.
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I upgraded it to a complete 83 model disc brake, forks and triple clamps, but still have the complete front end with drum brake in the shed, I'm not a fan of front drums :)
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Is the front wheel in good shape? Mine is a mess. Would you sell it?
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sorry I have forks/triple clamps and inner drum assembly except the wheel and hub, I have lost a few parts over the years and have no idea where they could be as I have moved house a few times since :-[
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Today I fixed the choke cable, the problem with it was the 'knob' at the end of the cable come off that attaches the cable to the lever, the simple fix was to 'weld' a blob of silver solder to the end. I dont know if anyone has thought of this before but it works a treat.
I also cut up a piece of perspex to fill in the KTM badge recesses on the tank and will put the big KTM stickers on them as the last task.
(http://i210.photobucket.com/albums/bb259/brebel327/ktmtank.jpg)(http://i210.photobucket.com/albums/bb259/brebel327/ktmtank001.jpg)
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The bits arrived from enduroklassiker the parts are generally good although the side panels are not nearly as good as the originals;
(http://i210.photobucket.com/albums/bb259/brebel327/ktmpanel001.jpg)
its a bugger that they dont come with the molded in lugs that holds them in place
(http://i210.photobucket.com/albums/bb259/brebel327/ktmpanel003.jpg)
and the right side panel is different but still can be made to fit, the detail in the moulding is poor.
I think I'll have a go at restoring the originals.
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Almost done :) took it for its first test ride it was awsome to start it and take it for a few laps around the block for the first time after 15 odd years, although it wasn't without some challenges, mainly discovering the cam timing was out by about 90 degrees!, once I got that sorted it fired up on the first kick, here's a pic after the first ride(http://i210.photobucket.com/albums/bb259/brebel327/ktm529.jpg)still have to do the exhaust from header to muffler I might still have to have to shorten it a bit.
This is a trial fit for the muffler:(http://i210.photobucket.com/albums/bb259/brebel327/ktm531.jpg)
The header is from a CCM:(http://i210.photobucket.com/albums/bb259/brebel327/ktm536.jpg)
exhaust and wheels are next on the 'to do' list and am waiting for some bits to arrive from Germany.
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Thanks for the pics that will give me a few tips on how will look, getting the engine done this week I hope, I plan on taking it to CD7
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Great job can't wait for my 390 to be that close to riding
Wish I was that far along with my project, going to chase for one more week the 1981 clamps.
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Damn' Liverpool exhaust quoted me $300 to make up 2 foot of stainless exhaust!! It had better be an impressive piece of work is all I have to say. >:(
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http://www.youtube.com/watch?v=ZLdVxsfAhRc
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Sounds good -worth the $300 8)
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Hey guys,
thanks Tossa for the lead to Sunrise KTM and Flash, I ordered all of my 'must get bits' like the exhaust headers and 'y' piece, airbox, tappet covers and rear break lever from him, he managed to source them from Europe second hand but all in great nick. I would highly recommend him if you need anything tricky. (www.sunrisektm.com)
Brebel, I'm about to strip my frame and get it painted, wondering what the paint code is for the factory orange?
I've got lots of other questions for you too so may be intouch often.
Have a great one....Tim
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Hey guys,
thanks Tossa for the lead to Sunrise KTM and Flash, I ordered all of my 'must get bits' like the exhaust headers and 'y' piece, airbox, tappet covers and rear break lever from him, he managed to source them from Europe second hand but all in great nick. I would highly recommend him if you need anything tricky. (www.sunrisektm.com)
Brebel, I'm about to strip my frame and get it painted, wondering what the paint code is for the factory orange?
I've got lots of other questions for you too so may be intouch often.
Have a great one....Tim
Glad Steve was able to help pity he's a pom living with Yanks, makes it hard to understand he can actually be helpful without whinging about it!!lol
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Hey guys,
tBrebel, I'm about to strip my frame and get it painted, wondering what the paint code is for the factory orange?
How are you going to paint. I found Jotun Coates orange is very close in powder coating. Or if you are going to use a spray can cheve engine orange.
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Hey guys,
Brebel, I'm about to strip my frame and get it painted, wondering what the paint code is for the factory orange?
I've got lots of other questions for you too so may be intouch often.
Have a great one....Tim
I had a mate who's a spray painter do it for me and he looked up KTM orange (dont ask me how but spray painters seem to know where to look ::)), I'm not sure if its exact but I am happy with it I would rather use a colour that looks better than the original if given the choice.
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On another note it was interesting to see there was no bikes like mine at CD7 they must be a rare beast, where was your bike slakewell?
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I took a KTM 77 250 and 400. I havent finished my rotax bike the engine is still in too many pieces
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Thanks for the suggestions regarding the paint colours, I'll take that on board.
Not sure if I'm going to blast the frame or not, I'm a bit worried about getting grit in the frame mounted oil tank.
Does anyone know or have a shot of one of these set up as a motorcross mount. I'm building mine to be a Heaven racer.
Should be finished ready for next year...........not sure whether that is what I planned last year though.
T
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The grit in the frame oil reservoir is a valid point, mine was full of it! I flushed it about a thousand times..but so far so good, there's plenty of oil filters on it though. You just have to make sure they plug the holes so the grit doesn't get in, I didn't tell them that :-[ .
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Does anyone know or have a shot of one of these set up as a motorcross mount. I'm building mine to be a Heaven racer.
I have one that was the motocross model. I thought it was a GS but recently read an old test and saw that they had a GS enduro model and a MX model. Picked it by the different exhaust. The MX had a Supertrap muffler. Which mine has. That and the fact it has no electrics or compliance plate. Was thinking it might be a bit rare as all I've ever seen are the GS's. I don't feel too bad about paying to much for it now.
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I havent seen a real MX in Aus dont think many would have been imported
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i had a 504 mx disc brake front conventional fork type bought new from i think the shop was called top rider over carlingford way in sydney.it came with a gs muffler and head light and gs rear plastics with t/light and wiring in seperate boxes. years later i wanted to register it so i rang floods and told them the frame number and when and where the bike was bought from and they posted me up a compliance plate (blank mind you which i had to stamp myself) how times have changed.the mx muffler wasnt a super trap type one but.loud as hell though.
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Finally got the wheels back after nearly 4 months!
and $1,170 >:( looks alright though :)
(http://i210.photobucket.com/albums/bb259/brebel327/SANY0004.jpg)
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What happened to the original drum front wheel? Do you still have it?
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I only have the centre I lost the hub years ago :-[
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I took it out for the first real ride in 20 years last weekend, well it was quite enjoyable, nothing came loose or broke, the carb needs work but what a difference it is to my usual steeds :both CR500 powered, its a real torque machine and I love the big power pulses right from idle. The chassis and suspension are superb, real plush, perfect for long trail rides it steers faultlessly I am amazed at how it can be flicked around compared to my CR500AFX and CR500E,one thing that is out of wack is the ergonomics when standing, this bike was obviously not meant to be ridden while standing up on the pegs as the bike is rather wide at the panels along the bottom of the seat, combined with tiny pegs, you have to be bow legged to stand, so all I really have to do now is get the carby working right and make the pegs bigger and slightly stiffen the forks as they bottom out too soon then it will be ready for some VMX fun.
(http://i210.photobucket.com/albums/bb259/brebel327/ktm.jpg)
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Hope your having fun bike looks great , cant wait to get mine finished
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wow brebel what a fantastic looking bike thanks for posting
any tips on how you cleaned up that white tank?
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Thanks for those kind words Nick, I was fortunate enough to have purchased a new tank many years ago and never fitted it until now, the long range tank that was on it looks terrible :-[
I took the bike out for a decent run in the bush last weekend, after I discovered that the cam timing was still not correct :-[ and now with that finally sorted, yipee it goes great now, good bottom end grunt but if you keep it pinned it revs out to a strong top end as well...I love these Rotax four valvers. ;D
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Do you have a photo of it with the long range tank or just a photo of the tank?
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The big tank is on the first pic in this thread
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haha i scrubbed ,sanded,polished and used about 10 different cleaning solution thinking there has to be a way to whiten this tank like brebels.
how are you finding the suspension? any mods?
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I had the shock rebuilt, the forks haven't been touched in over 15 years, they don't even leak! (maybe there's no oil in them ;D) the suspension is plush, cant fault the rear,but the forks bottom out too easy so I have to service the forks next. The manual says the forks are set up for a 70 kg rider, I'm 100kg so gotta do them asap .