OzVMX Forum
Marque Remarks => KTM => Topic started by: ozktm on August 09, 2011, 09:50:12 pm
-
Well, it's been nearly 10 years in pieces in the shed, but now i have finally started it!
Wifes out - quick crank the oven up and get them bearings out!
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7468.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7470.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7500.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7468.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7502.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7504.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7505.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7507.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7509.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7510.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7514.jpg)
-
great stuff Adrian, i look forward to watch this progress. i love the great whites.
-
You didn't think of filling the crank holes with lead?
Be good to see another beasty on the track
-
Looks great - how did you clean up the crank ? I've got one that needs a clean up before I install it.
Cheers
-
Will follow with interest. What year is yours? I was considering buying a 495 just for something differerent, what are they like to live with on a daily basis, parts, riding etc?
-
More please…
What model/year 495 is it?
-
1981 495,
Crank did not need cleaning, i have had the parts for nearly 10years now and always kept the bottom end in oil.
Swingarm is away for repair (thanks Ringo)
Thanks to Bill & Billy C (Canberra) for powder coating and dropping the frames off (250 and 495)
Just waiting on some parts to complete top end.
In the mean time i am putting my 81 250 back together after the chassis has been powder coated for a freshen up.
Andre' Horvaths here :http://www.enduroklassiker.at/ (http://www.enduroklassiker.at/) for parts.
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7523.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMGP7524.jpg)
-
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0615.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0618.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0620.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0683.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0619-1.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0609.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0536.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0904.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_0905.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1103.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1102.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1103-1.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1104.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1105.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1106.jpg)
-
Looks excellent Adrian, has it had it's maiden voyage yet ?
-
Looks great hold on and have fun.
I have just added a 84 495 to the next projects list so if you have any left overs ;D
-
Realy nice. Congratullations.
I am also in a similar project for a 83´s 495. Hopefully will be soon finalissed.
Did you do any changes / upgrade on the clutch over the original one (i.e. steels, fibres, etc) ?
-
Actually had issues with the clutch slipping while tuning the bike last weekend.
Luckily Victor Drew had some YZ250H clutch fibre plates with him, they are nearly a fit, just had to take about 1 mm off each finger edge to make it fit.
The plate is thicker by about 1mm and has more contact area. Threw it in the middle of the pack, and no more slipping clutch. Will look at upgrading the whole pack to these fibers.
Bike was run with TM38 flat slide with powerjet and ran great once the jetting was sorted out.
-
POWERJET ;D How much time at WOT(I knew you were pretty crazy but not that crazy)? If the clutch started to slip it must be making more HP. Nice job Adrian.
-
As per 495 engine manual, 495 standard clutch has 8 x 2.0 mm sinter disks plus one additional 2.5 mm sinter disk in the inner part of the hub. Then, there are 9 x 1.5 mm steel disks. Thus, total clutch pack is:
- Sinters: 8 x 2.0 + 2.5 = 18.5 mm
- Steels: 9 x 1.5 = 13.5 mm
Total: 32.0 mm
I have also been told that clutch disks for KTM's 420/495 79-84 and 350/500/550 85-87 are the same.
It seems easy and cheap to find Yamaha YZ 250 H fibres, so it could be a good alternative to the very expensive sinter plates if work properly.
If the YZ fibres are 3.5 mm, I would expect your setting is as follows:
- Fibres: 6 x 3.5 = 21.0 mm
- Steels: 6 x 1.5 = 9.0 mm
Total: 30.0 mm
This is 2.0 mm short when compared with standard clutch setting, resulting in lower spring pressure on this disk, which might get slipping.
Am I wrong?.
-
How many clutch plates did i put in? ;D Open heart surgery at Rockley. ;D
(http://i781.photobucket.com/albums/yy94/HuskyRacer/IMG_1377.jpg)
-
If the YZ 250 H fibres are 3.0 mm, the clutch set up should be:
- Fibres: 7 x 3.0 = 21.0 mm
- Steels: 7 x 1.5 = 10.5 mm
Total: 31.5 mm
-
Does anyone have the Yamaha YZ 250H Pt No for the fibres?
-
Being that the clutch push rod slack is adjusted by a screw in the actuating housing, the 1mm extra for the one plate did not make any difference.
Will look into changing to a full set later, Note that there is a shit load more contact area on the fibre plates that the sintered ones.
The clutch is nice and light too using a new cable and magura controls.
Adrian
hhhhhhmmmmmmm the little husky infiltrator........seems he had issues involving open heart surgery as well.......
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1132.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1134.jpg)
(http://i1089.photobucket.com/albums/i342/ozktm/495%20Rebuild/IMG_1133.jpg)
-
Adrian,
Memories of teething problems will give way to the terror of hanging onto that beast. Great work on bringing it back to life and can's wait to see it on the race track.
Husky, KTM, Maiico, Suzuki Pete