OzVMX Forum
Marque Remarks => KTM => Topic started by: Chuckie25 on September 17, 2012, 01:50:24 pm
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im working on restoring a 76 250 that i traded a 5 horse power briggs and stratton for but right now its prolly worth about a 3 horse lol. the previous previous owner left the jug off of it for some time and the bottom end filled with water and needless to say but my cases are completely ruined. what years will interchange on the KTM motors? and ill have plenty of other questions through out my resto/rebuild haha
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Not really sure but at least till 79 will fit , post some pictures will help
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I'll post pictures up as soon a I get home
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Have you done many bike restro's before?
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Have you done many bike restro's before?
So far just my 87 LT250R. but we have a whole host of bikes that need some love
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(http://i1122.photobucket.com/albums/l536/Cj15941/photo-182.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-181.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-180.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-179.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-178.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-177.jpg)
(you can see the ate up crank case in this picture)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-176.jpg)
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i need to know what other cases wil interchange with the 76 year model cases. i had heard that all the 73-78 250 cases will interchange but im not too sure on this. id like to just replace/repair mine so its the original engine but im open to swapping cases
it has the Motoplat ignition, Marzoochi shocks, and i was told a 38mm flat slide mikuni but the way it was described it sounds like it was a Lectron.
heres a couple other machines we own:
1971 Yamaha DT175 and a 1979 TT500 (over size valves, high comp piston. never finished because of head stud problems)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-175.jpg)
and heres before and after of my suzuki:
(http://i1122.photobucket.com/albums/l536/Cj15941/photo.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-9.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-10.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/cf9f377a.jpg)
(http://i1122.photobucket.com/albums/l536/Cj15941/photo-131.jpg)
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By the forks and swing arm looks to be 77 IMO
And yes it is not an easy restro and not for your average restorer/The cases can be repaired if you can find the right person. Good luck with it.
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Theoretically any case from 73 to 79 will do but try and get ones from say 76 to 79. Those cases look very ugly but as a last resort JB weld or Devcon may help with the repair .
Cheers Bill
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That Poor old KTM Look like it has not see any Love for a long long Time ...
And It may Need a Lot of Loving to get her going .
If I can Held Just call out Eg Engine work shop book ECT..
But But On the Off Chance You dont feel you want to Give it the Love
and want to Move it to a Good Home I would Happy to Buy it off you ...
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By the forks and swing arm looks to be 77 IMO
And yes it is not an easy restro and not for your average restorer/The cases can be repaired if you can find the right person. Good luck with it.
Oh really? What should I look at to find out what year it is? Like I said I traded my uncle in law a 5hp Briggs for it and he told me that its a 76. He said he didn't have the money to buy the engine and work off me but he said 'I got this Penton sitting over here I'll trade you' my eyes got about as big as a dinner plate lol I like challenges
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Theoretically any case from 73 to 79 will do but try and get ones from say 76 to 79. Those cases look very ugly but as a last resort JB weld or Devcon may help with the repair .
Cheers Bill
Ok thank you that's what I needed to know! I'll more than likely replace them and then have a friend of mine weld and remachine the old cases so I have a spare set to hang on my wall or something haha.
Where would I find the engine bearings for this machine? Or would it be easier to find cases with good bearings in them already?
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That Poor old KTM Look like it has not see any Love for a long long Time ...
And It may Need a Lot of Loving to get her going .
If I can Held Just call out Eg Engine work shop book ECT..
But But On the Off Chance You dont feel you want to Give it the Love
and want to Move it to a Good Home I would Happy to Buy it off you ...
I'm sorry but I'm a bike hoarder lol this machine will never leave my possession haha! Yes, she hasn't seen any kind of tlc in about 15-18 years (probably longer then that!!) but I'm gunna do my very best to bring it back to life! It's my first KTM, hopefully won't be my last haha
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Than Wecome to the KTM Family ....Ozktm Family
My offer still stands I can send you the Engine rebuild Book to get the motor back to a goer ...
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Than Wecome to the KTM Family ....Ozktm Family
My offer still stands I can send you the Engine rebuild Book to get the motor back to a goer ...
Thank you :]
I may take you up on the rebuild book offer once I get a set of cases cause I gotta put the trans back together and I'm no trans guy haha
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The rear frame loop were the shocks mount are the smaller tubing / not the GP frame that came out late 74 till late 76
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I made a little video showing the chassis
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Read below about differences. Note Cross Country model used the 74-76 GP frame that slakewell refers too.
1976
* Model line diverged into two distinctly different models - the MC5 and the Cross Country
* 125cc engine has black cylinder and head fins with "125 KTM" cast in side of cylinder with silver gear box - all other
engine sizes are totally finished in silver
1976 MC5
* Starting serial number is 55000000 (MC5's only)
* First year for MC5 (MC means motocross and 5 means 5 speed through many are found as 6 speed)
* MC5 model came in 125cc, 175cc, 250cc and 400cc sizes
* New non-breather frame and swing arm with magnesium air box
* Marzocchi shocks mounted at 45 degree position with no other adjustment postions
* Motocross seat with integrated rear fender
* Leading axle Marzocchi or Ceriani forks
* Sun rims
* New 2.1 gallon gas tank
* Finish is orange with yellow number plates
* MC5 gas tank decal was a long wide black and white stripe with the word "Penton" in white
* West Coast KTM bikes were mostly red and a few of the very first MC5 400's were white; European models were blue
1977
* First year for GS6 model (GS means Gelande Sport and Gelande means terrains ) and 6 means 6 speed)
1977 MC5
* MC5 same as 1976 except new black with white trimmed C-shaped decal around the word "Penton" which was in black
* Frames had a slight but noticable modification on some brackets as compared to the 1976 where the rear of the seat
bolts on
* Some frames had the option to mount the foot pegs in two different height settings
* Exhaust pipe had an extra strengthening gusset on top where the silencer is welded on to the pipe
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The bike is 1976/7 250cc if its got only 3 bars under the tank is a 77 if its all coverd its the High breather 1976 ...
Need a Fram number and a engine Number and all the gesting is then over !!!!!!!!!!!!!!!!
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OOPS!! Forgot to post the link to the video :-X
This one shows the engine
http://www.youtube.com/watch?v=-e1du9OYI8E&feature=youtube_gdata_player
This one shows the frame
http://www.youtube.com/watch?v=y2vHQki8O64&feature=youtube_gdata_player
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The clock on the case shows it was manufactured December of '76
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so whats the frame number
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This sticker that is on the side covers throws a hint at 77
(http://i1089.photobucket.com/albums/i342/ozktm/77%20Penton/Penton77decal.jpg)
, plus the late 76 engine date, and the tank decal on the bike is the 77 version.
Makes no difference as the 76 and 77 mc5 as per my previous post are basically the same.
Looks like a major task to bring this one back from the dead, but i assure you it will be worth ir when you throw your leg over it.
Contact Al Beuhner (details on Penton site www.pentonusa.org ) he will assist in any parts you need to get it going.
Might be worth your while looking for another engine - a couple are on ebay. Any from 76 to 79 will do fit. This way you won't have to attempt to repair the magnesium cases.
Adrian
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This sticker that is on the side covers throws a hint at 77
(http://i1089.photobucket.com/albums/i342/ozktm/77%20Penton/Penton77decal.jpg)
, plus the late 76 engine date, and the tank decal on the bike is the 77 version.
Makes no difference as the 76 and 77 mc5 as per my previous post are basically the same.
Looks like a major task to bring this one back from the dead, but i assure you it will be worth ir when you throw your leg over it.
Contact Al Beuhner (details on Penton site www.pentonusa.org ) he will assist in any parts you need to get it going.
Might be worth your while looking for another engine - a couple are on ebay. Any from 76 to 79 will do fit. This way you won't have to attempt to repair the magnesium cases.
Adrian
Thank you! As soon as I get the bike in my possession I'll get the frame numbers. And I've found everything I need on Mr. Beuhner's website besides the engine bearings. It says sold out or out of stock nect to them. And I was planning on finding a set of cases and just replace mine. If I could afford to buy a complete engine I would but I want to put my jug and head on what ever engine I use (wether it be new cases for mine or find another engine and swap the top end) because mine is ported. It's etched M.L. 4 - '80 on the bottom of the cyl. So, just gotta find cases, bearings and buy a gasket kit. Oh, and I need a carb for it. From what I'be read they came with either a Mikuni, Bing or Lectron. Was thinking of finding a stock Quadzilla carb for my LT250R and putting the stock TM38 off the LT on the KTM.
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36 Bing works best on them IMO but you have to how to file the file the slide to get them right.
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few questions:
what are the color codes for the cases? both the blue and white/silver
ppusa is sold out of the engine bearings, soooo what are the bearing numbers? my mom can get me bearings really cheap from her job so ill just get them that way.
how easily repaired are the fuel tanks? or can they be repaired?
seat foam is EXPENSIVE, could i just get some foam and cut my own (id need measurements if someone would be so kind as to take them for me :D )
and what is the brake rod length? mine is rusted in half and the onl ones on the pentonpartsusa website are for 175cc bikes :-\
lastly,
i need a manual. wheres the easiest/cheapest place to find one? (oz555, idk what it would be to send the rebuild book to the other side of the world and it wouldnt do to tie your book up over seas ya know?)
thanks kilos yall im slowly but surely getting stuff ready to start on this thing lol. so far got my stator and clutch cover sanded down and ready for paint and decided that im going to repace the rod and big end pin/rebuild the crank
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Color codes can be found on the Penton Site. Do a search on their forum, i found them on there, from spray pack to car codes that suit.
Bearings, i am sure Al Beuhner can help you over there, but we are running the flat roller versions over here. Which are available and cheaper.
I the tank is fibreglass then yes you can repair, or pass onto a boat repairer or similar to fix for you if you unable to complete it satisfactorily, otherwise there are a couple of Brand new plastic ones available on Ebay for about US$140.
Brake rod's - maybe ebay - or place a post on the Penton forum for some help.
Seat foam - the 74 long seat foam's on ebay will fit. About US$64, which i consider a good price.
Manuals - Al Beuhner has these available over your way, only other way is if we scan in a set. I do have the engine rebuild scanned in, but would have to scan in the Chassis and Engine Parts books.
The Penton Forum is probably your best chance for some help being that you are over that way. There may be some penton gurus nearby that would no doubt come and help you out if you needed it.
Regards,