Project 99 KTM 380EXC..... crap why didn't i just buy a new bike

[RT]

well picked this up fairly cheap and thought it might make a good project, just didn't think it would need this much work.....oh well

plan is to get it licenced so i can hoon up the footpaths, but need to get it running.

Bought the bike knowing that it required a full rebuild.

anyway sent the cylinder off over east to get rebored and nikasil plated. had some cracks in the cylinder that needed repairing as well. anyway got the cylinder back





anyway that crap out of the way, gotta get started on the bottom end, fairly sure the crank seals are fucked, because was bogging down and blowing a shit load of white smoke. plus the bottom end needed a clean out from the looks of the old clyinder.



more parts everything has arrived!
ordered
new piston
crank bearings
gasket kit
kickstand
forkseals
rear wheel bearings
shit loads of nuts and bolts
new brake and clutch levers
rear brake sensor
speedo
front brake pads
front sprocket
mirrors
tyres
+ heaps of other crap.....should have just bought a new bike

anyway semi stripped and top end off


flywheel off


engine out


work space getting ready to start tearing it apart


who knows what that is oh well pull it off......


last bastard who rebuilt this used a rattle gun to tighten the nut fucker!
was a bitch and a half to get it off!


motha fuka primary gear nut was just as tight! and to make it a little more interesting reverse thread. had to heat it and use the breaker bar again



all the shit off


cases split, was easy, as they just fell apart (atleast something whent smoothly)




more crap, got no idea how to put it all back in, must remeber not drink while pulling apart engines



anyway tried to get left hand side crank bearing out last night, but couldn't get it to budge, so will have another crack tonight. hopefully i can get this thing working again

[foolishboy]

Ooh looking like going to be an awesome ride, going to be following this one with interest.

Good luck.

[out_in_front]

Haha I remember doing this to my old RMX...

I would consider getting a small bearing press if you care going to do this properly (or get a mate with one) I think they start around $200 -you will need it for all the bottom end and gearbox bearings, getting the crank out etc

Looks like a fun bike though! - 380cc two stroke, will not be short on power with a nice fresh engine!

[Brendonv]

i hardly ever no what im doin when rippin apart engines. I find out as i go haha. (this is on small engines not motorcycle ones, i get a manual for those )

[Rob]

All the engine bearings are available from local bearing suppliers - dont buy the KTM ones if you want to save a few bucks.

Good motors and with the power valve too, great open classer - I had a few rides on one of these back a few years. I thought about doing the Athena thing to a Cr250 to have the same kind of bike a few times for different reasons, but stuck with the 500 instead.

Once it is all back together you will be right Should be a good steed then.

[Rob]

[RT]

hahaha nice rob

well got the bottom end back together, the crank bearings were an absolute slut to get out actually had to weld a bead in the inner race, and wait till it cooled and contacted to get it out, then i heated the cases in the oven at 160C and froze the bearings and they slotted straight in. made a dumb ass mistakes like putting the bearing in the wrong way......fuck!

also put the power valves back in and sorted the timing i think......

should hopefully have it running again on tuesday. still praying it wont blow up on me!

[MattyA]

So hows it looking? Im going to do the crank bearings on my rmx next week, its got a slight rattle and i want to get it before it gets bad.

[RT]

F@#K!!!!!!!!!! i got to the point on trying to start it, and i think i may have stuffed up when i was installing the shift roller, as it wont change gears........

think i will have to pull it apart again

[out_in_front]

Haha I remember doing that to my RMX too...

I could just take of the side cover and fix it without removing the engine from the frame - hope it is similar for you.

[Nath]

You learnt a valuable lesson... always check shifting after re-assembly.

[RT]

Haha I remember doing that to my RMX too...

I could just take of the side cover and fix it without removing the engine from the frame - hope it is similar for you.

Nope

You learnt a valuable lesson... always check shifting after re-assembly.

i thought i had because i got it into nutral, well i thought i had.... crap

now i cant find any more information on how to install it correctly

[MattyA]

Haha I remember doing that to my RMX too...

I could just take of the side cover and fix it without removing the engine from the frame - hope it is similar for you.

I might have to contact you when i do my RMX. If you like beer and fixing stuff. I am a mechanic and have all the tools, It would be good to have someonewho has done it before.

[chee]

who did your nikasil replating?

great thread btw.

[RT]

who did your nikasil replating?

great thread btw.

electrolsil in melbourne, cost $20 each way to post, only took a week.


just did some more research and it turns out that the crank seals i used aren't the best (seals that came with the bearings), so while i'm stuffing around with the transmission i might as well swap them out with OEM seals as well.....

My plan is to get this thing running and if it turns out to be a good runner i might invest in its look department later on, but for now i just want the bike to be mechanically sound. also got some new road legal tyres fitted, unfortunately this was also the point where i realised i had installed the transmission wrong....

[RT]

whoo hoo engine is finished and ready to go back in!!! got the crank seals swapped to ktm seals and few minor mods. But is all ready to go back into the bike this sunday!!

I just hoping this time is starts. Now it has a completely fresh engine!

[RT]

sorry for the crap quality, but yeah its works!

need to run it in, and give it a bit of a tune!! whoo hoo!

[Cbr Junkie]

Link doesnt work

[RT]

sorry should work now