KTM restoration

DAMN maintenance and repair thread; including Farkle Fests! :boohoo:
User avatar
Bucho
DAMN Grand Poohba
Reactions:
Posts: 4112
Joined: Sat Mar 08, 2008 10:57 am

Re: KTM restoration

Post by Bucho » Sun Mar 12, 2017 6:41 pm

I hope they find your exhaust soon.

Gonna be real sweet when all back together!
Suzuki DR650
Beta Xtrainer

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Sat Mar 18, 2017 10:24 pm

The exhaust did show up, finally. So did a few big boxes of parts. The motor should arrive Monday.

I started reassembly. I got the shock serviced and back from Allen. I did a fork oil change today. New brake pads on the front along with a brake rotor guard. New lower fork plastic. New front fender. New rear fender. New side panels. New grips. New foot pegs. New air box mud flap. All bolts going on this bike are new. New upper shock bearing. New lower shock bearing on the 2005 swingarm. New swingarm bearings for the 2005 swingarm with a special bushing from a 90's CR125 so it fits the 2003 motor/frame. New chain slider on the swingarm. New chain guide on the swingarm.

There's a lot more parts sitting in the garage. More are coming. There isn't much left going on this bike that won't be new at this point.

This is just today's progress:
Image
Jed Gregory
KTM 450 EXC

User avatar
Wingfixer
aka FlatFixer
Reactions:
Posts: 2866
Joined: Tue Nov 18, 2008 4:20 pm

Re: KTM restoration

Post by Wingfixer » Sun Mar 19, 2017 8:07 am

Sweet!
F*** work.
Ride motorcycles.

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Thu Mar 23, 2017 8:15 am

I was off the past couple of days and I had an engine and a couple large boxes of parts waiting on me. beejaytee came over to have a piece of metal welded to his head tube for a rally fairing he's building. While he was here, I suckered him into installing my tubliss systems for me.

I'll probably forget something, but here's what I think I accomplished the past 2 days:
I put the motor in and bolted it down. I put the 2005 swingarm I got from Sam on using 2005 bearings and special bushings to make it fit. New chain adjuster blocks to fit that 2005 swingarm along with a new chain and sprockets. New front and rear brake pads along with a front rotor guard. New GT216AA fatty front tire and a one ride old GT on the rear that I can't remember the number of, both with Tubliss inside wrapped around brand new Tusk rims and spokes on the OEM hubs with new bearings/spacers. New grips (I suck at installing grips). I fixed some of the wiring I took off with some weather pack connectors and installed most of the wiring so far nice and neatly. Installed the shock that I had DSA rebuild again. I installed the forks the other day that I put new fluid in since they had about 15 hours on them after a complete rebuild. Installed the header and muffler. Refurbished the rear brake pedal and bearings. New shift lever. Installed an eBay tail light and license plate mount. Installed the headlight and battery.

Things I have left to do:
Receive and install the radiators, radiator hoses, thermostatic switch for the radiator fan, new seals for the silver colored clutch cover I have, horn, rear turn signals, hand guard plastics. I need to put oil, coolant, and gasoline in the bike and I should be ready to roll after that.

I haven't totaled anything up yet (not sure I want to), but I think I've pushed past the $4000 mark now on this rebuild...

:loveit:


Image


Image


Image
Jed Gregory
KTM 450 EXC

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Thu Mar 23, 2017 8:21 am

I also got a package containing two Pilot Road 4 tires that I need to spoon onto the shark bike this weekend.
Jed Gregory
KTM 450 EXC

User avatar
beejaytee
aka KATO
Reactions:
Posts: 290
Joined: Wed Jan 04, 2017 6:56 am

Re: KTM restoration

Post by beejaytee » Thu Mar 23, 2017 8:29 am

Looks awesome. No issues with the tubliss I'm guessing. It looks like the front brake line should be behind the headlight housing.


Sent from my iPhone using Tapatalk
2007 525 exc
I work hard but live better.

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Thu Mar 23, 2017 12:42 pm

I had it there, initially. It seemed to work better in front. I'd prefer it behind and I'll explore that option again when I tuck the wires a little better back there.
Jed Gregory
KTM 450 EXC

User avatar
dirtygrunt
DAMN Grand Poohba
Reactions:
Posts: 1892
Joined: Sat Mar 08, 2008 11:51 am

Re: KTM restoration

Post by dirtygrunt » Thu Mar 23, 2017 5:08 pm

:cheers:

Basically a new bike for half the price.
2016 Freeride/'03 KLX 400

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Sun Mar 26, 2017 8:31 pm

The bad news:

I'm about $5300 into this project and just about done spending money. That's almost $2k more than I intended, but worth it. Some of the expenses were tools like the GM Weather Pack kit and tool. There's also a couple hundred there that I didn't actually spend due to RM Cash back on purchases.

I'm almost done.

The radiators and hose kit should arrive tomorrow. I need to put those on and fill the bike with coolant.
I need a new clutch cover gasket to put the silver clutch cover on.
I need to fill the bike with oil.
I need to paint my rear turn signal brackets black.
I need to wire up the horn.
I need to wire up the radiator fan.

I need to ride!
Jed Gregory
KTM 450 EXC

User avatar
juddspaintballs
DAMN Poohba
Reactions:
Posts: 939
Joined: Wed Nov 14, 2012 8:32 am

Re: KTM restoration

Post by juddspaintballs » Thu Mar 30, 2017 5:53 pm

Two things left to do:
Paint the rear turn signal brackets black
Put the skid plate back on. I'll do that after an oil change.

My radiators were due to arrive on Monday. UPS guy delivered 3 boxes from Mishimoto. A box of radiator hoses, a box that said it was the right radiator, and a box that said it was the left radiator. Inside the box for the left radiator, I found a right radiator. Inside the box for the right radiator, I found a right radiator. DOH! I called Mishimoto and a guy named Eric with an American accent that spoke English very well answered the phone. I explained to him what I received and noted that it probably wasn't a shipping error but a packing error further down the line that caused this problem. He assured me he'd call up the warehouse and have them check in the box for the left radiator before they shipped me another one expedited. He did want a picture of the two radiators as confirmation. I received a tracking number about an hour later for the radiator. The next day, I received a different tracking number from Mishimoto from the same location.

Today, UPS delivered two boxes from Mishimoto. One box said that it was a right hand radiator and the other box said it was a left hand radiator. Inside the left hand radiator box, I found a right hand radiator. DOH! Inside of the right hand radiator box, I found a left hand radiator. Success! Now I have 3 right hand radiators and a left hand radiator, plus the pair of GPI eBay radiators that I couldn't use with my new tank and an older but still good right hand Mishimoto radiator I've been keeping stored in the garage. Eric hasn't yet told me what to do with the 2 right hand radiators that they mistakenly sent me. All he said was to hold onto them for now.

So everything is on the bike and it's together except the skid plate (on purpose). I filled it with coolant, put gas in the tank, and hit the start button. A couple seconds of cranking and it purred to life. I let it sit on choke for about a minute before I idled it down to watch for any leaks. No leaks. I let it warm up to about 125 degrees before I rolled it outside and proceeded to run up and down the driveway a few times. It definitely has more power than it did before. After playing with it a bit, I let it sit in the driveway to get hot to test out my glue-on thermostatic switch to make sure it activated the fan at a safe temperature.

Whoohoo! :loveit:

I'll ride it around the property tomorrow, do an oil change, and then put the skid plate on and start looking for rides to join again with you guys.

Here's a video of it running
Jed Gregory
KTM 450 EXC

Post Reply