ADVrider

ADVrider (http://www.advrider.com/forums/index.php)
-   Thumpers (http://www.advrider.com/forums/forumdisplay.php?f=15)
-   -   KTM 620 rebuild/refresh (http://www.advrider.com/forums/showthread.php?t=866769)

gravityisnotmyfriend 02-28-2013 12:55 PM

KTM 620 rebuild/refresh
 
I’ve got a couple of threads splattered about on this bike, and I’m just looking to consolidate everything in one place I’ve restored vintage bikes and vintage snowmobiles on other sites and really enjoy going back the the threads and re-reading my projects.

So, anyway – the bike. I found a ’94 KTM 620 EXC for sale late last summer. I could tell it had been ridden hard and put away wet most of its life – but after a test ride, I just had to have it!

Here’s how it looked when I bought it:
http://i179.photobucket.com/albums/w.../th_ktm620.jpg

I got it for a price I was happy with and spent last summer/fall riding it and making a list of what it needed. I’m glad I didn’t have this list when I test drove it – I may not have bought it!

So here’s where I started:
Headlight – flickers
Tail light – doesn’t work
Turnsignals – sometimes work
Instrument lights – don’t work
Parking light – doesn’t work
Rear shock – shot
Front shocks – leak
Clutch – slips
Spark plug – needs replaced
Waterpump – needs new seals/bearings
Carbs – jetted too fat
Seat – I hate the white seat
Plastics – plain white
Luggage – none
Handlebars – too low
Steering - spooky at highway speeds.

Updates on the next post.

gravityisnotmyfriend 02-28-2013 12:58 PM

The shock is fixed. Bought a used one off an inmate in good shape.

Initially, I thought I could just pull the two bolts holding the shock on and slide it out the left hand side of the frame. No such luck. I ended up stripping just about everything off the top and back of the bike to get access.

http://i179.photobucket.com/albums/w...ps395a5995.jpg


That was taken after I got the new shock in.

I haven't had a chance to test the new shock. Since I had the tank off, I decided to tackle the water pump rebuild. And, since I was buying parts, I decided to buy a new sprocket shaft seal as well. I'll get some pics as I go.

MartinPetren 02-28-2013 01:03 PM

I love these kind of threads :-)

gravityisnotmyfriend 02-28-2013 01:15 PM

Headlight – flickers
Just a loose connection.


Tail light – doesn’t work
Handlebar wiring was redone - poorly


Turnsignals – sometimes work

Instrument lights – don’t work

Parking light – doesn’t work
Parking light deosn't exist. Need to buy a replacement.


Rear shock – shot
Replaced


Front shocks – leak

Clutch – slips

Spark plug – needs replaced

Waterpump – needs new seals/bearings

Carbs – jetted too fat
New jets ordered. 195-170MJ; 52-45 idle jet.


Seat – I hate the white seat
Painted with vinyl interior paint. Not lasting very well.


Plastics – plain white

Luggage – none
Luggage rack built. Top box acquired - but I need to mount it.


Handlebars – too low
Rotated back too far. Moved them forward and I think It'll wor
k.

Steering - spooky at highway speeds.
Steering stem had too much slack. Tightened her up.

Seikkailu_R 02-28-2013 01:29 PM

Quote:

Originally Posted by gravityisnotmyfriend

Initially, I thought I could just pull the two bolts holding the shock on and slide it out the left hand side of the frame. No such luck. I ended up stripping just about everything off the top and back of the bike to get access.

Shock drops down thru swingarm after links are removed...

gravityisnotmyfriend 02-28-2013 04:04 PM

Not in my garage it doesn't! To hell with that easy fix nonsense! I gotta take the hard way out!!!

I looked at that. I looked real close and decided that there was no way the shock would slide through the swing arm. Not with the nitrogen reservoir on the side. I was sure that if I too the linkages off, it would just frustrate me and I'd have to take the subframe off anyway.

Well, I've learned something. Next time - if I have to rebuild this one- I'll try the easy way!

Seikkailu_R 02-28-2013 04:34 PM

Few easy steps and shock is removed... :D

10) lower the shock about 2 inches until it's free of its bracket on the frame and try to rotate the reservoir ccw about 200 degrees towarts the chain, then tilt the head of the shock about 20 degrees to the left, then take it out through the hole in the swingarm . You might need to lower or raise the rear wheel a little to get enough free play but it will work!. Remember the shock's 'attitude' when sliding it through the hole in the linkage....getting it back in place only works in the same way!!!

Its simply matter of faith and right magical moves...

CSF 02-28-2013 04:58 PM

Nice bike, good luck with the rebuild. Looks great so far. Painting a seat seams like a terrible idea, like something someone would do to make the bike look pretty to try and sell it for top dollar.

Any chance you could post some larger pics?

bmwktmbill 02-28-2013 11:05 PM

Grav, Get a bible you disbeliever....

Loosen the shock, work the swing arm up and down, up and down slightly turning the shock.

It will come down fast and go back up the same way.

It will fall out and smash your finger because you are not ready for that.

Practice.

I think the pivot can stay?

You can adjust the spring tension with the hook on your axle wrench but you must remove the shock to do it.


Practice, KTM, Paris -Dakar winner.
bill

Seikkailu_R 03-01-2013 01:50 AM

Quote:

Originally Posted by bmwktmbill (Post 20837285)
You can adjust the spring tension with the hook on your axle wrench but you must remove the shock to do it.

Or just loose top adjuster nut and turn spring with hand...

gravityisnotmyfriend 03-01-2013 05:23 AM

Quote:

Originally Posted by CSF (Post 20834859)
Nice bike, good luck with the rebuild. Looks great so far. Painting a seat seams like a terrible idea, like something someone would do to make the bike look pretty to try and sell it for top dollar.

Any chance you could post some larger pics?

yeah, I've come to that conclusion myself. The seat was recently recovered by the PO. The vinyl is in great shape - so it seemed silly to rip it off and reupholster it. I found this Duplicolor product that is marketed to repaint vinyl seats:

http://www.duplicolor.com/products/vinylFabricCoating/

For a $4 can, I thought it was worth a try. Mostly, it worked. But, there are places that the seat cover folds over itself when I sit on it. The paint has come off those parts. So, it was worth a try, but I'll probably end up having a professional recover it - just not white.


Here's what it looked like for a couple of months after painting the seat:
http://i179.photobucket.com/albums/w...th_ktmside.jpg

The picture thing is a bit annoying. Photobucket has been resizing my pics. I may have to look at host my pics somewhere else.You do know you can click on them to make them a little bigger, right?

gravityisnotmyfriend 03-01-2013 05:27 AM

Quote:

Originally Posted by bmwktmbill (Post 20837285)
Grav, Get a bible you disbeliever....


bill

I've got a shop manual for the bike. Sometimes I'm just not smart enough to open it. I've been turning wrenches on bikes since I was 9 years old and I bent an intake valve on my CT70. Apparently I was under the impression I knew what I was doing! In all fairness, I did get the shock off and the new one went in really easily! But, then I just had all that stuff to put back on.

I'm just going to chalk it up to getting to know my bike! Lessons learned!

gravityisnotmyfriend 03-01-2013 05:35 AM

Turnsignals – sometimes work

Instrument lights – don’t work

Front shocks – leak

Clutch – slips

Spark plug – needs replaced

Waterpump – needs new seals/bearings

Plastics – plain white

Headlight – flickers
Just a loose connection.


Tail light – doesn’t work
Handlebar wiring was redone - poorly


Parking light – doesn’t work
Parking light deosn't exist. Need to buy a replacement.


Rear shock – shot
Replaced


Carbs – jetted too fat
New jets ordered. 195-170MJ; 52-45 idle jet.


Seat – I hate the white seat
Painted with vinyl interior paint. Not lasting very well.


Luggage – none
Luggage rack built. Top box acquired - but I need to mount it.


Handlebars – too low
Rotated back too far. Moved them forward and I think It'll work


Steering - spooky at highway speeds.
Steering stem had too much slack. Tightened her up.



The current project is the water pump. I got the new bearings in the mail from VXB yesterday. The new seals and Orings are coming from KTM-Parts. Hopefully soon. I'm getting some new jets in that same shipment as well as the Sprocket Shaft seal.

Not much I can do until the parts get in.

Any advice on getting that sprocket shaft seal out? I've got the sprocket, and spacer out. I'm just not sure how to attack it from here. Do I need to break down and buy a seal puller? Is there a substitute that I can use without risking damage to the case?

bmwktmbill 03-01-2013 10:51 PM

Make a slap hammer...
Buy a big cheap screwdriver, bend the end in a hooked L shape, big washer on blade up to handle, next a piece of pipe.

Slap it our or use a block of wood and pry.

Seal puller is cheap at...

http://www.tooldiscounter.com/ItemDi...le&kw=LIS56750


bill

gravityisnotmyfriend 03-02-2013 08:52 AM

Brilliant! That's exactly what I ended up doing. Bent the tip of an old screwdriver, grabbed the end with a big channel lock, and tapped on the channel lock while working around the inside perimeter of the seal. Now, I just gotta wait for my new parts to get here.

In the mean time, I've started digging into my instrument panel lights. The bulbs all appear fine - which means the wiring is hosed. I already had to fixed some botched wiring to get the tail light to work, looks like I gotta dig out the wiring schematic again.

I wouldn't be too worried about it, but I want to know if the bike is overheating. Especially since I'm going to be messing with the jets.


Times are GMT -7.   It's 07:37 AM.

Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014