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Old 07-11-2006, 10:55 PM   #1
Pezz_gs OP
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Joined: Nov 2004
Location: Sydney Skunkworks
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My KTM 660 Rallye rebuild

Well it starts like this . . .

I bought this 1997 640 Rallye with the intention of converting it to electric start, running the 660 Rallye crank, 80mm stroke. This is finished now and runs like a train. I had a charging problems but it appears to be fixed.


I was talking to the previous owner of the 640 and he had a 99 660 in bits he was going to sell. Actually he had a 1999 and a 2000 model 660 Rallye. The 99 frame was easily registerable in OZ (Compliance Plate) The 2000 frame wasnt. So he swapped the 99 frame and bolted his 2000 bits to it and he had this left over. He had the '99 head flowed and his Carbie oval bored and he wanted to keep them, so it was a 2000 model Frame, head and carbie with 99 everything else. I ask for 1st option on it . . .

A deal was struck, where I would pay him once I sold the 640 Rallye, and I loaded the parts into my Discovery for the LONG trip home. 1500km's each way.




I promised myself I would touch the 99 until I had sold the 640 Rallye, then buy the necessary parts, bearings Valves ect. So it sat in my garage for a number of months untouched. . . I ended up selling my R80G/s and then paid for the 660 Still trying to sell the 640 .

I moved it over to a good freinds workshop last week and I need to find out just what I have, and what I will need.

So its Dry assembly time . . .


Had a snapped off bolt in the bottom triple clamp, one of the 4 that hold the front guard on . . . its amazing how much time you loose on little things. About an hour later and it was out . . . .

This will be a long project as I get about 3 hours a week on it.
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Old 07-11-2006, 11:01 PM   #2
meat popsicle
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Is that a golf cart? I hear you can remove the voltage regulator and...

Anyways, your garage is bigger than my entire lot.

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Old 07-11-2006, 11:43 PM   #3
Trevor S
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Quote:
Originally Posted by meat popsicle
Is that a golf cart?
I think he needs it to get around in that shed Don't mind me, I have penis... err shed envy.. I have 2 SQ M or so in the corner of the garage I am allowed to use.
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Old 07-12-2006, 12:05 AM   #4
Pezz_gs OP
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Thats not my shed, it is the KTM "Bad Influence" workshop of Ian lovell. He led me over to the Orange side

Ian builds and fabricates bikes. Mainly Classic Race bikes and he has a KTM LC4 609cc that he races in Bears racing
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Old 07-12-2006, 06:56 AM   #5
Beez
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Talking

Hey Pezz, this looks like a chance for a lot of us to see what goes into a real KTM rally bike. Please take lots of photos and explain all the details.

Cheers



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Old 07-12-2006, 08:59 AM   #6
meat popsicle
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Quote:
Originally Posted by Trevor S
I think he needs it to get around in that shed Don't mind me, I have penis... err shed envy.. I have 2 SQ M or so in the corner of the garage I am allowed to use.
A mechanic who plugged my car tire said he used to work at a golf course, and they would remove the voltage regulator so that, well, he said they will reach 30mph w/out the regulator! With those bouncy tires and being top-heavy they are unstable at their normal speeds; so he said they are a blast at higher speeds. Occasionally someone would forget to put the regulator back in and a customer would get one... usually ended up in a water trap.

I think it would be a waste of time not to remove the regulator in this case. Just to get from one side of the shed to the other at normal golf cart speeds must be agonizing!
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Old 07-15-2006, 07:06 AM   #7
Young-Gun
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noice!

Hey Pezz,

Looks like you're gonna have a lot of fun putting that all together! Mine's all in one piece now, except I have an issue with super-hot exhaust... check out my thread.

Cheers,
Ryan
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Old 07-15-2006, 08:28 AM   #8
Arch
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Looks like a fun project, Pezz.
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Old 07-15-2006, 08:33 AM   #9
overlandr
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Good on you!

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Old 07-15-2006, 09:02 AM   #10
Loadedagain
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here we go...
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Old 07-15-2006, 09:11 AM   #11
ChrisC
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Good luck... pics, pics, pics
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Old 06-14-2012, 03:47 AM   #12
overlandr
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Hey, Pezz - wakey wakey to this 'ere old thread! I take it that the blue tank is a 30l rallye - did you ever find out the actual capacity of it?
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Old 06-14-2012, 04:28 PM   #13
Baja Dad
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did you ever sell the 640 Rally?
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