Olddogs 660 Rallye Rebuild

OldDog · 11-10-2006, 04:18 AM

G’day Everyone,
A few weeks ago I had the questionable

good fortune of picking up a ’99 KTM 660 Rallye, thought you guys might be interested in seeing it's rebuild. To the best of my knowledge this bike was raced in 2 Paris – Dakar’s and was raced here in the Australian Safari by Tim Fitzhardinge and then several times by Craig Hartley, heres some pics of him in action

It's 1 of 3 660 Rallye’s in Australia which has compliance for road registration. Craig sold the bike to Shane Martin (aka Leglessone) earlier this year, heres a pic

he in turn sold it on to me. For whatever reason, the bike has suffered some reliability issues recently and I picked the thing up in several large lumps and several boxes full of small pieces, queue more pics

After close inspection I decided to strip the bike right down and start again, replacing any bits required.

After disassembly the first thing I did was get some cans of crack test and go over the welds and joints on the frame and swing arm, all clear! Then the axles, gearbox shafts, swing arm pivots and triple clamps, all clear! Then I used a string line on the frame and again with the swing arm installed, plus checked the swing arm was true, those were all clear as well. Given that this bike would have copped a fair hiding from all those race miles I’m impressed that something isn’t bent. I noticed it’s had a hit in the front taking off the radiator mounts which were then welded back on but not painted so there was some rust there, also some rust inside the front frame brace as the drain holes were blocked, I’ve treated that. After a quick bead blast it’s received a few coats of some flash grey epoxy 2 pack wonder paint that a mate uses on mining equipment, I was a bit disappointed that it wasn’t the same shade of grey but what the hell it looks ok and the finish is tough. another pic or 2...

So far i can see that it needs a new main wiring harness and a new suspension linkage. The harness is just old and a new one will make sure I don’t get any unexpected “surprises” The pin in the suspension linkage where it bolts to the swing arm was frozen due to worn out bearings….or so I thought, turns out the bore is stretched out of round, possibly due to a hard landing (?) anyway, Pezz the Rallye Guru happens to have a spare which saves me trying to source an “out of stock” part. Thanks mate

The engine is in a bad way, the big end failed taking out the crank pin, conrod, piston and barrel. The scours in the barrel go deep so I dunno if it’s reusable although now that I think of it…. Pezz mentioned a 105mm piston kit :-0 so it may live again MMmmmmm big block!! Never mind though, it comes with a new barrel/rod/piston assembly ready to go in. There was an impressive amount of debris right through the motor so while it’s in bits I’ll replace all the bearings that would have been affected. I pretty impressed with this thing, it was still going strong despite the busted bottom end and still fired straight up, made a horrible racket though! The only other issue I can see so far is the gears in the gearbox, looks to me like 6 of the 10 gears have pitting, some of it pretty bad. Once I’ve saved up the $$$ for those puppies I’ll be able to get the engine nailed together and have the beast back on the road……errr tracks and see just what this things made of, well to the best of my ability I guess

I can’t see myself racing it so it will live a life of relative semi retirement, being mainly used to take me to those hard to get to places that I won’t take the GS, after my last accident that bike stays on the road or good dirt.

doyle · 11-10-2006, 06:20 AM

keep it coming!

Evil Invader · 11-10-2006, 06:35 AM

I´m waiting..

Ignore Amos · 11-10-2006, 06:46 AM

This is worth waiting for...

bugfnnuts · 11-10-2006, 07:25 AM

there lost boy

How ya been? You need a rallye project like this one. Would be perfect for your Baja trip.

Tim

Beez · 11-10-2006, 07:28 AM

Looking good!

meat popsicle · 11-10-2006, 08:05 AM

Frame on up restoration?

Hoder · 11-12-2006, 01:42 PM

Hey OldDog, did you happen to get any pics of the instrument bracket before you removed it?

OldDog · 11-12-2006, 05:00 PM

Quote:

Originally Posted by Hoder

Hey OldDog, did you happen to get any pics of the instrument bracket before you removed it?

G'day Hoder, no i didn't actually, i'm assuming you mean the whole cockpit includeing the ICO's and road book? I'll get a few pics when i get back and post 'em up for you. I'm heading off to get my GS which has just been repaired and it'll a long, slow ride home, should be back next Monday.

HighwayChile · 11-12-2006, 06:11 PM

good on ya for keeping a chunk of history on the road

if you get stuck on parts post on ktmtalk.com

thanks for keeping this out of the graveyard

9 Ribs · 02-06-2007, 12:03 PM

Excellent rebuild Olddog. Fortunate to be busy on a 2000 Rally 660. your thread helped a stack. Thanks. Where did you get the Dakar Granada decal? Any help appreciated.

Hambone950 · 02-06-2007, 01:52 PM

A swift Google did not find much on Andy that is recent. What a story.
Surely he is in the ADV Rider privateer Hall of Fame though along with Chris Blais of course. Is Haydon still racing? The Finke and other races seem every bit as tough and more than the US style BID including on the liver.
A few write ups as these things come along would be great.
Great photo btw.

OldDog · 02-06-2007, 10:19 PM

Quote:

Originally Posted by Hambone950

A swift Google did not find much on Andy that is recent. What a story.
Surely he is in the ADV Rider privateer Hall of Fame though along with Chris Blais of course. Is Haydon still racing? The Finke and other races seem every bit as tough and more than the US style BID including on the liver.
A few write ups as these things come along would be great.
Great photo btw.

Ribs, Glad it helped some

i hope you got my PM reply ok?

Hambone, I havn't heard of Andy racing for a bit now, the bloke is a dead set legend though, i've seen some spectacular shots of him in action. We have the Australian Safari back on again this year, maybe he'll be racing?

OldDog · 02-21-2007, 01:09 AM

Evenin All, Just a bit of an update. Up until recently i've been having great time wandering about the bush on this thing, i think it's a bit too much bike for me but what the hell! Anyway, the other day the starter decided to seize on while i was riding

It'd been playing up on and off for a bit but this time it wouldn't free up. Once i got home and stripped it all down i found the starter was fried, it was old anyway so i'm not really surprised

, i ended up getting a new one from Chip at Munn racing for less than half i would've paid here,
pic of nice new shiney starter motor

while i was at it i bought a carb gasket kit and a fuel pump rebuild kit for the spare fuel pump. I suspected that the starter clutch bearing was a bit dodgey as well so i got a new one while i waited. Once i pulled the ignition off this is what i found..

Turns out the circlip has come adrift from the bearing and slid down between the bearing and the starter wheel

. Originally i had pulled this bearing out to clean it, and i've stuffed up when putting the circlip back in, so with the help of KTMajor, this time i assembled it properly.
At the first oil change at 50km's i noticed metal in the oil, at the time i was very worried that i'd somehow missed some from the original blow up, now i know better

While i was waiting for the starter i'd also popped the head off and checked the bore and big end, thankfully they are bedding in perfectly without a sign of abnormal wear.
Another thing i did while waiting was to fit up a trailtech computer

Crappy pic i know, but you get the idea, now i have a temp guage, tacho and odometer, which will make it easier to live with.
The final thing i have to do to it is fashion up an oil pressure warning light......that works, the one in the pic is as supplied by KTM and is really just for show

. I'm going to fit up a double banjo bolt at the oil line coming into the crank, similar to the one at the oil filter cover, the extra banjo i'll modify to accept a small pressure switch and voila, low oil pressure warning system!
And now i need a beer

Later
Bill

OldDog · 05-21-2007, 03:59 PM

Howdy All,
Just a quick update. I've had a few problems with water getting in the oil, which stoppedme from getting to the Condo as planned. I originally thought it was the water pump but after some testing, (thanks for the tips on that JFN68) it seems to be okay. It turned out to be a warped cylinder head. I originally straight edged it and it seemed okay, but on the mill we had to take off 8 thou

to get it straight. It all seems to be good now, i took it out for a spin in the mud on Sunday and it performed perfectly.

Yeah yeah i know, thats not muddy by some peoples standards

11-10-2006, 04:18 AM	#1
OldDog ^OP Smelly Adventurer type Joined: Feb 2005 Location: Mudgee, Australia Oddometer: 3,666	Olddogs 660 Rallye Rebuild G’day Everyone, A few weeks ago I had the questionable good fortune of picking up a ’99 KTM 660 Rallye, thought you guys might be interested in seeing it's rebuild. To the best of my knowledge this bike was raced in 2 Paris – Dakar’s and was raced here in the Australian Safari by Tim Fitzhardinge and then several times by Craig Hartley, heres some pics of him in action It's 1 of 3 660 Rallye’s in Australia which has compliance for road registration. Craig sold the bike to Shane Martin (aka Leglessone) earlier this year, heres a pic he in turn sold it on to me. For whatever reason, the bike has suffered some reliability issues recently and I picked the thing up in several large lumps and several boxes full of small pieces, queue more pics After close inspection I decided to strip the bike right down and start again, replacing any bits required. After disassembly the first thing I did was get some cans of crack test and go over the welds and joints on the frame and swing arm, all clear! Then the axles, gearbox shafts, swing arm pivots and triple clamps, all clear! Then I used a string line on the frame and again with the swing arm installed, plus checked the swing arm was true, those were all clear as well. Given that this bike would have copped a fair hiding from all those race miles I’m impressed that something isn’t bent. I noticed it’s had a hit in the front taking off the radiator mounts which were then welded back on but not painted so there was some rust there, also some rust inside the front frame brace as the drain holes were blocked, I’ve treated that. After a quick bead blast it’s received a few coats of some flash grey epoxy 2 pack wonder paint that a mate uses on mining equipment, I was a bit disappointed that it wasn’t the same shade of grey but what the hell it looks ok and the finish is tough. another pic or 2... So far i can see that it needs a new main wiring harness and a new suspension linkage. The harness is just old and a new one will make sure I don’t get any unexpected “surprises” The pin in the suspension linkage where it bolts to the swing arm was frozen due to worn out bearings….or so I thought, turns out the bore is stretched out of round, possibly due to a hard landing (?) anyway, Pezz the Rallye Guru happens to have a spare which saves me trying to source an “out of stock” part. Thanks mate The engine is in a bad way, the big end failed taking out the crank pin, conrod, piston and barrel. The scours in the barrel go deep so I dunno if it’s reusable although now that I think of it…. Pezz mentioned a 105mm piston kit :-0 so it may live again MMmmmmm big block!! Never mind though, it comes with a new barrel/rod/piston assembly ready to go in. There was an impressive amount of debris right through the motor so while it’s in bits I’ll replace all the bearings that would have been affected. I pretty impressed with this thing, it was still going strong despite the busted bottom end and still fired straight up, made a horrible racket though! The only other issue I can see so far is the gears in the gearbox, looks to me like 6 of the 10 gears have pitting, some of it pretty bad. Once I’ve saved up the $$$ for those puppies I’ll be able to get the engine nailed together and have the beast back on the road……errr tracks and see just what this things made of, well to the best of my ability I guess I can’t see myself racing it so it will live a life of relative semi retirement, being mainly used to take me to those hard to get to places that I won’t take the GS, after my last accident that bike stays on the road or good dirt. __________________ "Never trust a man who, when left alone in a room with a tea cosey, doesn't try it on" Billy Connelly 1966 Norton Atlas "Ruby" Triumph Tiger 800XC Boxes of XR600's and a psychopathic Ducati OldDog screwed with this post 11-10-2006 at 04:24 AM

11-10-2006, 06:20 AM	#2
doyle RallyRaidReview-ing Joined: Jan 2004 Location: Off Piste Oddometer: 21,524	keep it coming! __________________ *Got Smugmug? Use code HWkDUhHwGv5Tc for a discount.* RallyRaidReview - @RallyRaidReview

11-10-2006, 06:46 AM	#4
Ignore Amos bruised, dazed & confused Joined: Aug 2004 Location: Tucson, Arizona Oddometer: 981	This is worth waiting for... __________________ Ignore Amos Women love men with big KTMs 07 BMW 1200 GS Adventure 07 KTM 950R Super Enduro 08 KTM 530 XCWR 09 BMW G450X BITD 066 AMRA 54S SCORE 22X

11-10-2006, 07:25 AM	#5
bugfnnuts Somewhat Regrouped Joined: Mar 2006 Location: Not the F'ing Canary Islands Oddometer: 958	hey there lost boy How ya been? You need a rallye project like this one. Would be perfect for your Baja trip. Tim __________________ "Dakar must be a race for few people, Dakar is a dream, the dream of the Rose Lake, if everybody finish it, the dream is over" Fabrizio Meoni A challenge for those who go. A dream for those who stay behind. " Thierry Sabine

11-10-2006, 08:05 AM	#7
meat popsicle Ignostic Joined: Feb 2004 Location: Circumlocution Office of Little Dorrit Oddometer: 13,843	Frame on up restoration? __________________ Kronreif Trunkenpolz Mattighofen LC4 640 Its not so much staying alive; its staying human that counts.

11-10-2006, 06:35 AM	#3
Evil Invader Studly Adventurer Joined: May 2006 Location: Hell-sing-land, Sweden Oddometer: 593	I´m waiting..

11-10-2006, 07:28 AM	#6
Beez Given to fly Joined: Aug 2004 Location: Framingham, MA Oddometer: 5,499	Looking good!

11-12-2006, 01:42 PM	#8
Hoder Card carrying greeny Joined: Mar 2006 Location: Buckley, Washington Oddometer: 1,015	Instrument bracket Hey OldDog, did you happen to get any pics of the instrument bracket before you removed it? __________________ See my pics Dave: The 610 really makes me want to ride like a punk everywhere I go. bikefrk: You now understand supermoto. Your training is complete.

11-12-2006, 06:11 PM	#10
HighwayChile greetings from Wa state Joined: Aug 2003 Location: Bow, WA USA Oddometer: 4,096	good on ya for keeping a chunk of history on the road if you get stuck on parts post on ktmtalk.com thanks for keeping this out of the graveyard __________________ “I would rather wake up in the middle of nowhere than in any city on earth.” .....Steve McQueen

02-06-2007, 12:03 PM	#11
9 Ribs Rocks?What Rocks? Joined: Nov 2006 Location: Down South Oddometer: 2	Decalls on 660 Rally Excellent rebuild Olddog. Fortunate to be busy on a 2000 Rally 660. your thread helped a stack. Thanks. Where did you get the Dakar Granada decal? Any help appreciated.

02-06-2007, 01:52 PM	#12
Hambone950 Mas Naranjas Por Favor! Joined: Jun 2005 Location: Calgary/ Houston/ Neuquen Oddometer: 676	Andy Haydon A swift Google did not find much on Andy that is recent. What a story. Surely he is in the ADV Rider privateer Hall of Fame though along with Chris Blais of course. Is Haydon still racing? The Finke and other races seem every bit as tough and more than the US style BID including on the liver. A few write ups as these things come along would be great. Great photo btw. __________________ Hambone

02-21-2007, 01:09 AM	#14
OldDog ^OP Smelly Adventurer type Joined: Feb 2005 Location: Mudgee, Australia Oddometer: 3,666	Starter woes Evenin All, Just a bit of an update. Up until recently i've been having great time wandering about the bush on this thing, i think it's a bit too much bike for me but what the hell! Anyway, the other day the starter decided to seize on while i was riding It'd been playing up on and off for a bit but this time it wouldn't free up. Once i got home and stripped it all down i found the starter was fried, it was old anyway so i'm not really surprised , i ended up getting a new one from Chip at Munn racing for less than half i would've paid here, pic of nice new shiney starter motor while i was at it i bought a carb gasket kit and a fuel pump rebuild kit for the spare fuel pump. I suspected that the starter clutch bearing was a bit dodgey as well so i got a new one while i waited. Once i pulled the ignition off this is what i found.. Turns out the circlip has come adrift from the bearing and slid down between the bearing and the starter wheel . Originally i had pulled this bearing out to clean it, and i've stuffed up when putting the circlip back in, so with the help of KTMajor, this time i assembled it properly. At the first oil change at 50km's i noticed metal in the oil, at the time i was very worried that i'd somehow missed some from the original blow up, now i know better While i was waiting for the starter i'd also popped the head off and checked the bore and big end, thankfully they are bedding in perfectly without a sign of abnormal wear. Another thing i did while waiting was to fit up a trailtech computer Crappy pic i know, but you get the idea, now i have a temp guage, tacho and odometer, which will make it easier to live with. The final thing i have to do to it is fashion up an oil pressure warning light......that works, the one in the pic is as supplied by KTM and is really just for show . I'm going to fit up a double banjo bolt at the oil line coming into the crank, similar to the one at the oil filter cover, the extra banjo i'll modify to accept a small pressure switch and voila, low oil pressure warning system! And now i need a beer Later Bill __________________ "Never trust a man who, when left alone in a room with a tea cosey, doesn't try it on" Billy Connelly 1966 Norton Atlas "Ruby" Triumph Tiger 800XC Boxes of XR600's and a psychopathic Ducati

05-21-2007, 03:59 PM	#15
OldDog ^OP Smelly Adventurer type Joined: Feb 2005 Location: Mudgee, Australia Oddometer: 3,666	Howdy All, Just a quick update. I've had a few problems with water getting in the oil, which stoppedme from getting to the Condo as planned. I originally thought it was the water pump but after some testing, (thanks for the tips on that JFN68) it seems to be okay. It turned out to be a warped cylinder head. I originally straight edged it and it seemed okay, but on the mill we had to take off 8 thou to get it straight. It all seems to be good now, i took it out for a spin in the mud on Sunday and it performed perfectly. Yeah yeah i know, thats not muddy by some peoples standards __________________ "Never trust a man who, when left alone in a room with a tea cosey, doesn't try it on" Billy Connelly 1966 Norton Atlas "Ruby" Triumph Tiger 800XC Boxes of XR600's and a psychopathic Ducati

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