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Old 11-10-2006, 04:18 AM   #1
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Laugh 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.

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OldDog screwed with this post 11-10-2006 at 04:24 AM
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Old 11-10-2006, 06:20 AM   #2
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keep it coming!
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Old 11-10-2006, 06:35 AM   #3
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I´m waiting..
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Old 11-10-2006, 06:46 AM   #4
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This is worth waiting for...
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Old 11-10-2006, 07:25 AM   #5
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hey

there lost boy

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

Tim
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Old 11-10-2006, 07:28 AM   #6
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Looking good!
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Old 11-10-2006, 08:05 AM   #7
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Frame on up restoration?
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Old 11-12-2006, 01:42 PM   #8
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Instrument bracket

Hey OldDog, did you happen to get any pics of the instrument bracket before you removed it?
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Old 11-12-2006, 05:00 PM   #9
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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.
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Old 11-12-2006, 06:11 PM   #10
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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
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Old 02-06-2007, 12:03 PM   #11
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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.
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Old 02-06-2007, 01:52 PM   #12
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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.
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Old 02-06-2007, 10:19 PM   #13
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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?
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Old 02-21-2007, 01:09 AM   #14
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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
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Old 05-21-2007, 03:59 PM   #15
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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
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