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Old 11-10-2006, 04:18 AM   #1
OldDog OP
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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
Evil Invader
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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
meat popsicle
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Frame on up restoration?
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Old 11-10-2006, 09:13 AM   #8
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Oh man, bookmarked.
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Old 11-10-2006, 11:55 AM   #9
Hoder
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Congrats on the cool new project
This is gonna be good
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Old 11-10-2006, 12:22 PM   #10
AndyBee
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Laugh oh yes

Crikey, I'm excited! Once it's finished, I'm going to emigrate to Australia in case you ever sell it.
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Old 11-10-2006, 08:48 PM   #11
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Thanks for the encouragement everyone! The pics will probably be a little slow as i'm stuck in the stone age and using a film camera.
If anyone out there has information on these puppies don't hesitate to post it up, also if anyone knows how to get more on this bikes history let me know.
Thanks heaps
Bill
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Old 11-11-2006, 03:17 PM   #12
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Very cool indeed. I'll be lurking in this thread.

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Old 11-11-2006, 11:33 PM   #13
bmwktmbill
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Dog,
Good work. Neat to see how the later machines followed from the early rally racers.
I am interested in the airbox and airfilter configuration. KTM changed the airbox on later CV carb models.
Any chance you could photograph the airbox cover and explain what the dohicky is on the side of your airbox?
What carb is you machine set up with?
Thanks, Bill.
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Old 11-12-2006, 03:58 AM   #14
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Quote:
Originally Posted by bmwktmbill
Dog,
Good work. Neat to see how the later machines followed from the early rally racers.
I am interested in the airbox and airfilter configuration. KTM changed the airbox on later CV carb models.
Any chance you could photograph the airbox cover and explain what the dohicky is on the side of your airbox?
What carb is you machine set up with?
Thanks, Bill.
G'day Bill, Below is a pic of the airbox showing the valve thingy on the side, sorry i have no idea what it does, it's just an alloy plate with a hole behind it leading into the airbox, the plate is a bit flexible so may let air in at some point, maybe theres someone out there can help? Filter is just a normal foam one, the airbox itself is much larger than a normal 640's, also see the holes drilled at the back, they're normally covered by mesh as is the top but the material is unavailable. The carb is a Dellorto PHM 40


Hope that helps
Bill (the other one)
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Old 11-12-2006, 06:41 AM   #15
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Quote:
Originally Posted by OldDog
G'day Bill, Below is a pic of the airbox showing the valve thingy on the side, sorry i have no idea what it does, it's just an alloy plate with a hole behind it leading into the airbox, the plate is a bit flexible so may let air in at some point, maybe theres someone out there can help? Filter is just a normal foam one, the airbox itself is much larger than a normal 640's, also see the holes drilled at the back, they're normally covered by mesh as is the top but the material is unavailable. The carb is a Dellorto PHM 40


Hope that helps
Bill (the other one)
320475 - FILTER BOX 660 RALLYE `99
Copyright ©2002 by KTM Sportmotorcycle USA. All rights reserved.
Powered by KTMWorld.com®
#DescriptionNumber
10SPLASH PROTECT.FOR FILTER BOX54606010000
15FILTERELEMENT 125/550/LC4/DUKE56506015100
16FILTER CARRIER `9758306016100
17HOLDING HANGER FOR FILTER `9758306017100
18HOOK FOR FILTER BRACKET58306017050
19CLAMPING DISK KS454606019004
20AIR FILTER BOX BLEEDING50206020000
27AIR FILTER BOOT 540/620/64058006026500
28HOSE CLAMP 60-80MM55006028000
29HOSE CLAMP 50-70MM51006027000
38HH COLLAR SCREW M 6X15 WS=80014060153
39HH COLLAR SCREW M6X10 WS=80014060103
40BUCKET72210079000
44FILTER BOX CPL. WITH VLIES `9858506001044
45VLIES CUT RALLYE `9858506099000


vlies means fleece in German, don't know why they call it that though
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