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Old 08-27-2007, 04:17 PM   #151
Cant ride for crap
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Joined: Nov 2004
Location: Sydney Skunkworks
Oddometer: 3,531
Originally Posted by rjf

Shit, I even feel motivated to put the adv back together tomorrow. It also has a slightly weeping base gasket. IIRC KTM went from a fibre one to a metal one. I might order in a gasket set and replace it soon.
No the base gasket is still paper.

The crankcase gasket (Between the Crankcase Halves) is available in Metal

Come on RJF get the sliver thing going . . . .

It should be in WA at the Safari . . . . .
Airhead Tragic
I'm not a complete idiot -- Some parts are missing
XR460/4 -

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Old 08-27-2007, 04:19 PM   #152
displaced Jeep guy.....
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Joined: Aug 2006
Location: Charleston, SC
Oddometer: 3,974
Originally Posted by OldDog
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
let me know how this works ou for you. I am considering doing something much the same for my KLR.
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Old 08-29-2007, 03:31 PM   #153
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Joined: Mar 2003
Location: Sydney Australia
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Great to see the rallye out on the road again !!!
1990 RD04 Africa twin 750
350,000km and still going strong
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Old 09-01-2007, 06:18 PM   #154
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Location: Mudgee, Australia
Oddometer: 3,916
Thanks Greg, alli gotta do now is find someone who knows how to tune the bloody thing! I want to keep the Dellorto carb, and i think i need a "specialist" to get the best out of it.
RIP Mandie, 16/10/71 - 14/09/13 Walk on little sister

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Old 03-09-2008, 11:44 PM   #155
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Joined: Feb 2005
Location: Mudgee, Australia
Oddometer: 3,916
Evenin all, Bit of an update. Following the repairs to the head i've been doing a fair bit of riding. I think the Rallye is probably a bit too "advanced" for a dirt noob like me, and i have the bruises to prove it . That doesn't mean i'll sell so get back you philistines!
In late January i headed off to the Limeburners rally, about 800 kms of mostly dirt, but at Taralga the next morning doing my morning check....i found bloody water in the oil again! I limped the bike about 150 kms to Bathurst where a mates wife gave me and the "Tupperware Timebomb" a lift home

I've stripped the engine down completely and found that the bloody water pump seal had blown again, thats twice now! I'm not sure whether it was a faulty seal, or me stuffing up when i rebuilt it last time. Either way, i'm a firm believer that coolant leaking past the seal should not end up in the engine oil! Bloody archaic design if you ask me, so i've done a little something about it, I've drilled a small 1/8 weep hole through the housing like so

The opening inside sits between the sel and the face of the bearing. Under pressure coolant will come out here rather than get forced through the seal on the bearing. I'll plug the hole with a dab of grease to keep the dust out, This is purely experimental, i've tried it with the blown seal in and the cooling system pressurised. It worked ok, not as well as i expected but when hot maybe it'll work better. Anythings better than the other dumbass idea.
RIP Mandie, 16/10/71 - 14/09/13 Walk on little sister

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Old 05-12-2011, 11:56 PM   #156
by hook or by crook
Joined: May 2008
Location: Melbourne - Amsterdam
Oddometer: 1,153
Just read the whole thread, great job, I am also keen to see where it ended up:
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Old 05-13-2011, 03:54 PM   #157
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Joined: Apr 2007
Location: Middle Park, Brisbane, Australia
Oddometer: 6,515
I can't beleave he didn't finish this thread...

All I will say is that he discovered why the water pump seal was failing, and it was aparenty running great when it was sold.

KDX Super Fan!

My Spot HERE .
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Old 01-10-2012, 01:56 AM   #158
OldDog OP
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Joined: Feb 2005
Location: Mudgee, Australia
Oddometer: 3,916
My goodness, I happened to wander past this thread to collect some info as I'm thinking about buying another Rallye and i see that theres been some activity on here!

And yes to finish the tale off I found the problem (s), and its something other Rallye owners should take note of if they start having the same issues -

1. The original water pump drive (which is the camshaft drive sprocket retaining bolt with a slot in it to drive the water pump tang) had been replaced with a normal bolt that had a slot hacksawed into it, looked like a makeshift "get it back in the race" repair. Anyway the slot was very slightly off centre so the pump shaft wouldn't run true and eventually wreck the bearings. and

2. The repair manual has the water pump seal lips both facing the direction of the engine.....when one seal should face the water pump and the other face the engine.

Lessons learned, and I'm happy to report that the bike is still racing. Shoulda kept that bike...
RIP Mandie, 16/10/71 - 14/09/13 Walk on little sister

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Old 10-17-2013, 10:25 PM   #159
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Joined: Nov 2009
Location: Flinders Ranges
Oddometer: 1
Hi Bill.

G'day Bill Tobes here mate the big fella who bought the Rallye from you jeez was that in 2008? Well I think I spoke to you a few years ago when I killed the motor again at a Blinman. Well shame on me but I only just got her going again. Was a ceased main bearing God knows what went wrong but having replaced main bearing and oil pumps the beast Snorts again. In fact is going like a train. Hope your all good I recall you where going to build some crazy off-road Ducati. Would be good to catch up for bullshit session. Also put the other cam you gave me in and seems to have increased power nicely was wondering what the story was with the cams.
You have to be cruel, to be cruel.
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