Olddogs 660 Rallye Rebuild

[Pezz_gs]

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 . . . . .

[JAFO]

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
Later
Bill

let me know how this works ou for you. I am considering doing something much the same for my KLR.

[atgreg]

Great to see the rallye out on the road again !!!

[OldDog]

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.

[OldDog]

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.

[bend27]

Just read the whole thread, great job, I am also keen to see where it ended up:

http://www.advrider.com/forums/showthread.php?t=686977

[tHEtREV]

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.

[OldDog]

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...