Bike Makeover
2006/2007

1998 KTM Lc4 Rally 660 bought in 2004 and in dire need of TLC

Dismantling begins
First of course drain all petrol
remove the seat
next the rear petrol tanks
the more you remove ....
... the more you see the rust on the framework
Front mask removed ...
and placed on the plastic pile
same for the main tank
starts looking naked
drain the oil
looks scary but no large parts on the magnet
lets move on, ..shall we ...?
exhaust removed in oe piece
rear frame work gone
internal oil filter removed ...
not so messy if the bike is on its side
close all orifices ...
on the engine
sort of interesting looking
soak it in bike cleaner ....
.... and give it a wash
drain the coolant
and put the radiators on the pile
yuck....rust, grime, dirt
.... more rust, grime, dirt .....
remove the engine mounts
remove the valve cover, won't clear otherwise
upps,....
engine out and on the bench mount
not much left now
handlebar and mounts are gone
remove top yoke
tripple tree, bearings do not look to bad ...
linkage removed
the tire is so square it stands up without help
now I can check the tire preassure ;-)
I found this 660 SMC Engine on Ebay. It is the 2005 Version of my Rally Engine but with better Cylinder Head, Waterpump and second oil jet for piston cooling. It also has the bigger oil pumps. So I got it to replace the Rally Engine  
At this point I had the stupid idea that if I refurb one bike I could do a second one at the same time and use the Rally Engine to create a KTM Baja Replica...
A few differences but in general the same optics.
The parts that came with the engine together with the collection of parts I already have will help .....

out comes the old Lc4 Enduro Frame ...

fit all the little things temporarily ....
engine in for mock up ...
Sumo swing arms, forks, sumo engine, sumo shock
20L tank Adventure seat
Tank mount turned into Radiator Protector

on it goes


exhaust going on, front first ...
sort of missing a part ....
SXC racing muffler. Not much muffling ....

accidantally bought another one brand new on Ebay

this time the legal one ...
spot the difference on the exit
hmmm ....
still hmmmm
try the rally seat ...? .....
I think we need to modify the subframe
but looks alright ....
yeah lets do it ...
using the old rally brackets ...
cut the old crossmember
plastics on ...
does this look right ?
not even remotly looking like the Baja .....
We will see. Fortunately the Dirtbike Show in Coventry is coming up.
Will go and fish for ideas .....
 
Charley Boorman's Dakar F650
swing arm looks cheap ...
cockpit ....
oh, the new X-Challenge .... cheap feeling plastics ...
ok, taste is relativ ...
ah more Rally bikes ...
Honda ....
CRF 450 ....
not bad ....
very slim ...
pivot pegs ...
.. on Patsy's bike
hello ..? EXC450 Rally .... shweeet!

the lorry isn't bad either ...
Back in the workshop .. Changing the rear crossmember
first weld after 25 years .... really crappy ...
cleaned it up, looks better but still is crap .. test fit ...
ok the wheels.

the rims are eaten away by salt ..

they can't be rescued
my 6 year old Desert, hard like marble ..
off with the rubber ...
inside not looking good either ...
rear rubber, give it a good lube ...
tire irons ready, break the bed ...
irons in and, zapzerapp ...
desert is off in winter at 8degrees, piece of cake ....
the rim is fu**ed
the spokes are fused to the nipples ....
so I had to resort to the grinder ..
same for the front
here we have the two hubs ...
ready to go to the powder coat place ...
The Baja actually as the low exhausts....
.. if I want something simmilar I'll need an engine with
electric start. Found one on Ebay with slight fault in the ALternator. The seller had removed the cam to repair his own engine.
   
2004 Duke Engine
suffered by the salt on winter roads
few parts missing
first remove the old alternator
change the reknown problem bearings
Inspect the rest as far as possible without taking it apart
check the timimg parts.
set engine to TDC
the 2004 and the 1998 Alternator are the same
groovy ...
10 years old but in good order
these parts are the ones from the sellers old engine ...
how can you miss the rocker roller going ?
parts from the '98 engine looking good ...
hmm, you can't spot a bike if it is dismantled ....
the old rally engine
Duke Engine
SMC Engine
the new big Airbox
the EXC '05 plastics
not a straight fit then ....?
ok that will demand some fabrication ...
the seat has to come lower ...
here you can see it ...
here you can't
and my welding was removed again ...
frame to wide for the plastics ....
easier than thought ...
it fits ..
but what now? the clamp looks stupid there ....
original cross member cut to size and welded in
welding is getting better ... Airbox fits in ...
looking good ...
slowly getting there
the seat still doesn't fit ....
what to do with this gap ...

finishing fabrication before powder coating

tap a few extra holes ..... done
clean the rocker cover
ready for reassembly ...
Rally cam goes in, timing set ...
chain tensioner ...
... re assembled
water pump and cover in place
gooey timing pickup ...

brand new exhaust flanges
SLS blocked and sealed off ...

to the alternator
gears, rotor and bearings in place
starter housing on and torqued up....
starter motor goes in, cover on ...
the cleaned bick up
cover sealant
cover on and torqued up
checked valve clearance and covers on ..
Mikuni HSR42 on for test ...
the frames finally came back from the Powder guys.
sub frames
bits and bobs
ready for the big assembly game ...
tool for removing exessive coating
the twats also removed the frame numbers ...
dumnuts, wankers, fu**ing idiots ..
cleaned the bearing seats
in goes the new linkage bearings with makeshift tool
tara ....
grease it up just fine ...
linkage on ... nicely cleaned on the wire wheel
Baja Frame ready ...
ready.., steady ..... go ...!
SMC Engine in Rally Frame
bugger. The extra oil line doesn't clear the frame ...
Duke Engine in Baja Frame
Engines are in ...
Rally Frame ...
Enduro Frame, slight differences in form and width .
Rally Swing arm ...
Linkage got cleaned and re greased
both with Land Rover Lithium Grease
Rally Linkage
Sumo Swingarm bearings re greased
in it goes
not looking to bad ...
Rally Sub Frame
Baja Subframe
first Plastic ...
nice ...
Rally Airbox goes in ...
new rear caliper ...
... goes i the Baja ...
break pedal ....
copper grease to prevent the fusing of steal bolt in aluminium thread

job done ...

cleaning the Rally caliper bracket, cooper grease ...
also a new caliper for the Rally ....
looking good ..
I tried to get a Sumo Axle in the Rally but to no avail
connecting the oil pipes on the Rally ...
...and the Baja....
remove the vac-connector from the Baja ...
and put it on the Rally for the fuelpump
radiators next ... here the Rally
bit of water piping
tank holder and plastic guards
other side..
Chris in Frankfurt had a short DAM exhaust ....
he send it over and it fits perfectly with the new ...
plastics on the Baja ....
Front forks next ///
old oil out ...
yokes, bearings off
new bearing seats in the snapped off bolt
nut on rest of bold
welded on
and no worky ..so file it down
drill it out and tap it ...
new bearing on and packed up with lithium grease
yummy ...
in it goes, top bearing packed and on it goes ...
top yokes on ....
fork legs dismantled
carefully put in the vice.
fork oil ready setting the oil level

and in they go
same for the Baja Forks
Magura Hymec to replace the missing clutch levers
400 quit less than a KTM part ...Ebay Australia ;-)
parts parts parts, need to clear up ....
bit more pipework
what to do regarding the frame numbers
repunch them ?
KTM UK recomended to not repunch them.
steering damper goeas on
bracket for the exhaust needs fabricating
here we go
good ...

side stand goes on the Rally
and on the Baja ....
ceramic sealing string for the exhaust
exhaust completed
Same for the rally
nice and clean

Baja Yokes ...

freezing spray (FRE)
bearing heating plate
and nicely greased up ..
in they go ...
fork legs in .

front brake
cleaning and greasing the moving parts
change the break fluid on my makeshift rig
on they go ...
rear brakes needed bleeding

Baja Radiators go on ..

hose pipes ....
all plubed up nicely ..
New clutch armature ... clutch fluid
Baja Front brakes need a good clean ..
dismanteling
copper rings made soft to be reused ..
all nice and clean ...
bleeding

te missing parts for the Baja Yokes have arrived ...
top yoke off
new covers on
yokes on ... job done ...
oil thermometer to be installed ...
... in the remote oil filter housing

nice fit ...

as if it was meant to go there ...
ready for the first start ...
test run... but what a desaster.
strange noises from the engine ...
Heavy rattling from the front of the engine.
Sounds like main bearing gone ....

lets check the magnet

yuck ...

not looking good after 2 minutes

out comes the engine .....

new plan, the new Head and ignition on the old engine

rockes look good

cam and everything looks fine
Head off the old engine
head off the SMC engine
headless children .....

this is a straight fit
very nice ..
the SMC cylinder is fubar'd too ..
piston too ..
ignition to come off
rotor
the SEM puller fits, good sign ..
rubber gromet nearly gone. That is why the SEM...

was flooded and not working properly

see ...
off it comes ..
the notch on the Rally Crank is in the wrong place ..
after regrooving the rotor everything comes together
head goes on

cam goes in
rotor on
ignition timing set
engine redy to go in .....
 

mid Feb. Time to get the bike running

Rally cockpit
nice and clean
roadbook holder
bit lower than before
rest of the cockpit goes on
looking good
new wiring made from scratch
new ignition plumbed in ...
cap plumbed in ...
new fuse box ...
cooling fan ...
all instruments in place
plastics on
new rear plastic ..
auxillary lights put on
gettin there
tool bag
new exhaust downpipes for spare ...
new road book for spare

so clean ...

came with the bracket



Finally, the Rally is done ...
nice
very nice ...


SMC Engine Main bearings
as thought they were fu**ed
the engine will be put together later ...

new Sumo downpipe for Ebay
SUMO SXC for Ebay


spare swing arms
one from the 1998 Enduro one from a Sumo

Whells go in the Baja
starter freewheel doesn't grip to start
bike on the side
Alternator off


remove the housing
pull the rotor
old freewheel
When I picked up the new freewheel,

I also picked up a new rotor of a '99 SC

Same as the SUMO rotor but ...
with the groove in the right place for the Rally Crank.
Done
new air filter
new sprocket bolt
chain guard

rescue strap

GPS craddle
the coated hubs for the Baja, cleaned
Bearings in