New project

[Trekker3]

Looks amazing, will look ace when it’s built up.

 

[rocky burns]

Not been on here for a while as busy with other things.

Front wheel vapour blasted and I have rebuilt it today with stainless spokes





Polished up the rim while it was off. Looks pretty good now.




Always worth checking bearings when a bike has been stood.
As you can see, These were perfect

 

[Mad Hatter]

Not been on here for a while as busy with other things.

Front wheel vapour blasted and I have rebuilt it today with stainless spokes





Polished up the rim while it was off. Looks pretty good now.




Always worth checking bearings when a bike has been stood.
As you can see, These were perfect

Very impressed with your workmanship

 

[rocky burns]

Very impressed with your workmanship

Thank you

 

[rocky burns]

Couple more bits done.

Was looking at motorworks at a wheel bearing set for the front wheel. Then a quick Google with the bearing and seal sizes got me them for just under half the price




The heads have been away and professionally honed with a dimond cutting machine and returned to me with a report that the nicasil coating is still spot on.
The barrels have been vapour blasted also so just waiting on rings now.

Fitted the new stainless pushrod tubes and seals ready.








New rear main seals have been done and also the oil pump seal. No wear in the oil pump itself and all in tolerance to the tight side if anything, so may have been changed at some point. Had some very fine lines on the cover but nothing I am worried about.






Flywheel refitted with new bolts so atleast I can mess around with the front cover again knowing the crank is sat tight




Anyway.... Off to Morocco to ride the bike instead the morning for a couple of weeks.. Can't wait

 

[peepingtom]

that's some fancy pants ktm what is it.? an actual 450 rally ?? it looks like it will be more than a bimble

 

[rocky burns]

that's some fancy pants ktm what is it.? an actual 450 rally ?? it looks like it will be more than a bimble

Yes 450 factory rally.
Did a perfect job






Back now though so can crack on with the build

 

[Micky]

You're doing a great job there Rocky

Thanks for posting up, so far, your progress .... now waiting for follow up instalments

 

[rocky burns]

Managed to get back on it today for a couple of hours
Someone had fitted a deep sump which was a bit battered but I want this bike standard so found the original shallow sump. The oil sive was now too deep so managed to get a shallow one from Mikeyboy as a freebie
That sorted and sump back on.



New 4 piece Sasch clutch pack fitted and had to make another tool to centralise it







Starter motor fitted, front engine casing on and all the electrical bits back together.

 

[rocky burns]

Cleared the ramp after lunch and set the bike up on it so it's at an easier height to work on.



Engine back in the frame then new piston rings fitted and ground the valves in.
Another hour this evening and got the right hand side back together and all torqued to spec..
Work tomorrow.....BooooHoooo

 

[Mad Hatter]

Cleared the ramp after lunch and set the bike up on it so it's at an easier height to work on.



Engine back in the frame then new piston rings fitted and ground the valves in.
Another hour this evening and got the right hand side back together and all torqued to spec..
Work tomorrow.....BooooHoooo

Got to love these bikes, they are so nice to work on, like the ultimate mecano set.

 

[Barnoe]

looks the mutts nuts

 

[rocky burns]

Got a fair bit done the last few evenings and at the stage now where I just want to see it finished
Got the engine back together and ready to go.
Front exhausts on.






Gearbox in and air box refitted, carbs on, swing arm fitted, crash bars on.
All cables refitted.

 

[rocky burns]

Rebuilt the front caliper and back Blead the front brake with a syringe.





Just got to check all the bolts on the front end once again and that's done. So I can forget about it.





Will crack on and get the final drive seals done tomorrow so I can get the rear end back together.
Got the seat cover to fit.
Rear lights to finish connecting up..




Noticed on the way out of he garage this evening that I had made a balls up and forgotten to connect the t piece and pipe which goes under the airbox
That off again tomorrow to sort it. Only a small job

 

[mikeyboy]

Looking like a really nice restoration.
Keeper or move on at some point?

 

[rocky burns]

Looking like a really nice restoration.
Keeper or move on at some point?

Keeper for a while I think

 

[rocky burns]

Just waiting on sticker kit, oil in the gearbox and final drive.
It starts and runs but just got to check the timing and ballance the carbs...

 

[tuftywhite]

That looks like you've done a superb job. I hope you're proud of yourself.

 

[rocky burns]

That looks like you've done a superb job. I hope you're proud of yourself.

First one of these I've done so a bit of a learning curve. Pleased with the results though. Cheers

 

[Richie N]

Cracking looking bike