Boring KTM Rebuild Thread

[Maico]

Forged steel IMS from RMATV. They come bare and rust fast, so I had them blasted and plated.

You might also want to look at a set of TUSK aluminum units. My buddy just picked up a set and they are sweet. Price is only a couple bucks over the steel pegs.

Tusk has really gotten aggressive on price and quality lately.

Were the pegs specific to your model or a retro fit from a different model ??

[El Camexican]

Were the pegs specific to your model or a retro fit from a different model ??

They were advertised and being for my bike, but as far as I know all 125 to 525 KTM's take the same pegs from 1998 to 2014 or 15. There are hundreds of aftermarket options that interchange for these years, but TUSK and IMS are the only ones I've installed.

I can take some measurements if you want to see if they'd fit your mounts.

[El Camexican]

Well, we’ll, what fun it’s been in the shop these past few evenings....

I got Mad Max assembled to the point that it could be started and against my better judgement poured in some 4 month old pre-mix and kicked it over. She fired on the second kick and after struggling for a few seconds to push out all the oil I‘d dumped into the cases after the antifreeze fiasco it ran nice and crisp. So it got pushed out of the way to await it’s new cargo rack and rad shrouds.

Piñata Bike was already assembled and waiting for fresh fuel as I didn’t really want to fill the pretty new Lectron with old gas, but I figured if the other bike started, why wouldn’t this one.

Poured in some fuel, kick, kick, kick, kick, think it fired? Kick, kick, kick. God my foot hurts, go get MX boot. Kick, kick, kick, kick, take a brake and curse the carb out. Kick, kick, kick, kick, kick. Stop to rest, sweat is running down my butt crack like a spring brook. kick kick, kick, kick, my knee feels like it’s bleeding internally, kick, kick, kick, kick Stop to remember Billy’s video of him trying to start his Rotax. Kick, kick, kick, kick, kick, WTF!!!!!

Pull the plug, it’s a little wet, but nothing serious, should probably check for spark even though I didn’t touch the wiring and drove it up onto the trailer the last time I used it. Bingo! No spark!!!

Change plug, no spark. Change coil, no spark, change CDI, no spark, change little aluminum thing with two wires, no spark, swap out the stator, spark!!!

Fired on the second kick, but didn’t run until I tried closing the choke. Seems it either doesn’t need choke at 100 degrees, or it’s richer than Bill Gates. Once running with the idle set it feels really crisp, going to take out out on the weekend for a test rip.

[El Camexican]

As always, the best part of any thrash is shuffle playing some Van Halen just loud enough to let the neighbors know that narco corrido accordion sh*t don’t fly in this vato guerros shop and cleaning up the mess.



Time too get ready for....



You guessed it, another boring KTM rebuild.

[bkm]

I need to turn your OCD loose in my garage one weekend.

[El Camexican]

This took boring to a whole new level.

Should have been done 2 weeks ago, but the local shop that had, and I quote ‘all the parts in stock’ ended up having one gasket and one seal only, so RMATV got the call.

Cheesy little unit, cool as all heck, but if you want something that your kid can just add gas to and drive all summer without you needing to pour money into this is not the bike you want. I doubt this has 50 hours on it and it’s on its second set of starter parts at $200 plus labor a pop and the rings are so worn I can turn it over with two fingers. I don’t know if it will even start.

[El Camexican]

I seem to be trapped in a perpetual cycle of rebuilds.

After popping my engine I decided that I may as well swap out what I believe is my tweeted frame for what I hope isn’t a tweaked frame. As well, I have a swing-arm that’s in pretty good shape, so I figured I may as well go the entire 10 yards and swap the engine, frame and swinger all at once.

Here’s the frame In the oven this morning.



And after...



Some years ago I made a personal vow to never polish another swing-arm. I broke that vow today and as much as I like a polished swinger, it bothers me that I could have helped a few hundred old ladies cross the street, or donated blood twice during the time that it took to sand the pits out of this thing.

[fieldy]

That's a large oven.

[El Camexican]

That's a large oven.

They have two ovens side by side running 12 hours a day. The quality is iffy, I always end up with some contaminates in my paint, but the price is right. $150 Pesos, or $8.00 US bucks a frame if I supply the powder, so I don't complain.

[Red Rider]

... it bothers me that I could have helped a few hundred old ladies cross the street, or donated blood twice during the time that it took to sand the pits out of this thing.

The fact that you are refurbishing basketball courts though, should not be overlooked.

[El Camexican]

The fact that you are refurbishing basketball courts though, should not be overlooked.

Took
Me a minute to figure out what you meant. I didn’t recognize what they were when I took the photo.

[ironchop]

The fact that you are refurbishing basketball courts though, should not be overlooked.

Yeah that's what I thought too..... It was very generous of El Camex to donate all that KTM orange for the Mexican Parks and Rec Dept whether he was aware of it beforehand or not

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[El Camexican]

Mad Max is finally done. Some black anodizing on a new rack and Wolfman bag as well as some Mad Max ink.









Piñata Bike is next.

[ironchop]

Nice work! Looks fantastic

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[El Camexican]

Nice work! Looks fantastic

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When are you coming to ride it?