KTM 504 rebuild

[stanbloke]

Well i finally got a bit of time to start on this bike.

The main problem was the flat refusal to start !, despite me kicking for all i was worth ,so starting with the engine, a service and general check over........ Done !

The wiring on inspection was horrendous to say the least, i attacked it with my trusty plastic butty box full of connectors, tape, fuses and other odds and sods that you sort of accumulate over the years. Wires cut back and re-connected, sprayed with silicon grease and taped took a good couple of hours to achieve but soooo satisfying when it was finished.

Next up was the Carburettor, a Monster Dellorto fitted with an accelerator pump, stripped only to find the usual "Varnish" (old petrol that has evaporated) copious amouts of carb cleaner and a toothbrush made it look a whole lot better .

From what i learned from researching on the net, Technique is the key to consistent starting of these big singles that are fitted with carbs that are big enough to drive a truck through , kick....fiddle...kick,kick...fiddle...swear...kick ...swear alot....kick...KABOOM!!!, and the bloomin air filter set on Fire ..ever tried to pull out an air filter when it's burning...singed fingers...Ouch!! .

Well at least i knew that the time spent sorting out the wiring had paid off with a big fat spark .

A couple of "Desperate Dan "style kicks....and ....ROOOOARRRRRRR....away she went...with huge amounts of Fuel being sucked into the Massive Dellorto card and the intakes trying to keep up by creating a vacumm consistent with a Dyson on steroids....the engine sat burbling away through the SuperTrapp exhaust......



Chuffed to bits is a bit of an understatement...but I am !!.

Now it's running ok and starting 2nd or 3rd kick, I can take it all apart for a re-furb and re-paint.......Cant wait !!!.

[Buggles]

Great stuff Stan!

So you'll be riding this one on the Longest Day?



JB

[Mudwiz]

Nice one mate!

A perfect toy!!

.

[AIRWOLF]

Nice work Stan

Take care there's no kid's or small animal's near that uncovered intake when you kick it up, . . . they may never be seen again.

[stanbloke]

Nice work Stan

Take care there's no kid's or small animal's near that uncovered intake when you kick it up, . . . they may never be seen again.

Cheers .

The main problem seems to be the Dell'orto carb, magic when they work, complete PITA when they dont......so .

A quick call to Mikuni and a new VM32 is on the way.. The guy said they sell loads of these for the Rotax motor, throw the Amals and Dell'ortos in the bin, fit the VM32 (already jetted...nice ) and it should fire 2nd kick.

Lookin forward to this arriving...my bloomin leg looks like Arnie's..bugger..

[stanbloke]

Some bits arrived via fleabay...

I just need someone to make a new steering stem..

[phil w]

This taking sooooooooooooo long come on Stan need to see this beasty running

[stanbloke]

This taking sooooooooooooo long come on Stan need to see this beasty running

It's gonna be a while yet Phil. I've got some stuff to fit to this bike 1st..

[stanbloke]

A bit of progress at last !!. .

New front end is now fitted with new bearings, Marzocchi 50mm forks, Brembo Master Cyl and twin pot caliper.

I found a 22L Acerbis tank that will fit ( with some new brackets to be made)as the std 12L would be a bit small for a decent day out.

Will start on the back of the bike and make a new loom, as the present wiring has been butchered..

Just got to decide on the black / Orange colors or the std White / Orange..

[digitalcaptive]

That front end is looking "the real mcoy" and I reckon Orange but then I am biased