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-- RS500 Build --

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Damon
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Joined: 24 Aug 2007
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PostPosted: 11:34 - 23 Jan 2011    Post subject: -- RS500 Build -- Reply with quote

Hi all,
As some of you may know I have been looking into fitting a big 2 stroke lump into my RS125 frame for some time. I have finally got around to starting the project.

The idea is to fit a KTM500 MX engine into my 2007 RS125 frame. I am going to make a custom subframe to fit a honda rs125 tail unit and make myself an expansion chamber (no choice as the standard wouldnt fit under the panels Rolling Eyes )

Once the engine is running in the ktm frame, I will sell everything I don't need and do the transplant. Should be exciting...

So here's the doner bike,

It looks like it's been dry stored as the amount of rust is nowhere near what I expected from a 25 year old shed of a bike. No furring and only some surface rust. The expansion chamber is in better condition that my 2007 RS Surprised

Here are a couple of pics before any sort of clean up was started. Didn't realise it was covered in lovely magnesium tarty bits Thumbs Up
https://img403.imageshack.us/img403/462/img0626i.jpg

https://img714.imageshack.us/img714/7074/img0627vb.jpg

https://img29.imageshack.us/img29/4264/img0628au.jpg

https://img16.imageshack.us/img16/9879/img0630cz.jpg


Had a bit of a play about and there is plenty of compression + a spark so I whipped off the bing 55 carb for a overhaul. Opened the carb up to find it was in a sorry state. 3 hours later and with the help of carb cleaner, my ultrasonic cleaner and plenty of 1200 grit wet and dry I finally got it resembling a clean carburetor.

Going to check out the cooling system next as it's looking a bit dry. Fingers crossed if it's all good It'll be time to drop the engine and begin the transplant.

https://img543.imageshack.us/img543/7874/img0633jv.jpg

https://img510.imageshack.us/img510/3383/img0634kt.jpg

https://img232.imageshack.us/img232/365/img0635kz.jpg

https://img39.imageshack.us/img39/7629/img0636ds.jpg

https://img211.imageshack.us/img211/5796/img0637t.jpg


Last edited by Damon on 16:12 - 03 Mar 2011; edited 2 times in total
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Damon
World Chat Champion



Joined: 24 Aug 2007
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PostPosted: 11:37 - 23 Jan 2011    Post subject: Reply with quote

Refitted the carb and started flushing out the cooling system. Filled up the rad with 2 ltrs of water to check for any leaks. Only one leak from a cracked hose so thats all good. Took off the water pump cover to find this lurking underneath Surprised

https://img209.imageshack.us/img209/4826/img0657w.jpg

https://img214.imageshack.us/img214/9369/img0658lj.jpg

https://img210.imageshack.us/img210/9055/img0659v.jpg

https://img809.imageshack.us/img809/3623/img0660h.jpg

Not a pretty sight... I will have to split the lump before attempting to start it.
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Tristan.
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Joined: 26 May 2007
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PostPosted: 11:39 - 23 Jan 2011    Post subject: Reply with quote

The engine looks like a childs picture of a bike engine. I like it.
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Damon
World Chat Champion



Joined: 24 Aug 2007
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PostPosted: 11:45 - 23 Jan 2011    Post subject: Reply with quote

So spent the day yesterday getting the lump out of the frame and taken apart for inspection. The top end looks great, there are no scores in the barrel or piston and everything looks fairly clean. Dug a big deeper however and it's a different story. Eveything below the conrod is covered in a thick crud and a mixture of water and oil Shocked

It looks like the water ingress is just from the bike being sat for such a long time. I hope so...

Some snaps,


https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs014.snc6/166430_10150383662035497_784455496_17131000_7696496_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs899.ash1/180767_10150383662490497_784455496_17131007_3151889_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs262.snc6/179046_10150383663015497_784455496_17131021_400132_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs776.ash1/166665_10150383663695497_784455496_17131034_7637644_n.jpg

I was given a gudgeon pin remover by a good friend of mine. Bloody brilliant bit of kit Thumbs Up

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1385.snc4/163725_10150383664495497_784455496_17131062_2914260_n.jpg

The difference between a standard RS125 piston and the ktm piston Shocked

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs242.snc6/179085_10150383665005497_784455496_17131092_1963093_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs248.snc6/179629_10150383665535497_784455496_17131110_2455924_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs003.snc6/165368_10150383666200497_784455496_17131116_6813493_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs254.snc6/180242_10150383667335497_784455496_17131132_2170266_n.jpg

And finally a picture of me being a machine haha

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs077.snc6/168783_10150383667860497_784455496_17131150_647328_n.jpg
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Paxovasa
World Chat Champion



Joined: 25 Apr 2010
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PostPosted: 11:49 - 23 Jan 2011    Post subject: Reply with quote

That water pump Shocked

Steve is coming along nicely. Keep up the good work Wink
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brooky
Brolly Dolly



Joined: 26 Jan 2006
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PostPosted: 12:24 - 23 Jan 2011    Post subject: Reply with quote

This is going to be an awesome project. I look forward to seing updates! Good luck Thumbs Up
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nightshaddow
Nearly there...



Joined: 18 Feb 2008
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PostPosted: 14:22 - 23 Jan 2011    Post subject: Reply with quote

very nice looking forward to more Thumbs Up
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MattJ
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PostPosted: 17:01 - 23 Jan 2011    Post subject: Reply with quote

Looks like it's going to be a good project, but why would you call it Steve? Every time you go for a ride you'll be riding a man. Laughing
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Damon
World Chat Champion



Joined: 24 Aug 2007
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PostPosted: 17:21 - 23 Jan 2011    Post subject: Reply with quote

MattJ wrote:
Looks like it's going to be a good project, but why would you call it Steve? Every time you go for a ride you'll be riding a man. Laughing


Wasn't my idea. Blame Paxovasa Mr. Green
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Tim..
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Joined: 11 Oct 2006
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PostPosted: 17:50 - 23 Jan 2011    Post subject: Reply with quote

Good choice going for a ktm lump in the RS, the chain drive is on the same side Thumbs Up .

Will be following the build.
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Benson_JV
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PostPosted: 17:52 - 23 Jan 2011    Post subject: Reply with quote

Really looking forward to seeing more of this!
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Gazdaman
I did a trackday!!!



Joined: 12 Aug 2004
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PostPosted: 18:21 - 23 Jan 2011    Post subject: Reply with quote

Amazing project, what's it like trying to get parts for that KTM lump? Detailed write up would be great, I've always wanted to do this project, although I was planning an older RS125, and potentially a CR500 engine.

Gaz
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woll
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PostPosted: 18:32 - 23 Jan 2011    Post subject: Reply with quote

What's that in the water pump? Limescale?
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Mystery
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PostPosted: 19:11 - 23 Jan 2011    Post subject: Reply with quote

looks like a good project Very Happy
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Damon
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Joined: 24 Aug 2007
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PostPosted: 19:44 - 23 Jan 2011    Post subject: Reply with quote

It's been a nightmare getting parts for the KTM if i'm honest. All my local KTM dealers only stock parts from the year 1994 onwards Rolling Eyes

I have had to use Ebay international for any parts so it gets expensive very quickly. In hindsight I should have probably gone for an old cr500 engine. Thing is with the RS is that the chain is on the wrong side and big engines with a RHS drive tend to be very old, expensive and like hens teeth Rolling Eyes

I'm not too sure what it was in the waterpump, limescale possible or some type of magnesium rust. All I know is that it was a pain to clean.

Todays update in 2 secs Thumbs Up
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CHR15
Turbo nutter bastard



Joined: 14 Jun 2008
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PostPosted: 19:46 - 23 Jan 2011    Post subject: Reply with quote

Quote:
What's that in the water pump? Limescale?


*singing voice*

ktm's live longer with calgon.



looks good anyway Thumbs Up
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N cee thirty This post is not being displayed because the poster is banned. Unhide this post / all posts.

Damon
World Chat Champion



Joined: 24 Aug 2007
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PostPosted: 20:15 - 23 Jan 2011    Post subject: Reply with quote

Update:

Spent most of the day cleaning and generally fixing the small bits. The clutch plates had formed a completely solid lump in the basket. It took hours worth of seperating and cleaning to get them slightly cleaner. Ideally I would like replacement friction plates but cannot find any. Does anyone have a CR250/450/500 clutch plate they can measure up for me?

I have a friend popping over tomorrow with a flywheel puller so I will pop that off and split the cases to expose the bottom end. All being well I will clean it up and start putting everything back together again.

On a side note I have bought a zinc plating kit so I can clean up and plate all the bolts on the engine. It should really tidy up the whole thing.

A couple of pics of the messy progress today...



https://img141.imageshack.us/img141/4482/img0688f.jpg

https://img257.imageshack.us/img257/7580/img0689so.jpg

https://img94.imageshack.us/img94/2180/img0690v.jpg

https://img545.imageshack.us/img545/3012/img0691o.jpg

https://img832.imageshack.us/img832/2553/img0692mm.jpg

After

https://img204.imageshack.us/img204/4650/img0696fr.jpg

https://img217.imageshack.us/img217/8052/img0695u.jpg

https://img37.imageshack.us/img37/720/img0694x.jpg
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Blackwolf
Burgerfist



Joined: 19 Nov 2006
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PostPosted: 20:27 - 24 Jan 2011    Post subject: Reply with quote

M O A R pictures... Mr. Green
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Damon
World Chat Champion



Joined: 24 Aug 2007
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PostPosted: 22:36 - 24 Jan 2011    Post subject: Reply with quote

Update:

So spent most of this evening working on the engine. Just getting the boring jobs done whilst I wait for the flywheel puller to arrive (had to go out today so my friend couldn't come round).

Have been talking to EBC and trying to sort out a set of clutch friction plates, cue lots of sending over silly little measurements Mr. Green They have been helpful so far though, so big Thumbs Up to EBC. Does anyone know if the standard plates are sintered or organic? I can't tell as the plates that came out are in a terrible condition. I've had to brush up on my German as the only place I found a gasket set was Germany. So after a couple of emails in broken german secured me a nice set. All for 50 euros posted which is great. Thumbs Up

Also bought some chemical metal and started repairing the Mag clutch cover. I got a wire wheel into the areas with the most damage and brought it back to metal. It then went straight in the dishwasher for some finish powerball cleaning...

Once dry I skimmed the areas with the chemical metal and left to harden. I will smooth everything off tomorrow Thumbs Up

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs061.snc6/167195_10150385390640497_784455496_17166306_7506783_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs079.snc6/168968_10150385390805497_784455496_17166310_7393825_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs057.snc6/168700_10150385390985497_784455496_17166315_6203184_n.jpg

Check up the thread of what the inside of the cover used to look like Shocked

As you can see the water pump housing has a piece missing from the top. I am going to make an ali squish plate to seal the gap up when the front of the cover is bolted on. This is the progress I've made so far..

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs254.snc6/180238_10150385391140497_784455496_17166321_2148085_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs785.ash1/167570_10150385391305497_784455496_17166324_2925889_n.jpg

I also started cleaning up the top end with the wire wheel. It just makes me feel a bit better now the cylinder is nice and clean. Mr. Green

A couple of snaps

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs061.snc6/167133_10150385391475497_784455496_17166329_32266_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs766.ash1/165773_10150385391565497_784455496_17166331_3802412_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs040.snc6/167092_10150385391755497_784455496_17166337_6760826_n.jpg

I will clean up the crankcases once I have them apart.

And finally I faced each of the mating surfaced on all the covers, cylinder head and cylinder. I used a sheet of glass and some valve lapping compound I had laying about to good effect. Eveything is all going to plan.

https://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs778.ash1/166890_10150385391890497_784455496_17166343_6721614_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs020.snc6/167065_10150385392100497_784455496_17166349_2629060_n.jpg

Now to find some bearings...
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Blackwolf
Burgerfist



Joined: 19 Nov 2006
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PostPosted: 00:43 - 25 Jan 2011    Post subject: Reply with quote

I asked M O A R. I got M O A R.



So again... M O A R!

Please. Mr. Green
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MarkJ
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PostPosted: 09:54 - 25 Jan 2011    Post subject: Reply with quote

https://www.threadbombing.com/data/media/52/Kyle_Moar.jpg
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Wozza
Brolly Dolly



Joined: 17 May 2008
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PostPosted: 11:24 - 25 Jan 2011    Post subject: Reply with quote

Thumbs Up Like

Will insurance be much of an issue?
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P.
Red Rocket



Joined: 14 Feb 2008
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PostPosted: 16:39 - 25 Jan 2011    Post subject: Reply with quote

Wozza wrote:
Thumbs Up Like

Will insurance be much of an issue?


Like you'd tell them Laughing Put some L's on it and really piss those cagers off Laughing
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69.9mph
Crazy Courier



Joined: 20 May 2006
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PostPosted: 18:00 - 25 Jan 2011    Post subject: Reply with quote

Damon wrote:


Should have put some cloth over the crank while you did that, grinding paste is bad news for big end and main bearings.

I got a severe bollocking when I did a similar thing as an apprentice and never forgotten it.

Project is looking good though.
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