[dennis da menaceMember]

mate, i got that bottle of loctite from my dad about 14 years ago :laugh: :laugh:

i wasnt going to drink it so i never looked for a use by date :laugh: :laugh: :laugh:

no i havent fitted it yet, i might do it tonight if i cant sleep, or tommorrow at Mals place

[dennis da menaceMember]

micknmeld wrote:

Quote:

That makes three of us poor non believers. The local dealer for those wrist bands here, wore one playing 1st grade soccer the other day and guess who now has a broken arm. :laugh:

im with you lot too.

hope is for suckers and zealots :laugh: :laugh:

and i aint either….

but as they say, theres one born every day :laugh: :laugh:

[dennis da menaceMember]

EAGLE`02 wrote:

Quote:

:laugh: HIGH SCHMIGH
I`ve been there & seen that Dog on Lino clay, it is more the case of the torrents that have already fallen on it the past 3 weeks that will have us slippin` & slidin` :woohoo:

Those pine singles are so dark in there it probably “never” dries out

Oh yeah I nearly forgot,,,,

4 :laugh:

eags, that post made my loins stir :huh:

its gonna be wicked. :woohoo: :woohoo:

[dennis da menaceMember]

pauly.

welcome.

you ride a 300.

its orange.

your have a 640 supa tard

its also orange.

are you a living deciple my Kato brother :laugh: :laugh: :laugh:

so mate…

how do you ride?, as in what grade would you call yourself. we have all grades of riders on here that we try to cater for.
around melbourne, we generally do level 2-3-4 stuff, depending on the place, distance and weather and shit
no one cares how good you are anyway, as long as everyone is smiling at the end of the ride, while sloshing a beer and crapping on about each others death defying feats, then it was a good day :laugh: :laugh:

after all, its all about the ride and the roost isnt it

its that simple

when d’ya wanna go chuck some mud, theres plenty around :laugh: :laugh:

[dennis da menaceMember]

you bring the beer Mick, I’ll be the pot…..

and we will laugh like crazed hyena’s at this big black kettle.. :laugh:

i dunno how Katgirl didnt bear a child immaculately just by being in the presence of the worlds 2nd most sexyest man, TB..
get a look at his sunday best’s :laugh: :laugh: :laugh:

he is only beaten by Fabio himself and everyone knows, 2nd is the first loser :laugh: :laugh: :laugh:

and this bloody chestnut…

neck cleavage really floats my boat :laugh: :laugh: :laugh: :laugh:

:laugh: :laugh: :laugh:

me and mick know we are dead sexy, :dry: :laugh:

you just keep chasing that dream big guy :laugh: :laugh: :laugh: :laugh:

[dennis da menaceMember]

micknmeld wrote:

Quote:

menace wrote:

Quote:

awesome spot for a house mick.

:laugh:

Yeah, I have thought that for 20 years. Couple of those Blackbutts have gotta go, to make the most of the view. That is looking due north in those pics. Can just picture myself sitting there on the verandah in the sun taking in the view.

i can picture me sitting next to you drinking your beer :laugh: :laugh: :laugh:

[dennis da menaceMember]

awesome spot for a house mick.

happy fathers day :laugh:

[dennis da menaceMember]

Boony wrote:

Quote:

The berry patch will have top fuel for us at the saturday lunch break.

if this causes you any inconvieniance,,call me a gaylord!!!.

😆

Boony

well ok then gaylord, :laugh:

what about 2 stroke? will they have that ready at 50:1 or will i need to bring something to measure my fuel….and some motul 800.

well gaylord, well???????

the mighty 300 is ready to go,
although i have a package awaiting collection at the PO…

could it be my damper??? oh, i hope so :laugh:

i welded up the jerry holder and a spare wheel bracket on the trailer…

are we going for a blat friday arvo Boon unit?
i want to run my bike in a little before the hills…..

unless i can con Mal into a blat around his fully sick paddock track

[dennis da menaceMember]

Tb told me about these…

http://www.vincestrangmotorcycles.com.au/dr.html

thats what i’d probably go, if i was going and the deal was still on.

bloody good value i reckon

[dennis da menaceMember]

KTM Bull wrote:

Quote:

Ring end gap is easy 4thou per inch of bore for soft riders
6 thou per inch of bore for some one that revs the motor hard or supercharge/turbo

to check piston to bore clearance i heat the piston in a pot of oil starting at room temp and go up in 10 deg incremt till piston wont go down the bore you want to do this fast as you want to keep the bore at room temp

what you are finding out is what sort of a temp increse you can get before it nips in the bore if you cant get to 80deg it will fail in short time

you can measure with dial bore gauge etc but wont take in to account the different expansion rates

gooday Bull, long time no chat.

that kinda makes sense. the 300 bore is 72mm, so nearly 3 inch and the specified ring gap is .3-.4mm (12-16 thou)

for soft riders like me anyway :laugh: :laugh:

your not just a pretty face Bill

buggered if im gonna go putting the piston in the deep fryer either…

i’ll just warm it up good mate :laugh: :laugh:

[dennis da menaceMember]

it wasnt really gunked up, just a layer of crap like plaque that chipped off.

i dont think i really needed to clean it, it was a learning exersize more so.

but yes mate, its always motul 800.

[dennis da menaceMember]

axel wrote:

Quote:

Good job menace thanks for the write up and pics.
So you cleaned up the powervalve too after 100hrs eh. Do you think it needed it?
That ring wear is quite good. I wonder what gap those blokes running 200hrs get to?? :ohmy:
Did you end up putting in the bigger piston from ktm?
I have to hit up suttos for a kit too soon. I keep holding off to sell the girl but there’s not enough genuine interest. Did you Know that boltons sell 1 ring, not pairs off their website? What the??

the powervalve was the dirtiest part of the whole lot. cooked on carbon and oil residue. if i had a wire brush for the grinder it would have taken about 5 minutes. it was more the contact surfaces on the PV flap shaft that i wanted clean, the rest is a bonus.

those blokes running 200hrs probably have 6 different ring gaps. that long on rings is looking for trouble. :angry:

yes i did put the group 2 piston in. it was pretty perfect to spec too.

Mal at sutto’s is the man Axel, he will look after you

Boltons probably sell single rings because the SX model only runs a single ring piston

i fixed my triple clamp too. mr big rubber hammer did a good job :laugh: :laugh:

still gonna replace the top one though when my damper arrives.

[dennis da menaceMember]

forkage sorted….

big rubber hammer fixed him up :laugh: :laugh:

bring on nundle :woohoo: :woohoo: :woohoo:

[dennis da menaceMember]

The differences include:

625 – no counter balancer
640 – counterbalanced engine

625 – MX gas tank
640 – larger tank (I have both tanks.)

625 – Wired for street legal, but not so.
640 – All the EPA crap & street legal.

625 – Enduro exhaust can.
640 – Portly super quiet and hot can.

The way I see it is that there are no new 640 Dualsport bikes being imported into the US. The 625 is a compromise which allows us to do the bare minimum legalizing needed to get plates. Something KTM cannot do theirselves. Once you add all the street legal stuff to the 625, and remove all the extra crap from the 640, you have about the same bike. Of course the 640 will still weigh a bit more as it has the counter balancer + a couple other things the 625 does not have. I spent some additional $$ changing the exhaust can, getting a Duke gas tank, bash plate and side stand. The charcoal canister just vanished one night – mystery.

For real tight woods the 640 will always be a handful. But for groomed trails, fire roads, and rough blacktop roads the 640 is a BLAST. Ear to ear grins. The darn bike was even fun at Moab

from
http://www.dualsportmagazine.com/Moab2003.html

[dennis da menaceMember]

Billt came over and gave me a hand to put her all back together.

i pulled the carby down this morning and cleaned her out and checked the float level which was ok. it was pretty clean in there. its a bit of a bitch getting the carb in and out.

i started by pulling out the power valve flap assembly. it looks a lot worse than it is and is pretty simple really to nut out. it pays to take note of where the lugs for the exhast springs go and also where the PV gears sit when it is fully open. i just took pictures to remember like this.

the little TORX bolts that hold on the PV backing plates are as tight as a waterhound arse. i managed to get 3 of the 4 out ok but started to strip the 4th with my crappy torx set. Bill brought his one over and with a skoll of whiskey and a quick prayer to lord Kato it gave up and finally snapped loose ill need to get another one monday to replace it.

i lightly scotchbrited the bore and washed the whole thing in warm soapy water to get any crap out of the bore and blew it dry.
heres the barrel all cleaned up and ready to go

bill did an awesome job of cleaning the PV flap. it was like new, thanks mate.

ready for another 100 hrs…

with a bit of clean 2 stroke oil slopped around i put the PV back together and siliconed the cover back on. got all the gaskets sorted and popped the head gaskets/o-rings in… ready to go!

one thing i really hate is putting wrist pin clips in. it is a bit of a pain of a job and can go really wrong without care. it shits me that i know how to do it but i dont do it enough to be good at it :laugh: :laugh:
i made ip a little device with a sharpened screwdriver and with a little swearing and coaxing got the first one in :laugh: Bill gave me a hand and put the new wrist bearing in. next jiggled the new slug into place. i should have taken a photo of the new piston ready but i was excited :laugh: :laugh:
i fought with the second pin, eventually gaining the upper hand and muscled it into place. we put the clip openings at 6 oclock. i hope its right :dry:

we oiled up the bore a bit and slipped the barrel over. it was a little fiddly holding everything and trying to check the rings were right as we slid it on. thanks again bill, your surgeons hand were a godsend 😆
i just guessed the base gasket as the old one felt the same as the thickest of the new ones anyway. with it torqued down the piston is dead flush with the deck which is perfect.

i should point out the tolerance differences too..

the old rings had a gap of 1.1mm at 20mm down the bore. they were pretty rooted as to be expected.
the recommended is 0.3 to 0.4
the new ones had 0.26 each and with a light draw filing i got them to a tight 0.3, perfect.

the piston/bore clearance is to be from 0.06mm to 0.1mm.
the old slug was about 0.12 at 20mm down the bore. so was just out of line but would still be good for another 30-40 hrs i reckon. i didnt check the skirts.

the new slug is a ‘tight’ 0.06…
as in the feeler guage was a little firm in there but ok.

perfect

there is no movement in the bottom end either, its all good.

here is the new shiney new slug installed and shining. :laugh:

we put her in gear and the piston slipped up and down as smooth as silk.
as i said, deck height was good so we bolted the head on and torqued it down.

then it was just the top mount, the PV covers, a new sparky, hoses and coolant…thanks AGAIN Bill, i had none and supercheap had just closed. Bill to the rescue :laugh: :laugh: :laugh: :laugh:

head on, hoses on, cover to go on.

the new exhaust flange o-rings are different to the factory ones as in the originals are a square o-ring and the new ones are thicker and rounder. probably because its a known fault that they chew out flanges…
i had a bitch of a time getting them to go in and the outer one shat itself. i used some heat proof silicon as well and it was a snug fit with just one. it should be right.
i did also notice that my expansion chamber has cracked its outer skin near the header end. its not right through. it looks like it had a hit and i suspect its because of my Hyde bashplate bolting directly to the exhaust and not the frame.
i might save up for a new whipps one. they look like the go maybe.

anyway we bolted her all back together and cracked the carb bown to get some fuel down.
i got on and gave her a few full throttle rolls through the kicker to prime it, pulled the choke and second kick she idled into life

i was a happy camper. we checked coolant and let her idle up to temp with a few high fives and woo-hoos’s.
she purrs again
i think Billy was as excited as i was :laugh: :woohoo:

i was quite suprised with the new compression on the kicker too, its heaps higher.
choppa has a comp tester so i will drop in and see him tomorrow and test it so i have a benchmark reading for the future.

when it got to temp i shut it off to cool down to cold again.
i will go out now and start her for another heat cycle before i start pulling the forks off and she will be ready to ride tomorrow.
i might even go hit some marginal roads on my own to prep her for nundle.

half a tank of tentativeness and its band time :woohoo:

see dudes, if i can do it anyone can

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