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View Full Version : The $1500 jigsaw puzzle: Or the only way I can afford a KTM


poser
12-11-2010, 09:18 AM
Background:
I've had a bad case of the "orange crush" ever since the dirt bug bit me. Unfortunately my budget did not agree. I ended up buying an older broke down XR400, and bringing it back to life. Rode it and LOVED it, such a great bike. Thought it would be what I needed for riding woods and stuff. After a few trips to SHNF, I started thinking lighter/smaller might be good. That was even further spurred on when i rode with a group of guys, one having a Honda CRF250X, and he was FAST [and bigger than me]. I was definiately thinking 250 range at that point. What finally sealed the deal for me was a trip to a MX park, Southwest MX park in Needville (http://www.twtex.com/forums/showthread.php?t=44292&highlight=needville). It was my firt time on an MX track, and I was rock'n the XR like I didn't know any better [got a few funny looks :lol2:]. It was then and I found I really like jumping, and the XR didn't like it as much as I did. So the wheels start turning and I'm trying to figure out how to turn my XR into a modern 250.
I came across a comment on TON in a thread of someone else looking for a project bike, of this dude selling the KTM. So I sent him a message asking if he was interested in selling. Long story short, I sold the XR, and took that cash down to Victoria and picked up the KTM. That was over a year ago :doh:

A few details about the bike:
I'm the third owner, firt owner had it for about a year, older dude and just trail rode it. The guy I bought it from had just come off a bad crash on a CRF450, and decided something less powerful would be more safe. He bought the KTM from the dude in Lubbock IIRC, and dropped it off in the DFW area at a racing suspension outfit called Donnie Elmer. He spent about $1200 getting it resprung and valved front and rear for a guy is his size. As luck would have it, this guy was my size! :thumb:
I takes it home, rides it for a while and loves it. As he tells it, he had just come off a jump and was down shifting and the shifter felt like it was sticking so he crammed it down as hard as he could and then just rolled. Pulled it apart and found a broken gear in the transmission. There it say, opened up for over a year, and he lost interest. Said he was going back to racing cars on dirt.
Everything was laid out nice and neat, and grouped together. So when i arrived, we looked evreything over and loaded all the motor parts [completely disassembled] into boxes. Things like the clutch parts were all bagged together in a zip-lock, as well as the cam stuff. All the bolts were in their holes where possible. So I felt pretty good.

Fast forward to now, I've had it just over a year, and finally motivated to get it going. I had a few 4wheeler project I wanted to get done first [Suzuki LTZ400 sport quad (http://www.twtex.com/forums/showthread.php?t=48530), and the beast (http://www.twtex.com/forums/showthread.php?t=43877)]. Then it was too hot to spend any amount of time in the garage. So now I'm iching to ride it, and tired of getting made fun of :lol2:.

Its going together nicely. So far I have the transmission back together [bought a complete one off ebay instead of just replacing the one gear, figured it was easier], shift forks and all that back in, and the cases are back together. A few other items are back in. I had to order a lock washer for the clutch basket nut, so I stopped the other night. I'm going to keep going and put the top end back on this weekend and stuff. My hope it to get to together and running sometime this next week.

Stay tuned......

A few teaser pics.
More pics to come...

sorry for the lame cell phone pics

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/IMG00391/1122336478_ZNvM7-M.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/IMG00392/1122336284_Z7W8Y-M.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/IMG00396/1122336069_czd5V-M.jpg
and yes I am that much of a poser that I put stickers on a bike before it is running :lol2:

gixxerjasen
12-11-2010, 09:48 AM
1. The days of blaming your cell phone for your crappy photography skills are just about over. 5MP camera in my phone. :mrgreen:
2. That is a heck of a jigsaw puzzle. You could have afforded an older already assembled KTM, but that one will go pretty darn nice once you get it up and running.
3. Since you chose an appropriate name, you don't need to defend your posership every single time.

DFW_Warrior
12-11-2010, 09:52 AM
1. The days of blaming your cell phone for your crappy photography skills are just about over. 5MP camera in my phone. :mrgreen:

One would think.... Heck I have an 8mp camera on my Evo and my 5 year old Canon point and shoot outdoes it with every photo.

Good luck Jason! It's going to be a sweet running bike once all is said and done. Oh yeah, what was wrong with it in the first place?

poser
12-11-2010, 09:55 AM
PO [the second owner] broke a gear in the transmission. I bought a complete tranny off ebay not long after picking the bike up.

Oh and I think its more about the lense than MP at this point. Unless lighting is perfect, my BB takes pics like these

gixxerjasen
12-11-2010, 10:33 AM
Oh yea, a DSLR will outdo an camera phone, but the current crop of cameras in phones are pretty sweet, and will take some nice photos. I'm just saying that the excuse of camera phones for crappy photos is going out the window. :mrgreen:

focus frenzy
12-11-2010, 10:50 AM
I bought a complete tranny off ebay.

I didn't know you could get them there???

http://img.photobucket.com/albums/v692/fantom_51/transvestite.jpg
:lol2::rofl::lol2::rofl::lol2:

Door4mat
12-11-2010, 11:08 AM
I didn't know you could get them there???

http://img.photobucket.com/albums/v692/fantom_51/transvestite.jpg
:lol2::rofl::lol2::rofl::lol2:

That one looks like it's been used quite a bit, might want to return it.

Texas T
12-11-2010, 11:27 AM
I didn't know you could get them there???

Oh? You've been looking for love in all the wrong places? :rofl:

poser
12-11-2010, 01:54 PM
updated first post to help get it back on track :rofl:

gixxerjasen
12-11-2010, 02:24 PM
I forget where we were going....ktm's, cameras or tranny's?

poser
12-11-2010, 04:33 PM
I forget where we were going....ktm's, cameras or tranny's?

KTM's :mrgreen:

focus frenzy
12-11-2010, 05:23 PM
KTM trannys I thought?

oh by the way, Don't google image search "KTM tranny" with the safe search turned off!!! :brainsnap:puke:

Sleepy Weasel
12-11-2010, 09:50 PM
So now I'm iching to ride it, and tired of getting made fun of :lol2:.

Don't worry, we'll still make fun of you once you ride it.
:mrgreen:

poser
12-15-2010, 01:25 AM
Made some good progress tonight.
Just about have the bottom end finished, all I lack is the clutch, torque down the flywheel, stator cover and shifter and stuff.
Got the top end all together, and hopefully the cams in correct.
I should be able to throw it in the frame the next time I work on it.
I'm too tired to post any pics

poser
12-17-2010, 09:55 AM
was putting on some of the last pieces last night, and then nearly made myself cry when I broke the inner clutch hub.
All thats left is the clutch, front sprocket, rear brake lever, and shifter.

Haven't really posted any pics because our laptop got pushed off the table and the old computer takes FOREVER to get pics off the camera and upload them. Soon I'll have pics

ed29
12-17-2010, 11:18 AM
Sorry to hear the mis-hap. Sometimes those five bolt hubs only fit one way. Be sure you can seat it by hand before putting the springs and bolts on. Five ways to line it up, four of them are wrong. Not always, not certain yours is that way, but have seen and worked on one that was.

poser
01-10-2011, 11:02 PM
Update:
Everything is together, well pretty much.
As I was trying to bleed the hydrolic clutch, I discovered a problem with the clutch slave cylinder. There was a little scouring inside, preventing the piston from moving in and out smoothly, and sticking possibly preventing the clutch from disengaging.
As it turns out this is fairly common, as in looking at the replacment part you get referenced to a new part number. i guess KTM figured it out and sourced a better unit. I found a few guys on KTM talk with the same issue. I can see how this problem would cause a situation for the previous owner to break the gear in the mannor he did.

That being said, I'm still waiting on that, but everything else is ready. I even dropped some gas in it to see it I could get it to start.
Choked it, kicked thru the stroke a few times, and it kicked over in just a few kicks!!!!
I was so excited I started helling and screaming :lol2: It sounds soooo good, especially considering how long its been in the garage, and me day dreaming about it :lol2:

Here's a few pics, and I'm going to try and throw together a little slide show of the motor coming together

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1109/1153344227_JLXSU-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1123/1153345326_f2Urt-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1137/1153346223_Mo4nD-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1144/1153347129_67iEv-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1108/1153343199_zQeg8-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1146/1153348159_2Mcu6-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1151/1153349108_ECE25-L.jpg

gixxerjasen
01-11-2011, 07:26 AM
Very nice. You are going to love that thing. On the other hand, those of us with really old KTM's know that you won't have that problem with a cable clutch. :mrgreen:

poser
01-20-2011, 10:24 PM
well she's finally finshed 100% :dude:
There were a few set backs, but she's ready to go. I'm going to take her out on a short "shake down" ride at a place close to the house this weekend, and then to the forest Feb 19.

Stay tuned for pics of the finished product :thumb:

gixxerjasen
01-20-2011, 11:33 PM
Nice, can't wait.

owtcast
01-21-2011, 12:15 AM
:thumb:Great job Jason.

poser
01-22-2011, 05:37 PM
shake down ride went great. let me tell you that thing is a beast for a 250. it really surprised and scared me a few times. Oh and it likes to wheelie :thumb:

First real world ride will be next month, Feb 19th, in the forest, everyone is welcome.
I'll post pics later tonight

poser
01-22-2011, 10:21 PM
Here's a few pics of the finished product, hope you guys like it :thumb:

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0994/1164905559_onyJW-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164905559_onyJW-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0995/1164906547_ckFrt-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164906547_ckFrt-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0996/1164907584_tmhnk-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164907584_tmhnk-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0997/1164908579_EDCWC-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164908579_EDCWC-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0998/1164909469_GNcfC-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164909469_GNcfC-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0999/1164893789_xdxL9-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164893789_xdxL9-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1000/1164894901_zSer4-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164894901_zSer4-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1001/1164895877_4rQzh-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164895877_4rQzh-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC1002/1164896400_bT76D-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164896400_bT76D-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0984/1164898734_b2Hdv-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164898734_b2Hdv-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0987/1164900920_u7Ya7-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164900920_u7Ya7-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0988/1164901578_e5hek-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164901578_e5hek-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0989/1164902076_LK5Tz-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164902076_LK5Tz-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0990/1164902510_qZvR5-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164902510_qZvR5-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0993/1164904736_kRYLK-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164904736_kRYLK-A-LB)

You know it was a fun ride if the bike looks like this afterwards :eek2:, hey they don't call it a DIRT bike for nuth'n :lol2:

oh and don't judge my bucket stand :rofl:

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030511/1164923574_RMcMH-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164923574_RMcMH-A-LB)

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030514/1164922839_XGkwH-L.jpg (http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/10903001_jvHWw#1164922839_XGkwH-A-LB)

poser
01-22-2011, 10:23 PM
still a few things on the wish list:
bark busters
skid plate
kick stand [maybe]
bar risers

gixxerjasen
01-22-2011, 11:01 PM
I was scrolling down wondering where the dirty pics were. No, not that kind of dirty pics either! This is a family site!

Kickstand, I use mine. But when the bolt broke and I didn't have one for a bit, any tree worked just fine.

BlazerRalph
01-23-2011, 07:15 AM
Great job Jason, after having a klr, I think the 250 is the way to go.:sun:

poser
01-30-2011, 09:59 PM
Great job Jason, after having a klr, I think the 250 is the way to go.:sun:

I was really suprised by the power of this little guy. Wheelies are no problem, just give it an hand full of throttle and the front end wants to come up.

On that first ride there was a KTM 450exc out there and in a flat out drag race from one end to the other, the 250 hangs right with him. I expected him to just walk away, but I was right there, not gaining, not loosing

jar675
01-30-2011, 10:42 PM
On that first ride there was a KTM 450exc out there and in a flat out drag race from one end to the other, the 250 hangs right with him. I expected him to just walk away, but I was right there, not gaining, not loosing

He must have been sandbagging.. :lol2:

poser
01-31-2011, 01:02 AM
He must have been sandbagging.. :lol2:

he must have ;-) or at least that's what we'll tell people to make the 450 feel better :trust:

DaveC
01-31-2011, 09:08 AM
So what is your total investment? Other than taking a year to put it together.

DFW_Warrior
01-31-2011, 10:26 AM
SX models from KTM, or R models from the big four will amaze you how fast they really are compared to a woods version. Ed's old CRF450r was night and day different compared to my WR450. My 450 didn't stand a chance when it came to power compared to his.

NitroRoo
01-31-2011, 11:25 AM
Very nice! Must feel great after waiting to get it going for so long!

wanabeguru
01-31-2011, 03:36 PM
Sweet job! Enjoy your "new" dirty ride!

poser
02-04-2011, 01:20 PM
So what is your total investment? Other than taking a year to put it together.

I estimate I've got just over $2k in it. Probably something like $2100 - $2200. Which is cheaper than I could have bought one and had suspension work done to it for. About $100 of the cost was do to intaller error and having to replace a clutch hub and lock washer twince. :doh:

Very nice! Must feel great after waiting to get it going for so long!

It did feel great! the firt time I heard it fire up was like music, and then the first ride was better than I expected.

Speaking of "feel", the last dirt bike i rode was my xr400, and this thing feels twitchy compaired to that :lol2:

Marc B
02-05-2011, 10:01 PM
Super job, I just know if I had a motor spread out all over the table, some one would have cut a piece of wood with the table saw close by, Congrats on getting her done.

poser
02-07-2011, 07:21 AM
Super job, I just know if I had a motor spread out all over the table, some one would have cut a piece of wood with the table saw close by, Congrats on getting her done.

Thanks, and thankfully I'm the only one in the house that uses tools :lol2: and no table saw. I'm just glad I didn't bump it doing something else and knock a bunch of stuff on the ground

ed29
02-07-2011, 08:18 AM
Looks great! That sense of accomplishment is a good feeling.

Seeing the parts spread out reminds me of a transmission repair long ago on a race bike. The replacement gears took a month to get here, so I had laid out gears, clips, bushings and shift forks in order on egg flats. Both shafts were completely apart. The lady of the house in an effort to tidy up my work space dumped both flats together into a three pound coffee can. Both shafts were the same diameter, so the puzzle was challenging.

Both her and the bike are long gone. I miss that bike. ;-)

poser
02-07-2011, 07:50 PM
Looks great! That sense of accomplishment is a good feeling.

Seeing the parts spread out reminds me of a transmission repair long ago on a race bike. The replacement gears took a month to get here, so I had laid out gears, clips, bushings and shift forks in order on egg flats. Both shafts were completely apart. The lady of the house in an effort to tidy up my work space dumped both flats together into a three pound coffee can. Both shafts were the same diameter, so the puzzle was challenging.

Both her and the bike are long gone. I miss that bike. ;-)

this guy had the transmission out and taken apart, and had a print out of the parts break down with the stuff needed circled. I opted to buy a complete good transmission off ebay, because i wasn't confident I could get it back together correctly :lol2:

Morgan Buchanan
02-13-2011, 12:02 PM
And FYI... be careful doing a google image search for "used tranny." Just sayin'.

Hood Ornament
10-10-2011, 03:54 PM
Oh yea, a DSLR will outdo an camera phone, but the current crop of cameras in phones are pretty sweet, and will take some nice photos. I'm just saying that the excuse of camera phones for crappy photos is going out the window. :mrgreen:

He wasn't talking about a DSLR. Even a $100 point and shoot still takes much better pics then any phone will. The lens is much more important that the amount of megapixels for image quality. I have yet to see a camera phone take what I would even consider a decent pic much less a good one. But everyone has his own standards.

Thrasherg
10-10-2011, 04:57 PM
Jason, It's great to see the bike running, but be careful with that hip of yours it's not fully healed yet!! Hope to see you on a ride soon.. :rider:

Gary

gixxerjasen
10-10-2011, 08:29 PM
He wasn't talking about a DSLR. Even a $100 point and shoot still takes much better pics then any phone will. The lens is much more important that the amount of megapixels for image quality. I have yet to see a camera phone take what I would even consider a decent pic much less a good one. But everyone has his own standards.
Dang dude, you pulled a thread from February for that? I'm well aware of all of that, spent quite a bit of time around lots of cameras myself. However, I was only saying that the excuse of having a blurry dark photo because it's a "Camera phone" doesn't apply. Current camera's in phones might not produce stellar images, but you can get pictures in focus with correct lighting. That's all.

poser
10-10-2011, 08:43 PM
Dang dude, you pulled a thread from February for that? I'm well aware of all of that, spent quite a bit of time around lots of cameras myself. However, I was only saying that the excuse of having a blurry dark photo because it's a "Camera phone" doesn't apply. Current camera's in phones might not produce stellar images, but you can get pictures in focus with correct lighting. That's all.

My old BB was terrible in anything but perfect light. And movement ..... fuggedaboudit.
My new BB is actually pretty good, and when I get my iPhone I'm expecting that one to be great :mrgreen:

Irishcoffee
10-27-2011, 07:56 PM
Only a select couple give a rats *** about the photos. The rest of us are celebrating the young man's accomplishment. Great job Jason!

Hood Ornament
10-27-2011, 09:21 PM
My old BB was terrible in anything but perfect light. And movement ..... fuggedaboudit.
My new BB is actually pretty good, and when I get my iPhone I'm expecting that one to be great :mrgreen:

Well, all I can say is I've got the new iPhone and it's pretty far from great.

Gravel Guy
10-27-2011, 09:28 PM
Only a select couple give a rats *** about the photos. The rest of us are celebrating the young man's accomplishment. Great job Jason!

+1 :clap:

poser
10-27-2011, 09:33 PM
Only a select couple give a rats *** about the photos. The rest of us are celebrating the young man's accomplishment. Great job Jason!

thanks :thumb:

I'm doing the same thing right now with a 4wheeler someone gave me. This thing was a mess, random parts in several boxes. She should be ready soon. What can i say, I like this type of puzzle :trust: