Superduke engine build

Having got the basket full of goodies home that I was told was a complete '06 Superduke, I set to work building the engine out of the assorted boxes of parts.
This thing was COMPLETELY stripped apart, every nut and bolt was out....
I started by reading and rereading the workshop manual numerous times to familiarise myself with the way it all goes together. Seemed simple enough.

I had a talk to my local KTM dealer and informed him of what I had bought and was about to do. He just said good luck as he has never rebuilt one yet....

He went on to say that if I dropped him a box of beers, I was welcome to use any of the specialised tool I needed, free of charge !!!!! waa hoo.....

Needless to say he had the beer before he finished the sentence!!!

So far I have done the whole bottom end, gearbox, oil pumps, crank, rods, replaced main bearings / shells along with the big end shells, all gearbox bearings, seals, o-rings, gaskets etc, generator, clutch, ballance shaft, timing chains, new waterpump.......

Piece of cake so far.

The only thing missing so far has been the flywheel bolt, no worries though, i got another one easily enough.

Last night while checking piston ring end gaps, I noticed one of the oil scraper rings was cracked!!!! I went to my local dealer and ordered 2 replacements, the only issue is that they are a 3 week wait from the factory. None in New Zealand!!! BUGGER!!!!

So it is now on to cleaning and checking the rest of the bike while I wait for parts.

I cant say enough about my local dealer MAKZGEAR in Tauranga, awesome to deal with and extremely helpfull!!

Cant wait for the parts so I can finally find out what all the hype is with these bikes....

At least I can still ride my motarded KTM 520 around....

Happy days.

Andy

Well thats some post......That box of beers must rate as one of the best all time deals ....nice one.....it will be worth it though

Cool post!

I understand its worth replacing the gudgeon pins (wrist pins if you speak American) as a service part when you rebuild the top end. Certainly I replaced mine when I rebuilt the top end. If your motor has done a few miles then it might be worth replacing the cam chain tensioner as they can get tired (I've replaced mine). You'll need the special tools for holding the motor in tdc and the KTM ring compressor as you have to slide the barrels onto the pistons with the pistons already attached to the con rods.
A box of beer well spent IMO.

What's the story behind getting an SD in bits?

Do keep us posted and lets see some pictures!

I have new wrist pins to go in along with new cam chains and tensioners, all came with the bike when I got it.....

The story goes that I was fixing a BMW car door lock as a homer job after hours (used to be a locksmith before my current vocation....) and when the owner came to pick it up, he saw my KTM 520exc in the shed. He made mention that he had a KTM in bits at a local bike shop the had shit itself.

It had been parked in there since October last year where it had been stripped, inspected, cleaned, reinspected and replacement parts ordered.

These arrived and nothing else was touched on it.

As a result, the previous owner got peeved with the mechanic and sold it to me for a song (1/3 of what it is worth) with all the parts etc...

I didnt want it at first but the SD bug bit hard.....

The reason it was in the shop is that while riding it, the PO saw the oil light light up on the dash so he immediately shut it down.

Further inspection revealed one of the clutch basket posts that the clucth springs go over had broken. The resulting spring pressure pushed it into the side cover, grinding out a whole lot of aluminium which blocked the oil screen.

This resulted in the scavenging pump being starved of oil and the resulting light comming on the dash.

The pressure pump was not affected at all, but the crankcase was filling with oil and not being returned to the tank.....

No damage was done to the rest of the engine. It was all in perfect condition when stripped and inspected.

So far so good

Happy days.

Andy

How much was the engine?

Sorry for the confusion.

I got the whole shooting box, complete bike for $5000 NZ

Just gotta assemble it.....

One question, do the arrows on the top of the pistons point towards the inlet or exhaust valves??

Happy days

Andy.

Typically the arrows point in the direction of flow (ie, exhaust). I'd double check the manual just to be sure.

John

Nevermind......

I got the heads out of the rapidly emptying bucket of bits and noticed the inlet valves are larger than the exhaust, and whaddayaknow, the reliefs in the pistons are too !!!

Fancy that....

Happy days

Andy

Went to fit the pistons to the cylinders and noticed the ham fisted person who disassembled the enging broke one of the oil rings on one of the pistons....

I have ordered 2 new oil rings but they are a 3 week wait from somewhere...... none in New Zealand !!!!!

I also ordered 2 new cam chain tensioners as the "new ones " I had in the box of parts were not to my liking.

Everything else is ready, just cant do anything else to it till the rings arrive..... BLOODY FRUSTRATING!!!!!!!

I keep reading about all the mods done to these things, ie, fly removal, o2 removal, SAS delete etc...... but I have to keep telling myself to rebuild it as standard at the moment, get it going as standard then see what mods I want to do. Be nice to have a base setting to compareany mods against.

Im fizzing at the bung hole to get on this beast !!!

I am getting a little tired of sitting on the rolling frame making Brmmm Brmmm noises......

Happy Days

Andy in NZ

Post some pics and good luck.