I’m currently getting the rolling chassis completed, as I have a small man-shed and there are currently parts everywhere.
So far –
- frame and subframe have been cleaned, blasted and resprayed satin black
- welded up the side stand hole and redrilled it, blasted then painted satin black
- swinging arm cleaned, blasted and new bearings fitted
- stock is single bearing and o-rings which is crap, I fitted 2 sealed bearings each side plus an extra seal on the exposed side
- rear wheel – rebuilt with new hub, spoke nipples, seals and bearings
- gallery below shows using a blow torch, gentle heat, and internal bearing puller, makes removing bearings a pice of cake
- airbox stripped and cleaned – issues with captive nuts – for another day!
- rear caliper rebuilt plus new piston – I use an airline on low pressure to pop pistons out
- ktm 28mm piston was very expensive at £40, and my local dealer was out of stock, did some measurements and bought a brembo car caliper piston for £9, same part, wtf?
- new brembo ceramic rear pads
- rear master cylinder rebuilt
- new rear brake line fitted
- new rear mudguard fitted
- new rear light fitted
- new side panels fitted
- front forks rebuilt – new bushes and seals – picture shows using long socket and ratchet to hold the fork leg when doing the bottom bolt up
- fork yokes blasted
- headstock bearings replaced
- new lockstop plate
- new renthal fat bars
- new throttle
- new renthal grips
- front wheel cleaned – new bearings and seals
- front brake caliper rebuilt
- stainless bleed nipples fitted to front and rear calipers
- new stock dash bought and fitted
- bargain deal, but kmh speedo, but sourcing a 60mm alternative is proving tricky
- Polisport MMX headlight and spacing brackets fitted
- ufo supermoto front mudguard fitted
- junked the CCM cable guide and fitted a plastic ktm one. required spacers – plastic 10mm OD x 5mm h x 6mm ID
- started cleaning carbs – wtf – how much chain do you need to use!