Dos Rios, I remember when you were restoring yours and the pics you posted when it was done - sweet. You have to admit though, it s*cks not feeling comfortable riding a bike you poured so much into because of the scarcity of parts.
Ktm450exc, I did rebuild my engine. This was one of those lessons learned about starting a project with as good a bike as you can get. My first clue things were bad was when I opened the clutch cover and found two whole tines were missing from the clutch basket. When I split the cases, the return spring pin was missing and there was a big hole where it used to be mounted. There were also numerous stiffening ribs and castings that were broken off and missing as well. The oil drain casting had been butchered and a pipe bolt had been forced into the drain hole. At this point I considered this project more of a rescue than a restoration and I was determined to restore the dignity to this poor bike so the other bikes would stop laughing at it.
I salvaged a few restorable parts and junked the rest. I found a nice set of center cases, an NOS crank and rod, low time main and secondary shafts, NOS tranny gears, shift drum, shifter arm shaft, and shifter arms. All the bottom end bearings and seals were replaced. All thrust washers, circlips and springs were replaced. For the clutch, I found an NOS outer inner and pressure plate and loaded it with NOS plates and springs to finish the bottom end. The cylinder bore was crap so I had a liner installed by Racer's Toy Store and fitted a new piston and rings topped off with an NOS head. Every nut, bolt, stud and washer is NOS.
Like everything else on this project, I tried to the max to recreate the bike just as it was the day it rolled off the dealer's floor. Originally, I had planned to install a PVL ignition (I even purchased one) but later decided to stick with OEM and managed to find an NOS stator, coil and rotor, the only piece I'm missing is an original wiring harness (I'm still looking though).
I spent many hours restoring the clutch and ignition covers which were covered with road rash, rock chips and scratches. As you know, Magnesium is a finicky metal to work with and it can quite lterally blow up in your face if your not careful. I used a TIG welder and magnesium rod to fill all the gouges then wet sanded the surfaces smooth followed by powder coat primer and satin black.
I know this a lengthy dissertation about the engine rebuild but it only scratches the surface. I have similar stories about every component on this bike. One thing is for sure, I have learned a ton and really look forward to starting on my '79. I think I am totally hooked on vintage bikes and vintage restoration.
Below is a picture of my engine just prior to "buttoning up" the cases.
dogger
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