KTM 640 Supermono Build

[silver]

This is something that's going to take a while, but its progressing nicely. Best place to follow progress is on my blog  www.puddingbag35.blogspot.com
Its a RS125 chassis with KTM 640 LC4 engine. GSXR 750 forks just fitted, cooling system half done. Exhaust fabricated in my shed, looks pretty good I think.

[timbo]

Great project, and great work. Thanks for posting 

[JOOLZ]

Interesting project, looking good

[tommy]

wow interesting project looking foward to following this

[silver]

Getting there.

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[CrazyFrog]

Wow, looking really good! 

[themoudie]

Aye David,

Making good progress and should deliver plenty of smiles.

All the best, Bill

[silver]

Well, its running now but has a few issues. Oil is spraying out of the front rocker breather, so I have ordered the gauze filter for that pipe, also the gasket for the cover and some copper washers.
Screen and new grips fitted since these pics.
Oh and ive removed the thermostat. I am not running a fan so I need to know how hot it is really getting.

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[timbo]

Looks the absolute b******** 

[silver]

I went to Castle Combe on sunday and saw Guy martin ragging the Honda 250 6 round. What a sight!.
Around the pits I got chatting to a chap on a KTM supermono. It had a special tubular frame and a 610 engine making around 70 hp. He said it weighed in at 95kg..wow. It looked just like a 125. sadly I didn't see it going.
May get mine to Mallory on Friday for a quick test run.

[CrazyFrog]

Silver, that really does look like the dog's do dah's mate. Hats off to you....

[JOOLZ]

Wow that looks great

[silver]

After sorting some cooling issues and killing the Li-ion battery with the starter solenoid woes,these batteries make a kind of hissing sound and a nasty stink when their time is up.
Itlooks like its going to be ok for a test run. I booked an evening trackday at Rockingham Friday 11t aug so fingers crossed.

I had two cooling pipes on the pump on the wrong spigots. While I was sorting that out I removed the thermostat and turned the outlet housing 180 deg to give  better hose run. I can now do away with one of the hoses that circulates water prior to stat opening.

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[silver]

Fortunately I got to Rockingham early and had time for fettling in the car park. Tried running it through the tunnel and back but it hardly managed that under its own power. Then the starter solenoid stuck on again. Fortunately I had fitted the isolater switch. Cancelled the track evening and went home. Got a few jobs to do before I can get back on this. I haven't given up on it ....yet.
Dave

[silver]

After much tinkering and swearing it is now running properly, goes well and sounds good. Looks like I cured the solenoid problem. I took the loom apart and removed all the excess wires and connectors and re bound it up. Fitted a big "sputnik" type solenoid which is good for 150A constant. Not had any bother since. Have small weep of oil from sprocket shaft seal, which I have the parts for to fix this weekend.
I ordered an R6 master cylinder but it turned out to be 14mm, so have ordered a TRX one which should be 16mm. Should sort the brakes out with new track HH pads.
 Have a trackday booked at Mallory 6th oct. Fingers crossed.
Dave