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I am planning on doing a FULL bottom up rebuild, I mean EVERYTHING torn down and built up the way I like it. 

 

I have some mechanical skills and I work on the bike all the time. BUT I have never down a bottom end. Where would be a good place to learn the "skill" or should I dive right in, buy a barn beater and go from there?

 

How did you guys learn?

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I am planning on doing a FULL bottom up rebuild, I mean EVERYTHING torn down and built up the way I like it. 

 

I have some mechanical skills and I work on the bike all the time. BUT I have never down a bottom end. Where would be a good place to learn the "skill" or should I dive right in, buy a barn beater and go from there?

 

How did you guys learn?

I learned by doing, even tearing stuff apart that didn't need it. Sounds like you have a plan.

Mike

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If you give it a go take plenty of photos for future reference at assembly time.

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Find a friend that's done it before and has all the tools. 

 

Do it a few times, spend some $ on tools of your own, then be that friend for someone else.

 

Just did a complete refurb on just about everything in my 525.

from this

IMG_20140523_163436828_HDR-L.jpg

 

Clean/repair some parts

IMG_20140526_194426318-L.jpg

 

Explains why the throttle didn't have the punch it used to... new gasket kit

IMG_20140531_174702898-L.jpg

 

and a good scrub-a-dub

IMG_20140531_192836339-L.jpg

 

Should have at least hosed the engine off while it was still in the frame...

IMG_20140602_221111815-L.jpg

 

Everything came apart.

IMG_20140604_205716186-L.jpg


Scrubbed clean, parts replaced as needed...

IMG_20140608_164054786_HDR-L.jpg

 

Trans shafts came apart and got cleaned up, found a cracked bearing race (plastic) under one of those gears...

IMG_20140608_172625864_HDR-L.jpg

 

Before and after... same gear

IMG_20140615_220107065-M.jpgIMG_20140615_220408849_HDR-M.jpg

 

Rusty shit punched out and replaced...

IMG_20140621_180459140-L.jpg

 

Huh, more broken parts.... :banghead:

IMG_20140627_221112807-L.jpg

 

Repair/rebuild all the hydraulics...

IMG_20140628_214907049-L.jpg

 

and I think i'm done tearing it down. :smirk:

IMG_20140701_195750669-L.jpg

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Had a neighbor stop by at about this point... "Oh, you ... uhh, have a motorcycle?"

Yeah, it's in that box, that crate, wheels are over there, forks are against that wall, and some of the engine parts are in my kitchen sink.

Drill out more rusted-in bolts...

IMG_20140701_203817958-L.jpg

 

Subframe off to the welder's shop for some fixin'...

IMG_20140706_145810690-L.jpg

 

Yaaaaay!  One of many...

IMG_20140711_192031632_HDR-L.jpg

 

Think of it like a puzzle.  Except you've got the how-to guide for that puzzle (service manual, parts fiche... you do have those, right?)

IMG_20140713_212554467-L.jpg

 

Look for the little stuff.  Most of it's in the service manual.

IMG_20140802_152514142-L.jpg

 

what is this i don't even

IMG_20140802_214707854_HDR-L.jpg

 

Assembled, filled with oil, and ready for installation

IMG_20140803_174602708-L.jpg

 

In the meantime, deal with some chassis items...

IMG_20140811_202330663_HDR-L.jpg

 

IMG_20140812_203349259_HDR-L.jpg

 

Starts to look more like a motorcycle now...

IMG_20140812_220332960_HDR-L.jpg

 

First time I fire it up after having it apart, especially as far apart as I had it this summer... always makes me nervous.  You'll find little stuff... like a fuel screw that fell out of the carb... :lol:

IMG_20140815_214842331_HDR-L.jpg

 

maybe a leaky gasket...

IMG_20140817_153648172_HDR-L.jpg

 

Pull on some gear, make sure you've got fuel, oil, coolant, throttle's working right, brakes are working well, lights/etc all working, tires aired up... thorough pre-ride check...

FILE2195-L.jpg

 

Finally!

FILE2067-L.jpg

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You just gotta dive into it! I'm currently rebuilding a 2011 xcf 350 from top to bottom. Mines missing bolts everywhere, stripped engine drain bolt, fried top end, and the list goes on and on. At least by the end of it I'll have a fresh bike!

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I love the rebuild. Especially on the KTM. I do have service manuals for all of my bikes and my I do have some others, although never tearing into an MX bike they are certified mechanics, and my brother-in-law spends every waking hour on his race car. 

 

Looks like I am looking for a beater.

 

 

 

Anything I should look out for when it comes to a beater. I mean, I know it wont be running and I will be redoing it but what are the NOGO's?

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