KTMito 380

[Jeram]

time to go work on the KTMito !

see ya soon lozza !

[2TInstitute]

I'll have a few other duties to attend to over the weekend................... but we still should get a fair bit done

[Jeram]

got lots of work done considering the unfortunate circumstances which I wont go into.

We managed over the weekend to get the engine mounts about 80% done which is a great milestone.
the motor now sits in the frame without any assistance and the motor is nicely held in place considering that none of the bolts are torqued up yet.

the mounts are made from 3mm mild steel flat bar, the bolts are all high tensile structural 8.8 and 10.9 grade, whch really is needed due to the high consequences if there ever was a failure.

the engine mounts have been thought out and designed over the past 9 months, and we have been collaborating with many old skool chassis gurus to find the best possible solution for reducing vibrations.
I say old skool because new bikes dont vibrate like they used to!

we settled on using a combination of dampeners from a Harley Davidson and skate board bushes and have found them to work splendidly.

we now just need to weld some thin flat bar around the mounts to 'box them up' to reduce side-to-side flexure.

this really will be a 'suck it and see' we wont know if it will work untill we start up the bike, if it doesnt work, it will just be a matter of finding where the vibrations are getting though and fix it


Top view


dampener in shell


We managed to get the wheel and chain aligned perfectly so that the brembo rear caliper can have its bracket made up.





finished mounts with dampeners, just needs some spacers made and the hanging mounts need to be boxed to increase side to side rigidity.





New shock ordered
Nitron Race Spec shock with preload, high and low speed adjusters, ride height adjustment and set up for my weight and the bikes weight.



more updates coming soon hopefully!

[Jeram]

Just got my hands on a SP525 shorty subframe + pista seat unit and under tray

I have never ever seen anything like this (apart from cheap seat replicas) up for sale so jumped at the opportunity.




looks awesome IMO, cant wait for it to turn up.

[2TInstitute]

Subframe looks good

[Antman]

Why has this build taken so long?

[CBR600]

Because the 2TI's too busy building Australia's fastest dt200 engined Dt200.....

The project is not a 5 minute job.

Be patient

[Jeram]

the project is mainly worked on when Im up in Newcastle which is roughly 3 times a year as both myself and lozza are pretty busy with life and a million and one other projects.

Considering Iv only been up there to work on the bike for the equivalent of 4 or 5 weekends, we are making some mighty fine progress.

All that we have to do now is get the rear brake sorted, the top end of the motor, the pipe and the electrics.

hopefully these things can be done in the new year... that's probably only a couple of long weekend trips to Newcastle to finish her off

[2TInstitute]

Why has this build taken so long?

Life gets in the way sometimes

[Jeram]

I think it might be quicker for us to finish if we follow the plot of the movie "Multiplicity"

we will clone you...

one lozza for working away in the shed..

and the other for all the other less important things ...

[2TInstitute]

Sign me up, though feeding and cleaning up after my clone might be a drawback

[Jeram]

just experienced the fastest postage of my life.

a box of goodies for the KTMito and my mates KTM supermoto project sent via TNT from California to Melbourne.

Postage paid for on Friday afternoon

Items turned up this morning!


I got myself a more powerful stator, with pickup and backing plate.
a higher capacity aftermarket rec reg
and a brand new heavier flywheel (+4oz)

[Jeram]

heres what we got up to this weekend

All in all it was a pretty productive weekend but a few setbacks stopped us from getting the bike fired up.
1. putting the 'bling' orange clutch master cap on removed the magura cap which warned not to use brake fluid.
brake fluid was accidentally placed in the MC which ruined the seals preventing any hope of starting the bike.

2.Dropped the cluch shaft double needle roller on the floor, losing several rollers.
couldnt find an exact match so had to machine a couple new rollers from similar rollers.

3. my ankle exploded on the 3rd day, swelled up like a balloon and I could barely walk for the remainder of the trip...

so yeah, considering the above I think we did pretty damn good



First off we finished the front brake system by installing the 19mm forged master cylinder, connecting the braided lines, and installing high tensile bolts/washers on the callipers



engine cases were again split open to investigate a gearbox issue, turned out to be the shift forks/drum had derailed

Luckily an engine removal is quick and easy, four bolts to swing the engine down for quick/easy top end work and slide the swingarm pivot half way out to drop the whoe engine.



Im happy to report that my new engine mounts look like they will work amazingly.
They are super firm but have a surprising amount of dampening flex when required.

It consists of a bar which runs through the front mount of the engine cases, this bar connects to an aluminium mount on either side of the engine which then passes all forces and vibrations through half inch bolts and into the four independant dampeners before tranfering the loads to the frame rails.

here is a picture from earlier in the weekend before finished


chain installed and aligned with a laser... is absolutely spot on!



engine back in the frame, and bodywork installed so that the expansion chamber could begin being fabricated.




Minimalist cockpit/dash area. just needs to have the micro LED tacho installed


Nitron shock installed


I really like the look of the slick, the race tail/tray and the nitron race shock...
gives me an ear to ear grin just looking at it


just some more pictures



really reminds me of the Cgiva GP593/594 from this angle


couldnt find the OEM intake boot so begun fabricating one from alluminium.
didnt quite get it finished but it is a short/straight intake boot with a tapering ID, from 41.5 round at the carb to almost 60mm rectangle at the mouth of the Vforce-2 reed block


And a quick walkaround video of the bike





Major things to do now before bike can be taken for a ride:
-Finish the Exhaust
-Rear brake

[DOC03]

Damn thats coming up nice mate. Love the fairing and particularly the tail, sweeet !

[2TInstitute]

Some progress on the 'anaconda' pipe