KTM 100cc 1969 dirtbike restoration

<< To start << Go back Go to step 2. >> gearbox and shafts Go to step 3. >> mounting together Fixing and restoring the saddle. Restoring this KTM 100cc 1969 I bought this bike unseen. I knew from the description that it was a steel tank KTM/Penton model with a Sachs 125cc six gear engine. I will restore it in good working order with a new look. It turned out to be a 100cc and that the kickstarter shaft and kickstarter had to be replaced. There was also a crack in the piston but everything will be fixed here. Many thanks to Dough Wilford, the treasurer at P O G (Penton Owners Group) for assisting me with advices and sending me an original service and spare parts manual. Removing and dismantling the engine Removing the engine was pretty simple and straightforward. Two bolts at the rear of the engine and one bolt in the front. One thing about the front bolt. It was neccesary to remove the front mounting too since there wasn't space enough to lift the engine up otherwise. Two bolts, simple stuff. I also had to remove the exhaust system. I had to split the engine case to replace the kickstarter shaft and inspect/adjust the gearbox. I normally replace all bearings when splitting an engine but all bearings inside this little screamer was in excellent condition. I detemined to keep them all. Splitting the engine case order Remove the cylinder head. It's attached with four allen bolts. Carefully lift up the entire cylinder. Try not to damage the piston. If your piston is in good condition you are lucky. The skirt of the piston is simply too thin and you will normally find cracks there. Remove the circlips locking the piston pin, push the pin out and remove the piston. Remove the clutch housing. Remove the clutch basket, one circlip. The primary drive on the crank. and the shifting mechanism by loosening the two allen bolts that holds it into place. Do not take this thing apart though. There is no need to remove these parts. The flywheel The clutch inner wheel. The primary chain sprocket on the other side. Remove the shift fork with the pin at the end of the shift shaft. The idea is to split the engine keeping the clutch shaft in the left case. The gear shaft, the crankcase and the kickstarter shaft in the right case (This one can slide out though). Loosening all bolts keeping the cases together, all on the right side and don't forget those behind the ignition plate or flywheel. Press the shifting shaft into the bottom, thus engaging the sixth gear. Carefully try to split the cases, you need to turn the primary sprocket a little to make all gearwheels slide off the shaft. The result Go to step 2. >>	Accosato AJS Alfer Ancillotti Aprilia Ariel ATK Benelli Beta BMW BSA Bultaco Cagiva Can-Am Cannondale CCM Cooper CZ D-Rad Dalesman Derbi DKW Fanatic FN Gas Gas Gilera Harley Davidson Hedlund Hercules Hiro Hodaka Honda Horex Husaberg Husqvarna IMZ Indian IZh Jawa Kawasaki Kramit KTM L Lem Lito Maico/MStar Malaguti Matchless Mazzilli Monark Montesa Nauder Norton NSU Ossa Penton PMZ Praga Puch Rickman Rokon Rotax Sachs Sokol Standard Suzuki SWM TGM TIZ TM Triumph Velocette Vertemati Victoria VOR Yamaha Zündapp


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