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It seems that depending on the race weekend a lot of my Cagivas and 90s KTMs can get grouped together…it will be cool to have a twin shocker, as it seems in the NW anyway that those classes normally have the biggest gates.
If anyone can help…I can’t seem to find any machinist that can do internal splines to remake the lower kickstart piece. It was a poor design, the splines wipe out, and obviously not much demand to reproduce 81-83 KTM 250 kick levers.
The Shop
Things that are no fun…lacing 40 hole drum brake rims!
BTW, I had the 81 KTM 250GS (same fox Shox as well) -- great mid-range and top end (ran great with a Bing to 36Mikuni conversion too). Didn't turn as well as any of my Maicos, but it was close - and the motor made up for any handling deficiencies it may have had.
Wish you the best.
Never owned or even ridden a dual shock bike but that may be something that I will need to do at some point but for now we have way too many projects.
Here is a sweet 79 YZ125 that my boy Jeremy picked up and has been working on. We picked this up shortly after the Washougal NWCVMX event that we finally met you at. More cool stuff coming and I am still working on getting an 89 Cagiva 125 from someone that has one, been trying for years and he may be coming around to selling it soon.
Again, nice work bud!
Post-race 2013, AHRMA Vintage XC race, took 2nd place that day at Wicomico in MD
AND finally, my 77 Penton 250 GS6. Holding on to this one. Love this bike.
This bike actually started as a GS. I got a MC motor, found out the only difference is they took 1st gear out of the 6 speed GS to make the MC 5 speed. A few small parts needed to be switched to make the MC…like the rear brake hubs and stay arms are different between the two.
Since it's a 14mm shaft you could use a KS completely assembly from 72-78 KTM 125-175 (which are most robust, IMHO, than the stock 81 KS). Saw this on Al Buehner's site and thought it might be of some for use for you:
Reproduction KTM Kick Start Levers for 1972 thru 1978 bikes
A - #52-33-036-244 - Sold out
125 & 175 lever assy. Fits 14mm shaft NOTE: will also fit 1981 250 engines
http://www.pentonpartsusa.com/images/3-%20ktm%20photos/KTM%20kick%20sta…
I've bought new ones for my big bore KTM 400s and the newer steel or whatever material that they use these simply couldn't handle the compression - so I ended up buying used KS levers for my 78 & 79 400's.
I've even seen older style KS used on 81 & 82 250 models - see Al's page on the Penton owners group: http://www.pentonpartsusa.com/images/3-%20ktm%20photos/72%20kick%20star…
Unless they're OEM NOS I won't buy Repros for the big bore KTMs. I'd do it for the 250 for though, but still, I prefer to buy used oem KS levers (at least for KTMs and Pentons) on ebay -- seems they were made of better material way back then.
Looks like Al is sold out, but I think you could find a 14mm KS on ebay. And yeah, if all else fails I'd definitely give that PW KS lever a try.
Looks like this 14mm KS lever on this 81 is the same lever that's on a Sachs motored Penton/DKW/Herc/etc...and these are always easy to find on ebay.
http://suprememotos.com/uploads/postfotos/ktm-250-gs-1981-1.JPG
Maico…I had a question. You mentioned swapping the Bing for a Mikuni? I have seen lots of different posts saying to get rid of the Bing or that the Bing is the best for this piston port engine.
I looked at using a different carb. But the problem is that the Bing is much smaller on the back side than anything else.
Originally I wanted to try this new 37mm Dellorto that I had off a 88 Cagiva WMX 250.
I was also taught by some old timers that you can use a accordion style cv boot (trimmed of course) in lieu of an oem airbox/aft carb boot. Also have successfully used rubber couplers from Lowes for the airbox/aft carb connection as well (trim to fit).
With my DKW, Pentons and late 78 & 79 KTMs I stuck with Bings - the Mikunis were too hard to fit and required fabrication and modification that I just didn’t feel like dealing with.
Due to the cylinder and engine redesign, Mikuni carb installs for the early 80 KTMs were def an easier fit.
Btw, 3 out my 4 Maicos have 36mm Mikunis installed. Have quite a few Bings - which I do believe are probably better overall performance - but I like Mikuni for their ease of maintenance, reliability, and improvement and ease of starting these old pieces of iron.
Not racing anymore, so I prefer the path of least resistance - at this point.
https://www.lowes.com/pd/Fernco-6-in-x-6-in-x-4-46-in-dia-Coupling-PVC-…
Keep an eye on those Marzocchi (magnesium) lower fork tubes around the axles and pinch bolts - they have a tendency to develop fine hairline cracks. Talk about trying to replace those - it's def a needle in a haystack experience. They can be repaired as well - you just have to find someone who is good with welding magnesium.
Just in case you wanted to know I'm pretty sure my 36mm Mikuni set for the KTM was 35-40 pilot jet, and 310-340 main, and needle jet clip was in the middle - adjusted for temp, elevation accordingly.
Edit: My GS was actually an 82 - and it had a reed valve cylinder. My Penton & Late 70's KTMs (all piston port) run just fine with the Bing (all rebuilt). All of my Mikuni carbed Maicos are piston port - and they run and idle nicely. Even the 1 Bing mounted Maico runs well. I just prefer the ease of a Mikuni and parts availability & durability -- and of course price.
Pit Row
The problem I ran into on my forks was the typical 80s Magnesium rot. When I pulled the stock fork rubber caps off water had rotted the forks severely around the seal retaining clip.
I found a nice set of lower tubes off a Can Am in California.
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