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KTM Adventure 620 - Rebuild

Full teardown and rebuild of a 1997 KTM Adventure 620
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  • Clutch hub

    Clutch hub

  • Clutch hub

    Clutch hub

  • Micro oil filter removed

    Micro oil filter removed

  • Micro oil filter cover

    Micro oil filter cover

  • Jug removed

    Jug removed

  • Jug

    Jug

  • LC4 620 jug/cylinder

    LC4 620 jug/cylinder

  • Piston

    Piston

  • Piston and crankshaft

    Piston and crankshaft

  • Closeup of the crankshaft and connecting rod

    Closeup of the crankshaft and connecting rod

  • Piston skirt and rings

    Piston skirt and rings

  • Cylinder bore

    Cylinder bore

  • Cylinder bore

    Cylinder bore

  • Cylinder bore

    Cylinder bore

  • Wrist pin coming out

    Wrist pin coming out

  • Piston removed

    Piston removed

  • Closeup of bottom of piston

    Closeup of bottom of piston

  • Small end of connecting rod

    Small end of connecting rod

  • Test fitting 2003 Adventure subframe to 1997 mainframe

    Test fitting 2003 Adventure subframe to 1997 mainframe

  • Mockup of 2003 subframe to 1997 mainframe

    Mockup of 2003 subframe to 1997 mainframe

  • Untitled photo

  • Frame epoxy coated

    Frame epoxy coated

  • 2003 rear subframe and swingarm retro fitted to a 1997 mainframe

    2003 rear subframe and swingarm retro fitted to a 1997 mainframe

  • Rebuilt 1997 WP 50mm Extreme forks

    Rebuilt 1997 WP 50mm Extreme forks

  • Mockup of 2003 rear to 1997 front

    Mockup of 2003 rear to 1997 front

  • New plastic (front fender and side covers

    New plastic (front fender and side covers

  • 2003 rear plastic

    2003 rear plastic

  • New grips and mirrors

    New grips and mirrors

  • Rear brake connected and side covers installed

    Rear brake connected and side covers installed

  • Rolling chassis

    Rolling chassis

  • Mockup rolling chassis

    Mockup rolling chassis

  • Preparing electrical

    Preparing electrical

  • Clutch hub removed and preped for bearing upgrade

    Clutch hub removed and preped for bearing upgrade

  • Polish and port work on the old cylinder head

    Polish and port work on the old cylinder head

  • Intake side port work

    Intake side port work

  • Exhaust port work

    Exhaust port work

  • Exhaust port work

    Exhaust port work

  • Bowl work and pocket polishing/porting

    Bowl work and pocket polishing/porting

  • Cylinder back from plating

    Cylinder back from plating

  • Fresh cylinder waiting for paint

    Fresh cylinder waiting for paint

  • Freshly painted cylinder

    Freshly painted cylinder

  • Painted with ceramic high temperature paint

    Painted with ceramic high temperature paint

  • Freshly plated and bored cylinder

    Freshly plated and bored cylinder

  • Cylinder waiting for reassembly

    Cylinder waiting for reassembly

  • Case covers after paint

    Case covers after paint

  • Engine getting a good scrub

    Engine getting a good scrub

  • Cleaning the dirty engine case

    Cleaning the dirty engine case

  • Dirty

    Dirty

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