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Old 01-21-2013, 07:47 AM   #1
seavoyage
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Atk 605

Moved from Dirty BARFing to be accessible to current and future ATK 350 or ATK 605 owners:



A few things I learned:

With the exception of the Aermacchi Sprint or the XR750; the ATK is the closest thing to a 'dirt' Harley-Davidson: American made C&J frame with a Rotax engine similar to type used on the Harley-Davidson MT350E or the legendary Ron Woods 'Harley-Davidson' Rotax flat-trackers.

SPECS: http://www.motorcyclespecs.co.za/mod...k_605%2096.htm

Quite an aesthetic design. Lighter than a BRP (Big Red Pig AKA Honda XR650). Relatively unpolished construction compared to a XR, DR, KLX, or KTM LC4. If the bike is a ATK 605 LE Police bike it has an upgraded electrical system and luggage subframe: The CA Police bike contract with ATK was cancelled since it didn't meet CA emission standards.

ATK built the 605 from 1996-2003. Rotax stopped making the Type 348 motor in 2001, resulting in the end-of-the-line for the 605... and the ATK acquisition of Cannondale 440EFI as a replacement. CCM was affected in a similar way and switched to the DR650 mill.

Capable desert sled popular with D-37 staff. Was competitive in the LA-Barstow-Las Vegas http://www.desertpistons.com/4strokesd/ATK/atk.htm

Old-school Thumper power: Lugs low and makes linear power, not like modern 4-stroke MX bike. Handling: Feels top heavy. Long wheelbase.

Wealth of knowledge on the ATK Forum, ADVrider, and Yahoo ATK Group. Additional maintenance info on ATK Motorsports link.

Download the:Local dealers? I recommend you develop a close relationship with Dan Blum (707) 446-4282 at MotoXotica in Vacaville.

Fuel range 90-125 miles.: 3.2 gallon, and that's it. This was the limiting factor, with some preferring the Pre-94 single backbone frame that permits aftermarket fuel tank or a CCM 604.

Bullet proof Rotax motor. Very low engine maintenance required.

Oil change every 1000 miles. Oil filter every 5000 miles. Oil filter access is on the magneto side (on the right). This is a 3 Quart dry sump system. Rotax used Castrol GTX2 15W50 HD; ATK used Spectro 20W50 in the summer; 10W40 in the winter. One inexpensive alternative is JASO DH2 compliant Shell Rotella T-3 15W40 from Walmart ($4/Qt.) Go cheap and find HiFlo 151, K&N 151 or EMGO 10-26950 oil filters for $3 at your local auto parts sport.

Interesting belt driven cam. Easy to maintain, but inspect the cam belt often and replace it every year. Here's a video: http://www.apophisparts.co.uk/index.php?p=10_22_Cambelt

Valve Adjustments: Very easy to check and adjust valves. Screw type adjusters: no shims. The factory calls for .002" (.05mm) for both, Ron Wood, suggests .005" in and ex. I set mine at I: .004" (.10mm) E: .005" (.13mm) .

Source the Cam belt from Apophis (UK), Force, or cross reference the Gates part (Timing Belt NSN 3030-00-408-2420 Goodyear 322L075 Positive Drive Trapezoidal Tooth Profile Belt, Light, 32.2" Pitch Length, 0.14" Height, 0.375" Pitch, 0.75") at local auto parts store. You'll need a Rotax crankshaft fixation screw M8x30 P/N 241-965, from Apophis or Vintage CanAm Parts, white paint pen, and a straight edge ruler to set cam timing.

If the air-cooled motor overheats, the belt tensioner nut may come loose... not good.

Apply Hi-temp silicone on the edge of the lower left side case covers which does not have a gasket. This prevents water/dirt entering the cam belt area.

Spare parts sourced from ATK (Utah), Ron Woods, or AmericanDirtBike (ADB). Keith @ ADB (951) 283-5447 focuses on pre-96 Horst Leitner designs.

Rotax parts are much cheaper from ultralight aircraft suppliers: California Power Systems; or from UK suppliers ( Apophis, Haines & Co.) that supports the Armstrong/Harley Davidson MT350E or CCM. The Rotax Type 348 engine family was used in the KTM 504 and eventually evolved into the liquid-cooled version used in the BMW F650/Aprilia Pegaso.

If you sincerely believe you need more power (and less reliability) explore the Woods-Rotax kits, Swap Rotax 865 for 860 cams with HD springs, larger intake valves; and contact Mike Crowther's EdCO (Nee. Engine Dynamics) in Petaluma. Mike will get you sorted out to get you serious HP.

Carburetor: 40mm Dellorto with Domino throttle... I'll leave it up to the owner if that's good or bad. Option for remote choke vs. 'flip-up' lever choke at carburetor. Dellorto Spare Parts: Guzzino.com . Many have tried Mikuni 38mm TMX used on the pre-94 models. Lee @ ATK (801) 298-8288 x109 tested Electron and Qwiksilver. Keihin cables are on the wrong side.

Terrycable has replacement cables.

WARNING: If you purchase a Rotax 4-stroke that isn't running; DO NOT attempt to electric start prior to confirming the cam belt is OK, and timing is correct.

To start the ATK605 cold with choke, you have to keep the throttle slightly open to keep revs up until it's warm. This was a common trait.

Kick Starting routine is like any other big thumper: Ignition on/Fuel on, choke on if cold; Kick through 3-5 times with decompression lever pulled in and throttle closed; Set to TDC: push (don't kick) the kick start lever slowly down until you feel tension or it stops AND decompression lever 'clicks' out, then return kick start lever to top of stroke); Open and shut throttle 3 times; slight throttle; give a firm kick... repeat full routine if it doesn't start. Only kick if at TDC.

Decompression actuator on headcover can get stuck = no compression. May be challenging to kickstart: get your jetting right, and use the decompression lever.

Stock air filter is K&N pleated cylindrical type P/N KSP2538E. Get the foam outer wrap ATK P/N 060205 for better filtration.

Exhaust: Have a header heat shield or header wrap so you don't burn your right leg. Look for Big Gun exhaust (no longer manufactured), much better than the Supertrapp which probably won't pass a 96db sound check. We used a FMF Q2 (P/N Product #: 044120 for '03-'05 YZ450F) and required some mods to the midpipe. Upgrade silencer mount to a 2-bolt design. '96-'97 1-bolt design was prone to fractures.

Get a Magura hydraulic clutch from ADB. The decompression lever is integrated with the Magura hydraulic clutch (KTM, Husqvarna) master cylinder. The perch is prone to breaking and quite costly. I highly suggest hand guards. Clutch maintenance means access behind the cam belt assembly - a P.I.T.A. Confirm if you have a 8 or a 9-disc clutch.

Electricals: Nippondenso electronic ignition. 190W Stator is very capable (Harley-Davidson 12V 190W 15.8A 3-phase AC Generator Part #84820620 NSN 2920-01-384-3744). Regulator/Rectifier OEM part#100007 is a Tympanium; tends to overheat, and require replacement; explore TrailTech Regulator/Rectifier (3-phase) if compatible with 190W stator.

Use a TrailTech dash if the OEM is missing or you need an odometer. I installed a TrailTech Endurance, but you'll have to check if an Endurance II or Vapor for air-cooled motor will work.

Notorious for going through wet cell batteries, The 190W stator and OEM regulator/rectifier may over charge the battery. A Shorai battery is highly recommended. My regulator/rectifier failed one evening, and I couldn't kick start or bump start. Just glad Tom G and Doc Wong were around, and we ran jumper cables straight to the starter motor. Lesson Learned: carry jumper cables and a tow strap. Starter Solenoid relay 4KB-81940-00-00-4KD from Yamaha. DO NOT jump start using a battery from a running car engine, just connect straight to the 12V battery with the car ignition off.

Suspension: WP4054 USD forks and WP or Ohlins shock: pretty standard KTM. Yes that is a 40mm mid-80's fork, so quite a bit of flex. primitive by today's standards. Try to get the 1999 and up with the Paioli 46mm forks conventional (Showa innards) with Ohlins rear shock. The rear shock is linkage-less like the KTM PDS so look for a suspension tuner with experience with PDS (Dick's, SPS, etc.) or you'll have a difficult time tuning the rear suspension. Inspect the lower shock mount for fractures.

Comes stock with Pro-Taper fat bars/handlebars. D.I.D. rims.

Brembo calipers/master cylinder (KTM). Rear Talon hub is unique, and isn't a cush drive. Rear brake rotor is unobtainium (if you wear down, Good luck on finding a replacement). Answer Radialite Rear Sprocket is a Suzuki standard bolt pattern. Front brake rotor (Front brake rotor: Same part as '06-'09 KTM 450 XC '04-'06 450 MXC; '99-'02 LC4) and Talon hub matches KTM. Front Wheel Bearings 6204-2RS (20 x 47 x 14) ; 2 required. Rear Wheel Bearings: 6005-2RS (25 x 47 x 12) ; 3 required.

Locktite the Countershaft Retaining Nut, mark so you can check for rotation, and check frequently before and after every ride . It tends to come loose resulting in catastrophic failure and damage to the transmission shaft.

Plastic: UFO Rear fender is a mid-90's KTM300. Almost impossible to find in white. Still on backorder at ATK. Side panels are unique to ATK and of different color for different years.

KTM Part#'s
FF: 50208410100
RF: 50208414000
Side Panel (left): 54608441000
Side Panel (right): 54608541000

Seat cover: Guts Racing.

Front hydraulic line plastic protector and decals are hard to source.
Tank decals are still available.

Frame: What frame? it's just a 3 Qt. oil tank and steering head attached to the heavy 100 lbs. motor. Yes, it's asymmetrical: a one sided 'frame'. Swingarm bolts to the motor. Inspect the steering head welds for fractures.

The footpegs are small, and unlike the '88-'94 no aftermarket available, but you can try modifying XR100 mounts then fit Fastways or Pivotpegs.

The subframe was prone to fractures at the mount points. Aluminium airbox is integrated with the subframe. Since the subframe wasn't designed for significant weight bearing, you may have to make some reinforcing mods. Panniers? Here are some ideas.

Kickstand: Do not put your weight on the kickstand. It is only designed to hold the bike upright. If you mount the bike with the kickstand down, it will bend and eventually break at the tab on the swingarm. Unobtainium, and any weld just weakens the swingarm.



Source an ample field tool kit for field repairs for the Armstrong MT500 or Harley-Davidson MT350 from the British Army or Bundeswehr. For the curious, here's what the Harley-Davidson MT350E looks like:

UK MoD
Yes, that Rotax engine is bullet-proof!
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Last edited by seavoyage; 02-03-2013 at 02:22 AM..
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Old 01-21-2013, 02:51 PM   #2
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Amazing amount of info. Thanks!

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Old 01-21-2013, 03:09 PM   #3
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actually, the kickstand issue isn't the tab on the swing arm, it the spring that has so much force it breaks out the front of the stand (still, you shouldn't sit on it while it is down).


it will break out of the janky pos stand brace. Otherwise, a very capable old bike that can be pretty fun and interesting. Powerful and handles well albeit for a 25 year old design.
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Old 01-21-2013, 03:25 PM   #4
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Was waiting for Goose to chime in with real world test results.
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Old 01-22-2013, 09:26 PM   #5
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I had one of those. Kick start, not electric. Like he said, bulletproof. Someone had installed the "860" cam, not exactly sure what that was, but it sure wound out on top, it was the cam the flattrackers used in the Rotax engine. I wouldn't mind having that bike back again, except for that left side kicker way up in the air.
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Old 01-27-2013, 04:44 PM   #6
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Relocated the kickstand on the oATK 605 when we modified the foot pegs.
Hopefully the ATK 605 for the height impaired build thread will begin on Tuesday.

Seavoyage to you sir
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DMV test is not there to teach or prove you can ride the bike, it is there to prove that you can control the bike.
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Last edited by ThumperX; 01-27-2013 at 04:50 PM..
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Old 02-09-2013, 08:46 AM   #7
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I gotta get my 406 running. The Motoplat is bad...
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Old 02-09-2013, 08:50 AM   #8
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Quote:
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DMV test is not there to teach or prove you can ride the bike, it is there to prove that you can control the bike.
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Melissa"everyone does have issues, it is what makes us all so very interesting. Psychoanalysis however could be left to the professionals."
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Old 09-07-2020, 10:05 AM   #9
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1997 ATK 605 fork build

I recently purchased a 1997 605. Somewhere along the line someone put shorter WP forks and a 19” wheel up front and 17 on the rear. I have the original wheels and forks and plan on using them. The forks are blown out. Are the originals WP 4054s. Where do I find the seals and bushings to repair them?:cool
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Old 09-07-2020, 11:01 AM   #10
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I've got a set of 605 Swingarm decals. Anyone interested let me know.
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Old 09-07-2020, 11:56 AM   #11
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I recently purchased a 1997 605. Somewhere along the line someone put shorter WP forks and a 19” wheel up front and 17 on the rear. I have the original wheels and forks and plan on using them. The forks are blown out. Are the originals WP 4054s. Where do I find the seals and bushings to repair them?
You are a long way away... but down here MotoExotica is a solid resource for these beasts. They're in Livermore.

I have huge envy btw, I had one of these for a brief minute in "semi running project"state and never had a chance to ride it.
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Old 09-07-2020, 11:59 AM   #12
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Originally Posted by Brad Elkin View Post
I recently purchased a 1997 605. Somewhere along the line someone put shorter WP forks and a 19” wheel up front and 17 on the rear. I have the original wheels and forks and plan on using them. The forks are blown out. Are the originals WP 4054s. Where do I find the seals and bushings to repair them?
I run a local “rescue” for the 605s. GREAT GREAT FANTASTIC bike! I opted to mothball Beastie and replace it with a Beta but am seriously reconsidering overhauling the ATK and rekindling my love affair.
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Quote:
Originally Posted by atoyf View Post
DMV test is not there to teach or prove you can ride the bike, it is there to prove that you can control the bike.
HOHO
Melissa"everyone does have issues, it is what makes us all so very interesting. Psychoanalysis however could be left to the professionals."
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Old 09-07-2020, 10:11 PM   #13
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picked up my 605 about 10 years ago. Found it in an SF garage not running. It turned out to be a stuck open decompression lever.

Cleaned it up and went through the carb. Replaced the timing belt and it was a tank. Used it on the Sheetiron 300.

Eventually, I sold it because I had too many bikes in the garage. One of the coolest bikes I ever owned.
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Old 09-07-2020, 10:14 PM   #14
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picked up my 605 about 10 years ago. Found it in an SF garage not running. It turned out to be a stuck open decompression lever.

Cleaned it up and went through the carb. Replaced the timing belt and it was a tank. Used it on the Sheetiron 300.

Eventually, I sold it because I had too many bikes in the garage. One of the coolest bikes I ever owned.
I thought you got yours after I got Beastie? I wound up buying your bike, it went to Oregon for a while and now it’s back in CA with my nephew.
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Quote:
Originally Posted by atoyf View Post
DMV test is not there to teach or prove you can ride the bike, it is there to prove that you can control the bike.
HOHO
Melissa"everyone does have issues, it is what makes us all so very interesting. Psychoanalysis however could be left to the professionals."
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Old 09-17-2020, 02:30 PM   #15
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I thought you got yours after I got Beastie? I wound up buying your bike, it went to Oregon for a while and now it’s back in CA with my nephew.

I don't remember the date but I think I got it in 2013. I'm sure the BARF archives will have exact info.
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