Not sure if you have all the right tools and parts for this job? No worries, we have you covered. www.rockymountainatvmc.com/Sales/1710/Top-End-Rebuild?
This video despite being extremely old is still so helpful for my first ever rebuild on my 2004 KTM 450 exc. The crazy part is that your videos no matter how old will always be a part of history for all of us to look back to when we need information and I'm sure I'm not the only one referring to this video even today. Rock mountain is by far the best and most useful.
10 year old video with over a million views, yet still soooo useful. I thank you, got my full rebuild parts, gaskets, and tusk tools(and one 5mm x .8 heli coil, don't want to talk about it) all from Rocky Mountain ATV was a pleasure to do business with you guys. And again I thank you for the technical information in this video. Great job! To those who care rebuild on a 2004 KTM 450sx.
Thats an exceptionally well done video actually. Thats pretty much the same technique as me except on the gasgets I mix up some graphite and oil into a paste and apply on 1 side of a gasget, and what that does is make it possible to pull covers and what ever else that has a gasget on it off without ever breaking another gasget and it never leaks either. This is something I learned from an old timer, it works.
That is the first time I have ever seen someone break the timing chain to do a rebuild. I have never done that, and I found it interesting. I haven't watched the first part of your rebuild video, so I will to see why you broke the chain. A good video, and will definitely be helpful to those who are new to this type of work. Rebuilding the top end is pretty easy, and I have done a few over the years.
Thanks for watching! Yep on this bike it was necessary to break the timing chain in order to complete the rebuild. KTM sells the replacement master links to put it back together when it's time.
Appreciate your videos are so useful and nice and slow explanation step by step sir . Hopefully you will do one on valves clearance ; inlet and exhaust.
We have heard excellent things about both bikes and either bike is going to be reliable depending on maintenance. I have heard the WR is a little lighter but i'd say it's personal preference deciding between both of them. I don't see any big advantage to either one
Just installed a new cam, water pump and a few other parts (all ordered from Rocky Mountain of course) on my 2006 KTM 450 SMR. This video along with the previous about the KTM RFS engines were super helpful! Thanks a lot for all the videos you guys put out!
- you can look up pricing on our website. 4-strokes cost a lot more; more moving parts! If you take care of a YZ450 though, it will last a long time. In my oppinion it is the most reliable 450.
@BowHunt1229 - Already bolted together? no. Some case halves use a liquid gasket maker instead of a gasket, but it has to be pulled apart. If your bike requires a gasket you must use one.
this guy has experience and makes it look easy. if anyone plans on doing this themselves make sure its a bike you can afford to screw up on. good video though, but i was disappointed he didnt turn the bike on
@deathslayer0102 - there are several factors here. it depends on how hard and often it is ridden as well as how often the oil was changed and whether or not anything got past the airfilter. Refer to you manual for recomended inspection and rebuilding intervals.
I have really enjoyed your videos, and they have helped me a lot to understand not just the models that you are working on, but working on motorcycle engines in general! I think it would be great if you gave more "why's" to the "how to's". For example, giving short examples of what would happen if one failed to do some step in the procedure. That way, if something doesn't work, tracking the problem down would be much faster! Once again, thanks for outstanding videos!
Thank you most complete n helpfull ktm 4 stroke assembly tutorial on youtube. But i couldn't help but notice at 4:58 the cam gear sprocket teeth look worn or rounded of. I had a 426 yzf i rode every day all day n shared it with my best m8 bro we must of put 20 thousnd on the motor but it waz always serviced with the best oil air filter plug n ridden n treated rite and when it came tii.e 2 replace a worn gear selecter we foun the crank teeth were just about non exxisten gone n the timming chain was seized stiff we left it too l8 because we were not well off but we made the most of it.great memories what lifes about
I'm sure your dad could manage the rebuild. Anyone with the correct tools, a service manual and some basic knowledge of motors would be able to manage a rebuild. As long as you do everything in the right step you should be fine. We also have these videos for you to follow through the rebuild.
you probably dont give a shit but if you are bored like me during the covid times then you can watch all the new movies and series on Instaflixxer. Have been binge watching with my girlfriend these days :)
- I would guess the nikasil is better - that is why the OE's do it. However, I have never had a problem with a sleeve. The one we did in this video is still running strong 3 years later.
Replacing the top end on a bike isn't hard so long as you've got the correct tools such as a service manual and some other common hand tools and then you would need a valve spring compressor if you plan on replacing the valves. We are actually working on a YZF Top End Replacement Video right now that would help you out but you are going to need to refer to your service manual mostly for this job.
Oil Starvation was ultimately the cause. This damaged cylinder was bored and sleeved slightly larger than stock. Most resleeving companies will restore your cylinder back to stock specifications.
Thanks for the video, it helped a lot. When you put the screw in for the engine to stay at TDC, does it automatically stay at the correct TDC where the valves are adjusted, or could it be at false TDC?
I need a video for the CRF 250! but this helps almost the same thing as honda honda doesnt have the waterpump on top looks easier ty for the video Rocky Mountain!
Hi. Did every step in your toturial, but my piston stops on the top of the cylinder and will not move after. I can pump the kickstart so the piston moves down and up 1 time and then it stops. What do you think I have done wrong
@fengluzon - I had a valve video done, but my hard drive crashed before i rendered it. it is now gone. i will have to start over one of these days. No Yamaha video yet.
Ha Ha Thanks! 2 Strokes are definitely a little easier to work on but 4 strokes aren't bad as long as you've got the correct tools and you get all the steps in the correct order.
Just had a 2005 ktm450sx rebuilt for burning oil like a 2-stroke. Get it back from the builder and 4 miles on the bike and I have crazy blow by like a lot and drips about 3in puddle of oil out of the crankcase vent tube so ik think broken compression rings? Builder wont stand by he work began cussing us out over the phone when we informed him about the bike. Thinking about trying it myself this time while watching your videos for guidance.
Yeah having that much oil coming from the breather is a good indication of a bad seal on the rings so you're on the right track. I would recommend starting with a compression and leak down test to try and figure out where to go from there. That's a real bummer that happened to you after just having it rebuilt!
Great videos. Thank you very very very much. Why can't i see the valve replacement video? Do you have a video for a wr250f or a yz250f? (450 will be great to). Thank you very very very much for all the videos.
ya i replaced the outside one because the tusk kit had two different oring sizes and one seemed to big for both grooves. do the orings need to be a real tight fit around the two grooves?
so what would you say running in time is with a new top end is how many miles ? very nice tutorial allso helped alot with the rings as im used to 2stroke.
i took the head cover back off and the 4 head bolts were not tight enough. But now the only place where there is a leak is out of that little bolt hole right next to the lower right of the water pump cover. it wont stop drizzling out of there
Hi on the video you say please refer to our video on the valve replacement instructions ...I cant seem to find the video , do you have a link to the video please?
I still not understand because you remove the ignition cover! Could you explain that? Do you use the flywheel to move the piston? Why don't you use the kickstarter? Thanks regards
How does it go long term with the resleeve I had mine recoated with nikasil my local KTM dealer mechanic who has 10 + years experience said in no way shape or form should you resleeve these cylinders as the cast iron sleeves cannot disipate the heat like the nikasil coated aluminium, I don't know but I went with his advice and got it recoated as I was just about to do the resleeve any thoughts or experiences you have had with the resleeve would be much appreciated. Mike
maybe it's irrelevant but I was taught that circlip gap orientation should point either up to the piston top or down to the crankshaft. just a thought btw thanks for your videos
Well thank you very much! but no, not at all. Any motor that is maintained regularly and taken care of correctly is going to last you. Obviously all the manufacturers are striving to to improve their design and to be the best and so in my opinion any modern bike is going to be a good quality bike for you . . . it all comes down to maintenance now
Awesome piece of work! It seems incredibly confusing to me. How come you know which bolt goes in which hole! Which brand's engine is easier to go for this kind of rebuild? Honda, KTM or Husky? Very best to you!
ok and how long will a yz450 last me if i do take care of it? I will only ride once or twice a month on the bike and its only trail/woods riding. Also how long would my yz125 last compared to the 450? I do the same amount of riding on it as well and always clean hear and maintain everything. I"m VERY OCD on maintaining and cleaning my bike and cars. So last question....Should i stick with my yz125 and learn how to it or trade it for a 450 based on the style/time i will put on the bikes...
@RockyMountainATVMC a head without the cams and everything in it, just the basic piece, its for a 450 ktm, its got a big knick in it, the guy who is selling the bike says it would prolly have to be replaced
so can can i bend a feeler gauge at the tip so i can get it in between there to adjust the valves on my GS300? I have the bladed feeler gauges but they are straight and wont clear the top of the head where the valve cover gasket surface is.
hey i am just wondering what do you mean on 7:14 7 :30 minutes. what kind of measurements. ??? i am trying to fix my motorcycle.. your help and fast answer would be very helpfull. thank.. you
@hdidane00 - No locking screw on your WR. you needto line up the timing marks on your flywheel. Pull both caps off the cover to do this. Your WR is much easier than this KTM.
I just rebuilt the same engine as in this video. It starts up and runs great but out of the bottom cylinder gasket it is driblling oil out and the top has anti freeze seeping out. Ive used new gaskets and installed them correctly with yamabond. Could the 4 cylinder bolts not e tight enough? what do you think is causing this?
hey so this is probubly a stupid question but i dont know it do you have to like do anything after you empty you radiator or can you just fill it back up with coolant like i dont know if you see what im asking its hard to explain.
how much more is it to buy a top end for a 450f yz compared to a yz125 top end? this is a new cylinder, piston, rings, bearings, but no bottom end work at all I really wanna know cuz i might have to get a 4 stroke, and am worried about the cost on the 4 strokes. Plus how many years or hours would i get on a 450f that i will just baby and trail ride it?
Not sure if you have all the right tools and parts for this job? No worries, we have you covered. www.rockymountainatvmc.com/Sales/1710/Top-End-Rebuild?
This video despite being extremely old is still so helpful for my first ever rebuild on my 2004 KTM 450 exc. The crazy part is that your videos no matter how old will always be a part of history for all of us to look back to when we need information and I'm sure I'm not the only one referring to this video even today. Rock mountain is by far the best and most useful.
Thanks, we're glad it helped!
Best video on any RFS or KTM period.... thank you..
Glad you liked it! Thanks for the feedback and views.
10 year old video with over a million views, yet still soooo useful. I thank you, got my full rebuild parts, gaskets, and tusk tools(and one 5mm x .8 heli coil, don't want to talk about it) all from Rocky Mountain ATV was a pleasure to do business with you guys. And again I thank you for the technical information in this video. Great job! To those who care rebuild on a 2004 KTM 450sx.
That is so awesome to hear! Thank you for the support and we're glad the video helped you out!
Thats an exceptionally well done video actually. Thats pretty much the same technique as me except on the gasgets I mix up some graphite and oil into a paste and apply on 1 side of a gasget, and what that does is make it possible to pull covers and what ever else that has a gasget on it off without ever breaking another gasget and it never leaks either. This is something I learned from an old timer, it works.
Just did a rebuild on a 2007 XCW - this video is still HELPING US!!!!!!!!! THANKS
This made my entire day. Kids with two strokes.... Has the world really come to this?
That is the first time I have ever seen someone break the timing chain to do a rebuild. I have never done that, and I found it interesting. I haven't watched the first part of your rebuild video, so I will to see why you broke the chain.
A good video, and will definitely be helpful to those who are new to this type of work.
Rebuilding the top end is pretty easy, and I have done a few over the years.
Thanks for watching! Yep on this bike it was necessary to break the timing chain in order to complete the rebuild. KTM sells the replacement master links to put it back together when it's time.
you are right. I am finishing the editing on it now. I should have it done soon. thanks
Appreciate your videos are so useful and nice and slow explanation step by step sir .
Hopefully you will do one on valves clearance ; inlet and exhaust.
Watching this 1) reminds me why I got a 2 stroke and 2) makes me want to watch it again to marvel at your talent. Great video.
We have heard excellent things about both bikes and either bike is going to be reliable depending on maintenance. I have heard the WR is a little lighter but i'd say it's personal preference deciding between both of them. I don't see any big advantage to either one
Thanks, this video pushed me over the line for doing my own head gasket repair!
@juoj8 - thanks. We will keep that in mind on our new videos.
Great video. Just seized my BETA 525 a couple days ago. Engine is basically a KTM. This video sure has helped me out. Thanks
We will be doing a CRF soon and then a YZ a little later. Just need to find the time. thanks.
Just installed a new cam, water pump and a few other parts (all ordered from Rocky Mountain of course) on my 2006 KTM 450 SMR. This video along with the previous about the KTM RFS engines were super helpful! Thanks a lot for all the videos you guys put out!
You're welcome! Thanks for watching our videos.
are the head bolts new ? or can these be reused ?
assembly lube. We offer 3 brands. Belray, PJ1, and Pro Circuit. All 3 work great.
I have a CRF250 video, but I have not had time to finish editing. I will get to it soon.
- you can look up pricing on our website. 4-strokes cost a lot more; more moving parts! If you take care of a YZ450 though, it will last a long time. In my oppinion it is the most reliable 450.
@BowHunt1229 - Already bolted together? no. Some case halves use a liquid gasket maker instead of a gasket, but it has to be pulled apart. If your bike requires a gasket you must use one.
You bet! Thanks for watching
this guy has experience and makes it look easy. if anyone plans on doing this themselves make sure its a bike you can afford to screw up on. good video though, but i was disappointed he didnt turn the bike on
@deathslayer0102 - there are several factors here. it depends on how hard and often it is ridden as well as how often the oil was changed and whether or not anything got past the airfilter. Refer to you manual for recomended inspection and rebuilding intervals.
I have really enjoyed your videos, and they have helped me a lot to understand not just the models that you are working on, but working on motorcycle engines in general!
I think it would be great if you gave more "why's" to the "how to's". For example, giving short examples of what would happen if one failed to do some step in the procedure.
That way, if something doesn't work, tracking the problem down would be much faster!
Once again, thanks for outstanding videos!
We are also putting one together for a crf250, but not a kfx250. The process is about the same though. It will be done in a few weeks.
Thank you most complete n helpfull ktm 4 stroke assembly tutorial on youtube. But i couldn't help but notice at 4:58 the cam gear sprocket teeth look worn or rounded of. I had a 426 yzf i rode every day all day n shared it with my best m8 bro we must of put 20 thousnd on the motor but it waz always serviced with the best oil air filter plug n ridden n treated rite and when it came tii.e 2 replace a worn gear selecter we foun the crank teeth were just about non exxisten gone n the timming chain was seized stiff we left it too l8 because we were not well off but we made the most of it.great memories what lifes about
@qwikyking - I have no idea what you are looking to buy. Are you talking about a cylinder (that is below the head)? What machine?
@londonTown1989 - a few cycles of letting it heat up and then cool off.
@kraden18 - refer to the manual. there should be a mark on the flywheel that matches up with a mark on the cover.
Which cap are you referring to? because two strokes don't have valves
I'm sure your dad could manage the rebuild. Anyone with the correct tools, a service manual and some basic knowledge of motors would be able to manage a rebuild. As long as you do everything in the right step you should be fine. We also have these videos for you to follow through the rebuild.
you probably dont give a shit but if you are bored like me during the covid times then you can watch all the new movies and series on Instaflixxer. Have been binge watching with my girlfriend these days :)
@Rylan Eddie Yup, been using Instaflixxer for since november myself :)
Thank you! If everything goes smoothly you can do this in an hour or two depending on experience and how smoothly the job goes.
@zobel929 - did you replace the O-rings around the water pump? It sounds like they may be bad.
You guys always put together great vids! Thanks!
@zobel929 - it could be the problem. you shouldn't have needed yamabond on the o-rings or the base gasket though.
- I would guess the nikasil is better - that is why the OE's do it. However, I have never had a problem with a sleeve. The one we did in this video is still running strong 3 years later.
@mycat8urskidoo - they are pretty much identical kits. The tusk works great.
@SoobaaSteve - You need to call a shop in your are to find out. But why not do it yourself?
you say to put the 2 smaller rings on top of the oil scraper ring. do you mean on either side of it. or both on the top side of it?
+Liam Chalk Very true, nice catch. His wording could get a little confusing, but do as shown in the video. Top and bottom.
+Rocky Mountain ATV MC thanks
Replacing the top end on a bike isn't hard so long as you've got the correct tools such as a service manual and some other common hand tools and then you would need a valve spring compressor if you plan on replacing the valves. We are actually working on a YZF Top End Replacement Video right now that would help you out but you are going to need to refer to your service manual mostly for this job.
Oil Starvation was ultimately the cause. This damaged cylinder was bored and sleeved slightly larger than stock. Most resleeving companies will restore your cylinder back to stock specifications.
very nice vid the best i seen on youtube so far
@HondaRider342Q - you would need to pull it apart and inspect it. then go from there.
@ridinhonda4life - There is no real relation between the two; however, You should check the valves and adjust them.
@rama6maiden - i suppose you could say that about any part inside of an engine.
Thanks for the video, it helped a lot.
When you put the screw in for the engine to stay at TDC, does it automatically stay at the correct TDC where the valves are adjusted, or could it be at false TDC?
I need a video for the CRF 250! but this helps almost the same thing as honda honda doesnt have the waterpump on top looks easier ty for the video Rocky Mountain!
Hi. Did every step in your toturial, but my piston stops on the top of the cylinder and will not move after. I can pump the kickstart so the piston moves down and up 1 time and then it stops. What do you think I have done wrong
@fengluzon - I had a valve video done, but my hard drive crashed before i rendered it. it is now gone. i will have to start over one of these days. No Yamaha video yet.
@emoskater1212 - refer to the manuals recommendations for replacement. Don't wait till something breaks!
@2hot4you369 - yep. 2004 EXC 450. not real clean anymore. It has been used and abused by one of our employees!
Ha Ha Thanks! 2 Strokes are definitely a little easier to work on but 4 strokes aren't bad as long as you've got the correct tools and you get all the steps in the correct order.
@MrAhkmed - You are correct!
Just had a 2005 ktm450sx rebuilt for burning oil like a 2-stroke. Get it back from the builder and 4 miles on the bike and I have crazy blow by like a lot and drips about 3in puddle of oil out of the crankcase vent tube so ik think broken compression rings? Builder wont stand by he work began cussing us out over the phone when we informed him about the bike. Thinking about trying it myself this time while watching your videos for guidance.
Yeah having that much oil coming from the breather is a good indication of a bad seal on the rings so you're on the right track. I would recommend starting with a compression and leak down test to try and figure out where to go from there. That's a real bummer that happened to you after just having it rebuilt!
Good job!
Great videos.
Thank you very very very much.
Why can't i see the valve replacement video?
Do you have a video for a wr250f or a yz250f? (450 will be great to).
Thank you very very very much for all the videos.
Thanks for the Video , very useful and to the point, thumbs up, love the RFS bikes.
ya i replaced the outside one because the tusk kit had two different oring sizes and one seemed to big for both grooves. do the orings need to be a real tight fit around the two grooves?
Did you squeeze the piston rings with your hands to fit on the cylinder? Its tight and I find it hard to do.
On the valves is that between .004 - .005 for all the valves, or just the exhaust valves, or just the intake valves?
@PureN3WZ3ALAND - a lot of factors play into that. regular instection is a good idea.
so what would you say running in time is with a new top end is how many miles ?
very nice tutorial allso helped alot with the rings as im used to 2stroke.
Very well done. Clear video and precise instructions.
@acraze21 - there are certainly similarities. Your XR should be a lot easier.
i took the head cover back off and the 4 head bolts were not tight enough. But now the only place where there is a leak is out of that little bolt hole right next to the lower right of the water pump cover. it wont stop drizzling out of there
Hi on the video you say please refer to our video on the valve replacement instructions ...I cant seem to find the video , do you have a link to the video please?
Does the Crank Lock Bolt for TDC have any play in it (slotted) or does it locate and prevent the crank from moving at all (hole)?
I still not understand because you remove the ignition cover! Could you explain that? Do you use the flywheel to move the piston? Why don't you use the kickstarter? Thanks regards
How does it go long term with the resleeve I had mine recoated with nikasil my local KTM dealer mechanic who has 10 + years experience said in no way shape or form should you resleeve these cylinders as the cast iron sleeves cannot disipate the heat like the nikasil coated aluminium, I don't know but I went with his advice and got it recoated as I was just about to do the resleeve any thoughts or experiences you have had with the resleeve would be much appreciated.
Mike
do you think that just plain ol seal maker would seal up a split case sufficiently if its already bolted together?
@ed563 - it doesn't exist yet. My hard drive failed and I lost the video. I will make a new one someday. sorry about that.
maybe it's irrelevant but I was taught that circlip gap orientation should point either up to the piston top or down to the crankshaft. just a thought
btw thanks for your videos
Well thank you very much! but no, not at all. Any motor that is maintained regularly and taken care of correctly is going to last you. Obviously all the manufacturers are striving to to improve their design and to be the best and so in my opinion any modern bike is going to be a good quality bike for you . . . it all comes down to maintenance now
i look on ur web site for an appropriate torque wrench but only dounf the spoke wrench can u provide a link for the appropriate torque wrench?
Awesome piece of work! It seems incredibly confusing to me. How come you know which bolt goes in which hole! Which brand's engine is easier to go for this kind of rebuild? Honda, KTM or Husky? Very best to you!
How’d you guys get the side plate on for the timing chain? I notice in the video he did it by hand but that doesn’t work in real life.
when you install new rings does it matter where they sit on the piston? like where the gap on the rings are on the piston?
@sk8perez2 - Most likely not. The steps are similar to those is this video.
ok and how long will a yz450 last me if i do take care of it? I will only ride once or twice a month on the bike and its only trail/woods riding.
Also how long would my yz125 last compared to the 450? I do the same amount of riding on it as well and always clean hear and maintain everything. I"m VERY OCD on maintaining and cleaning my bike and cars. So last question....Should i stick with my yz125 and learn how to it or trade it for a 450 based on the style/time i will put on the bikes...
@RockyMountainATVMC a head without the cams and everything in it, just the basic piece, its for a 450 ktm, its got a big knick in it, the guy who is selling the bike says it would prolly have to be replaced
so can can i bend a feeler gauge at the tip so i can get it in between there to adjust the valves on my GS300? I have the bladed feeler gauges but they are straight and wont clear the top of the head where the valve cover gasket surface is.
when or how often should the head be re done and valve seats cut? when the valves need a second shim? and replace valves and cut valve seat or?
thanks
i was wondering if your susposed to put silicone on a 96 kx250 head gassket, need to no asap thsnkd
Could you be able to upload the CRF top end video some time?
did you torque everything to spec? because that could do it, and did you clean the mating surfaces?
Did you use lube on the cyclinder and rings when you installed them or was it dry?
@171apples171 - yes, i bend mine all the time!
nice vid guys how much would somthing like this cost for someone to do it on a KTM250sxf
@spruland - not usually
How often does a Husaberg FE 501 2003 need to change the piston?
When only driven normal on asphalt
hey i am just wondering what do you mean on 7:14 7 :30 minutes. what kind of measurements. ??? i am trying to fix my motorcycle.. your help and fast answer would be very helpfull. thank.. you
How much was the cost to get it sleeved?
@hdidane00 - No locking screw on your WR. you needto line up the timing marks on your flywheel. Pull both caps off the cover to do this. Your WR is much easier than this KTM.
I just rebuilt the same engine as in this video. It starts up and runs great but out of the bottom cylinder gasket it is driblling oil out and the top has anti freeze seeping out. Ive used new gaskets and installed them correctly with yamabond. Could the 4 cylinder bolts not e tight enough? what do you think is causing this?
Very well done and very-very informative.
Thanks Guys.
Will the Tusk Chain riveting tool do the trick on the RFS motors or would you recommend the motion pro
hey so this is probubly a stupid question but i dont know it do you have to like do anything after you empty you radiator or can you just fill it back up with coolant like i dont know if you see what im asking its hard to explain.
how much more is it to buy a top end for a 450f yz compared to a yz125 top end? this is a new cylinder, piston, rings, bearings, but no bottom end work at all I really wanna know cuz i might have to get a 4 stroke, and am worried about the cost on the 4 strokes. Plus how many years or hours would i get on a 450f that i will just baby and trail ride it?