Motorcycle Top End Rebuild for 4-Stroke (Part 2 of 2)
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- Опубліковано 20 вер 2024
- Top End Rebuild Parts & Tools:
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This is part 2 of our 4-stroke motorcycle top end rebuild video series. Rebuilding the top end on your 4 stroke motorcycle may seem like a daunting task, but with the right tools and know-how, it doesn't have to be. In this video, we show the proper steps to replacing the top end on this KTM RFS engine, but the same general steps will be very similar for other make and model motorcycles. Please refer to your bike specific service manual for the correct procedures and spec for your machine.
Watch Part 1 Here:
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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!
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!
Best video on any RFS or KTM period.... thank you..
Glad you liked it! Thanks for the feedback and views.
Just did a rebuild on a 2007 XCW - this video is still HELPING US!!!!!!!!! THANKS
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.
This made my entire day. Kids with two strokes.... Has the world really come to this?
Thanks, this video pushed me over the line for doing my own head gasket repair!
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.
you are right. I am finishing the editing on it now. I should have it done soon. thanks
Great video. Just seized my BETA 525 a couple days ago. Engine is basically a KTM. This video sure has helped me out. 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.
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.
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.
Thank you! If everything goes smoothly you can do this in an hour or two depending on experience and how smoothly the job goes.
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
We will be doing a CRF soon and then a YZ a little later. Just need to find the time. thanks.
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!
Thanks for the Video , very useful and to the point, thumbs up, love the RFS bikes.
assembly lube. We offer 3 brands. Belray, PJ1, and Pro Circuit. All 3 work great.
You guys always put together great vids! Thanks!
@juoj8 - thanks. We will keep that in mind on our new videos.
@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.
I have a CRF250 video, but I have not had time to finish editing. I will get to it soon.
@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.
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.
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
@kraden18 - refer to the manual. there should be a mark on the flywheel that matches up with a mark on the cover.
- 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.
@mycat8urskidoo - they are pretty much identical kits. The tusk works great.
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.
- 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.
Good job!
@londonTown1989 - a few cycles of letting it heat up and then cool off.
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 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
Very well done. Clear video and precise instructions.
@SoobaaSteve - You need to call a shop in your are to find out. But why not do it yourself?
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.
@zobel929 - it could be the problem. you shouldn't have needed yamabond on the o-rings or the base gasket though.
@2hot4you369 - yep. 2004 EXC 450. not real clean anymore. It has been used and abused by one of our employees!
@HondaRider342Q - you would need to pull it apart and inspect it. then go from there.
very nice vid the best i seen on youtube so far
Thanks for the tip!
You bet! Thanks for watching
@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.
@ridinhonda4life - There is no real relation between the two; however, You should check the valves and adjust them.
It depends on what "all of this" means. Check out our website for prices specific to your model.
@MrAhkmed - You are correct!
Very well done and very-very informative.
Thanks Guys.
@rama6maiden - i suppose you could say that about any part inside of an engine.
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.
@PureN3WZ3ALAND - a lot of factors play into that. regular instection is a good idea.
@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.
@emoskater1212 - refer to the manuals recommendations for replacement. Don't wait till something breaks!
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
- because the belray works great!
thanks for uploading this
Which cap are you referring to? because two strokes don't have valves
@acraze21 - there are certainly similarities. Your XR should be a lot easier.
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!
one of these days i will get to it:)
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 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
@sk8perez2 - Most likely not. The steps are similar to those is this video.
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
@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
@qwikyking - I have no idea what you are looking to buy. Are you talking about a cylinder (that is below the head)? What machine?
whoah readjusting valves on ktm looks easy compared to other brands :O
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 thanks a lot as soon as it is out i'm gonna check this out :)!
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
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
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!
We're not sure, there wasn't any oil in the bike when we fixed it
@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.
On the valves is that between .004 - .005 for all the valves, or just the exhaust valves, or just the intake valves?
Really great work, thanks a lot for your video.
@spruland - not usually
check ebay if its a powervalve cover than you can find it but 2 strokes dont have valves for the piston
@171apples171 - yes, i bend mine all the time!
sure you can - I am not sure why you be be taking it out though.
@penc5use3 - I think the KTM is harder. a few more steps than the Japanese bikes.
@lastaferyn - I lost the file and have to make a new one. sorry
Thank's for video. You very help me !!! Thank's
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.
@zobel929 - no, you just need to get them in there.
Not unless my WR bottom end fails me.
nice vid, but why would the 2strokers go by the wayside, simple & powerful
Great video guys very informative
- we lubed the cylinder wall with motor oil.
@9139475 - you certainly could, but this one was fine.
wow thats a huge tank
@zobel929 - did you replace the O-rings around the water pump? It sounds like they may be bad.
If you have a 400 sxc 2000 and try to follow this video you will most likely fail. The main problem is the original oil ring, totally different design. IT IS EXTREMELY SENSITIVE! Very easy to snap.
mann.. i want to take motorcycle engine, make agood snow blower out of it.. great and kool video
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)?
Hello friends from Rocky Mountain ATV MC, I'm from Brazil, São Paulo and also motorcycle mechanic'm here, I have a youtube channel (vba bikes), like many of his videos and try to be organized the same as you guys, thank you for the videos and hug here from Brazil.
great info you explain nice and clear tanks pal . dublin ireland
aaaaaaaaaaah great video but man.. I wanted to hear it run!