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well ive finally got motivated and ripped the slug out of my 300 for a little freshen up.
it has done 108 hours and 4320km.ive researched the internerd forums worldwide and reckon i can bugger it up like the rest of them…. :laugh:
im sorta going in blind, the last topend i did was in ummm… 1998 :laugh:
and was an ’86 KDX200, so it wasnt really rocket science :laugh:the ktm was a little more daunting but i just hooked in and, voila!
heres a little detail…
washed down the beast, blew her off and ripped off the neccessities, including the pipe.
drained the coolant into the bucket but mainly succeeded in spilling it on the floor and myself…(sorry, no picture of stupidity)
took off the plug cap, water hose and top engine mount
had a sticky up the exhaust to see the state of the piston….
it looks nearly new!!! bugger all blowby and shit.
rings look spot on…
bugger all buildup on the powervalve flap too.i am a little concerned about this though,
there are grooves worn into the housing from the o-rings being shagged and the pipe rattling around. i was warned about this happening earlier but didnt think much of it… now it looks like a new powervalve housing or a weld job after nundle. i will just wrap a heap of teflon tape around the new o-rings when i re-install the pipe….
unless anyone has any other suggestions??i see a mob called Diamond Strike has brought out a new fandangle rebuild kit for the KTM’s. They claim you can fix anything on a KTM, anywhere and anytime with this kit…
check it out Melon boys
part 2
anyway, i undid these two bolts and tapped the starter out so i could get to the left PV cover.
took the left PV cover off as you need to to expose a nut needed to get the barrel off. A little bit of oil and muck but pretty clean.
this got me thinking about spooge and its uselessness in life. :laugh: :laugh:
heres my pipe, engine end…..slight carbon, no wet spooge, little buildup
and muffler end, just as dry and clean…
its all tooooo clean…..!
i was starting to think there was something wrongtoo lean, not enough premix!!
luckily, then i remembered that its a bloody KTM300, the highly refined and efficient big bore 2 banger, whose superior burn pattern allows it to run clean even when it is lugging around in places only goats and boony venture…effortlessly too i might add :laugh: :laugh: :laugh: :laugh: sorry bruce, couldnt resist
anyway, i ripped the RH PV cover off as you need to get into another barrel nut and remove a little clip off the actuator arm. i didnt get any pics because i was getting too excited, here is one of the cover :laugh:
Next, i took the head off…and low and behold it looked new :woohoo:
there was very little carbon on the top of the slug. i reckon half of this was from sweeping last ride and lugging home with a dodgy fork.
barrel is in perfect condition with no lipping or scoring :woohoo:
i then whipped the barrel off(or JUG as the seppos call it )
the piston is still near perfect. i reckon it would have been good for another 50+ hours.
a light scotchbrite-ing and it will be apples
the cross hatching is still visible on the bore down low.
very little wear….good oil pays off!!
motul 800 is the best!even the PV flap is pretty clean, a bit of carby clean and wire brush and it will be sparkling again.
i looked all over for the best and cheapest piston kit for the Kato.
the best i found for a ‘group2’ kit (one size up) was $240. and believe it or not in sydney, from ProRider. they didnt have one in stock when i enquired.
the next cheapest was also from sydney, ProCycles at $263.Seeing procycles is a KTM dealer and they were doing them that cheap, i thought id give Mal at Suttos a go.
in typical dealer fashion he quoted me an astronomical price :laugh: i think the piston was $300ish :laugh: :laugh:i told him what they were going for and he matched the price on the spot
good onya Mal, much appreciated.i should have the bits express post tomorrow.
to be continued
blah blah blah Bruceee :laugh: :laugh: :laugh:
its just fine for me as it is, imperfect burning and 36mm carb and all :laugh: :laugh:
im really happy with the condition of its innards though. i was expecting a little scoring or a bit of lip, but nothing :woohoo:
cant wait for the postie so i can wack it back together
im already dreading putting those f**king gudgeon clips in though :laugh: :laugh:
next fear to face will be my triple clamps. im not sure whether or not to fix them with a hammer and risk major damage to myself if they snap, or bin them and get some faster flasher ones
menace wrote:
Quote:bnext fear to face will be my triple clamps. im not sure whether or not to fix them with a hammer and risk major damage to myself if they snap, or bin them and get some faster flasher ones
Go the bling triple clamps mate. Metal fatigue is hard to see,aluminium that has bent that far, wouldn’t have my confidence.
micknmeld wrote:
Quote:menace wrote:Quote:bnext fear to face will be my triple clamps. im not sure whether or not to fix them with a hammer and risk major damage to myself if they snap, or bin them and get some faster flasher ones
Go the bling triple clamps mate. Metal fatigue is hard to see,aluminium that has bent that far, wouldn’t have my confidence.
thats the lines im thinking along Mick.
considering they are cast solid and slotted to allow for a couple of mm, bendind it out 20+ must have rooted it somehow or way :Smicknmeld wrote:
Quote:menace wrote:Quote:bnext fear to face will be my triple clamps. im not sure whether or not to fix them with a hammer and risk major damage to myself if they snap, or bin them and get some faster flasher ones
Go the bling triple clamps mate. Metal fatigue is hard to see,aluminium that has bent that far, wouldn’t have my confidence.
Hey Spidy
Mick’s right mate. If the clamps were cromo all would be good but I have seen what how alloy behaves when it has been stressed. As soon as you try and bend it back the problem will start if it has not already. Alloy is light but fatigues like a fat guy in body armour on a summer day. Bin it and bling it!!!
STM
menace wrote:
Quote:blah blah blah Bruceee :laugh: :laugh: :laugh:its just fine for me as it is, imperfect burning and 36mm carb and all :laugh: :laugh:
im really happy with the condition of its innards though. i was expecting a little scoring or a bit of lip, but nothing :woohoo:
cant wait for the postie so i can wack it back together
im already dreading putting those f**king gudgeon clips in though :laugh: :laugh:
next fear to face will be my triple clamps. im not sure whether or not to fix them with a hammer and risk major damage to myself if they snap, or bin them and get some faster flasher ones
if you get a lip in the composite bore it means the coating is GOOOONNNNNNEEEE and you’re toasty marshamallowed, but KTMs have one if not the best plating around. Piston clips put one in on the bench, piece of cake, the other sorta “wind” it in using fingers, or get a real short bit of pipe around the same id as the od of the wrist pin and using a bolt with a good fit push it in using bolt and thumb pressure, You’ve got a god set of hands on you you’ll piss it in.
Maybe next time it’ll get150 hrsMr Blue wrote:
Quote:Agree with the lads on the triples too, just replaced my twisted upper one with a fully adjustable asv one, it’s gooodddd as gold mate.Just do it, cause if the other one breaks I don’t need to go to vicco for a wheelchair run.
yeah, after mulling over the idea a bit i think i’ll have to lash out on some flash ones…
Hmmmm, i think black ones would go nice.
what is the go with the ASV ones Bruce, are they any lighter?
mine are fully adjustable from the factory so i lose out on that advantagenow im thinking under bar dampner while im there :laugh: :laugh: :laugh:
wish my moneytree was an evergreen :laugh:
Mr Blue wrote:
Quote:if you get a lip in the composite bore it means the coating is GOOOONNNNNNEEEE and you’re toasty marshamallowed, but KTMs have one if not the best plating around. Piston clips put one in on the bench, piece of cake, the other sorta “wind” it in using fingers, or get a real short bit of pipe around the same id as the od of the wrist pin and using a bolt with a good fit push it in using bolt and thumb pressure, You’ve got a god set of hands on you you’ll piss it in.
Maybe next time it’ll get150 hrsi reckon 150 easy mate, maybe 200 even!!
im not really worried about the ‘jesus clips’ as my dad used to call them :laugh:
i pre grooved some old pointy plier just for the job
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