Lefty’s 2008 KTM 450 EXC Rebuild

[Geoff ForshawMember]

After purchasing MY 08 KTM 450 EXC-R from Sutto’s back in September of 2007 With over 200hrs and almost 7600km of trouble free (almost, kill switch failed Coff’s ride last year)off road riding it is time for a rebuild. I have noticed lately that the old girl has been using some oil and when they only hold 600ml it is a bit of a concern. Having said that I have a CPW oil cooler on my Kato which holds another 450ml but i still don’t want to lunch an engine. The 08 model was the first of the XC4 engines and has since had some slight engine up grades as you would expect with a new model machine. These upgrades include Piston and Rings due to oil consumption, Oil pump gears and shaft as well as the engine oil pressure pump cover and o-ring due to oil bypass issues which can drain the engine and fill the gearbox. :ohmy: I have probably been very fortunate where as I have never encounted any of these issues and my Kato has run faultlessly. I will however install these upgrades with the rebuild as it is cheap insurance.
I will also service the cylinder head and may do a little porting. :whistle: :whistle:
All of this can be done in the frame as the cases do not need to be split.
ODO Hrs

ODO Kms

Cam Cover removed

Cam Shaft Removed

Cylinder Head and Barrel Removed

Piston Removed

Will keep you all posted on the finer details as they are done.

Cheers,

The Left One

[Nick JacksonMember]

Cheers Lefty , I always enjoy reading your reports and pics on bike mechanics . I seem to always learn something ( often ‘ leave it to pros like you ‘ !! )

Nick

[Robert ClarkMember]

I was thinking of doing the oil pump gears / o ring upgrade too. There is a nice doco on how to do it here if that is any help.

http://ktmtalk.com/index.php?showtopic=425020&hl=

Clarky.

[James RookyardMember]

Lefty if the KTM is anything like a Honda CRF then I would replace the crank and con rod at the same time. That many hours on a modern 4 stroke and that big end has got to have limited life left in it.

[Geoff ForshawMember]

Thanks for the advice there Jimmy, I will look into it.

Cheers,
Lefty

[Geoff ForshawMember]

clarkyktm wrote:

I was thinking of doing the oil pump gears / o ring upgrade too. There is a nice doco on how to do it here if that is any help.

http://ktmtalk.com/index.php?showtopic=425020&hl=

Clarky.

Thanks Clarky I saw that too. I am tossing up whether to put the upgraded KTM Plastic gears in or get the after market aluminium set. :whistle: :unsure:

Cheers,
Lefty

[GregMember]

Lefty wrote:

With over 200hrs and almost 7600km of trouble free (almost, kill switch failed Coff’s ride last year)off road riding it is time for a rebuild. I have noticed lately that the old girl has been using some oil and when they only hold 600ml it is a bit of a concern. Having said that I have a CPW oil cooler on my Kato which holds another 450ml but i still don’t want to lunch an engine. The 08 model was the first of the XC4 engines and has since had some slight engine up grades as you would expect with a new model machine. These upgrades include Piston and Rings due to oil consumption, Oil pump gears and shaft as well as the engine oil pressure pump cover and o-ring due to oil bypass issues which can drain the engine and fill the gearbox. :ohmy: I have probably been very fortunate where as I have never encounted any of these issues and my Kato has run faultlessly. I will however install these upgrades with the

Blah blah blah should have more oil capacity to start with, 08 no different all KTMs are shit boxes, XR has more than 600hrs on it and 48k plus, Chicken’s had 3 times your euro trash :laugh: :laugh:

Ok sorry Lefty ol mate. Seriously awesome write up will watch with interest mate sure it will be good and of your normal high standard.

TB

[Geoff ForshawMember]

Well I’ve got the cylinder head and barrel back from the machinist and now it it time for reassembly. :woohoo:
I have decided to use a Wossner piston Kit as they have a better ring pack than the std piston and will seal better for longer. I have also decided to use a Cometic Head and Base Gasket kit as I have had many years of success in using these components in many of the race engines that i have built.
After checking the piston/bore clearance and the piston ring end gap she is all good to go.

Barrel and Piston Kit and gasket Set

Wossner Piston Kit

Piston in Barrel ready for assembly

Barrel on and piston installed

Cylinder head On

After re-installing the camshaft, timing chain, rockers and shims then the timing chain tensioner and checking the valve clearance she was ready to go.

I then installed the rest of the accessories, radiators, exhaust, rear subframe, clean air filter, new oil filter. I then filled her up with coolant then new Motul 5100 10w50 engine oil in both the gearbox and engine. Installed the tank, connected the battery then it was time to hit the starter………… Brrrrrrp! She was fired into life and purred like a kitten. Ready for another 200hrs of fun.
Happy days eh! All in a Sunday’s work really. :laugh: :laugh:

Cheers,
The Left one

[GregMember]

Oh it will last now mate thats Honda oil you borrowed this arvo

Good job mate

TB

[Geoff ForshawMember]

Trailboss wrote:

Oh it will last now mate thats Honda oil you borrowed this arvo

Good job mate

TB

:laugh: :laugh: Yeah mate of course! Thanks for that eh!

[alanMember]

Trailboss wrote:

Lefty wrote:

With over 200hrs and almost 7600km of trouble free (almost, kill switch failed Coff’s ride last year)off road riding it is time for a rebuild. I have noticed lately that the old girl has been using some oil and when they only hold 600ml it is a bit of a concern. Having said that I have a CPW oil cooler on my Kato which holds another 450ml but i still don’t want to lunch an engine. The 08 model was the first of the XC4 engines and has since had some slight engine up grades as you would expect with a new model machine. These upgrades include Piston and Rings due to oil consumption, Oil pump gears and shaft as well as the engine oil pressure pump cover and o-ring due to oil bypass issues which can drain the engine and fill the gearbox. :ohmy: I have probably been very fortunate where as I have never encounted any of these issues and my Kato has run faultlessly. I will however install these upgrades with the

Blah blah blah should have more oil capacity to start with, 08 no different all KTMs are shit boxes, XR has more than 600hrs on it and 48k plus, Chicken’s had 3 times your euro trash :laugh: :laugh:

Ok sorry Lefty ol mate. Seriously awesome write up will watch with interest mate sure it will be good and of your normal high standard.

TB

ktms are shit boxes hay TB 👿 just wondering Lefty is that a high comp piston going in there just looks like one to me.did you have any problems with the cam chain tensioner just curius

[Geoff ForshawMember]

Hey There Rocket,

The Wossner piston is std comp which is plenty at 12:1
The cam chain tensioner is a Dirt Works one so no problems there. I forgot to take some photo’s of the cylinder head for you to see. :angry: But one thing that I can say is that the valves are Delwest Titanium inlets and Stainless steel exhausts. As stated they have done 7600km and over 200hrs and they are still the original ones. I showed TB the head when it was complete. I put the original shims back in and the valve clearances are well within spec.

Lefty

[alanMember]

i never changed the valves in my 530 it done a bit more than 200hrs they last good hay

[Craig HattonMember]

If you don’t mind me asking lefty, what sort of dollars???

cheers Hatto

[Geoff ForshawMember]

Hatto wrote:

If you don’t mind me asking lefty, what sort of dollars???

cheers Hatto

No problems Hatto.

Parts
Piston kit, Gasket Kit, Oil, Filter and Cylinder Hone
Cylinder Head Service and Mild Porting c/w new valve stem oil seals using original valves and springs
Around $600

This does not include labour of course.

If anyone requires any work just call or PM me and OBT Discounts will apply.

Cheers,
Lefty

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