[AlexMember]

You still waiting on that spring Rocket? Thats not good wonder whats going on there.

[AlexMember]

Yep as Bruce said, reeds stop the charge from coming back out the inlet during the transfer part of the stroke on it’s way to where the action is. Good riddance to the daisy wheel valves of old.
Lifting the exhaust ports higher in the cylinder results at better power at higher RPM but compromises lower RPM power (becomes a peaky bike). So why not have the best of both worlds and have the ports change depending on RPM – win win.
My WR200 here has a stepper motor PV and as Bruce said they have a habit of dying and being hard to replace/expensive.

[AlexMember]

Champion effort Roy. You can now charge to do everyone elses! I told you that manual would save some explaining.
I was a little worried about you setting the Z dimension but if you don’t hear the piston hitting the PV flap then your all good!
It still takes me most of the day, I check everything 10 times over as I don’t do them very often (had a nasty 4T for a while – good riddance)
Yep the circlip in piston dance is best described with words best left unsaid. Why in the F*&^*&^*&^ would they put that extra rim/step/level in I don’t know.
0.7 eh? That’s a 0.5 and a 0.2 then as the next size is a 0.75. Happy to see my trick helped. It’s a prick of a job getting the piston to exactly TDC as I said so rocking it like that is a sure fire way.
As for the torx screws consider yourself lucky they phased out the phillips head screws before it. They chewed out twice as easy. If you don’t have one already the cheap impact driver/socket combo is good to get that sort of stuff out. If you have the extra dollars (highly recommended) you would buy the cordless impact drill that plays nicer and is good for a million other uses.

[AlexMember]

Two Middle East mothers are sitting in a cafe chatting over a plate of
tabouli and a pint of goat’s milk.

The older of the two pulls a small folder out of her handbag and starts
flipping through photos. They start reminiscing.

”This is my oldest son, Mujibar. He would have been 24 years old now.”

”Yes, I remember him as a baby.” says the other mother cheerfully.

“He’s a martyr now though.” the mother confides.

“Oh, so sad dear…” says the other.

”And this is my second son, Khalid. He would have been 21.”

”Oh, I remember him,” says the other happily, ”he had such curly hair
when he was born.”

”He’s a martyr too…” says the mother quietly.

”Oh, gracious me…” says the other.

”And this is my third son. My baby. My beautiful Ahmed. He would have been
18”, she whispers.

“Yes,” says the friend enthusiastically, ”I remember when he first started
school…”

”He’s a martyr also,” says the mother, with tears in her eyes.

After a pause and a deep sigh, the second Muslim mother looks wistfully at
the photographs and, searching for the right words, says . . .

“They blow up so fast, don’t they?”

[AlexMember]

Crikey! Drowned it too!?

[AlexMember]

Thats right Damon they must be taking the piss. Your free to use their preffered nickname – Ass Gas.
Welcome to OBT.

[AlexMember]

Hmmm now thats changed things. I would rather not go on my own for a number of reasons. If anyone is going up that way still let me know otherwise that weekend has just become free for a ride…

[AlexMember]

Thanks for the heads up, im in the hunt for some. Also chains and sprockets but thats another matter…..

[AlexMember]

Ive been trying to work out how to catch Galey in tbe tight stuff and am willing to change brands too. Ive been thinking Honda for its towing capacity. Is a CR500 with a steering dampner a good choice?

[AlexMember]

Hay iv livd in Camblltown b4. Boy did my life take a turn for the better….. I fink.

[AlexMember]

Yep he should have v3 already thats why im wondering if theyre broke. Roy they are not something that wears out so easy but good idea to check ob them as Mr B said above. Go the rad valve then maybe?

[AlexMember]

I got one one of those teza. My bike has trued to kill or mame all its owners including myself. Just needs a firm hand and tight reign.

[AlexMember]

Looks like some progress here.
I didnt look at your pics Roy but whatever the marks are dont sweat it. Yes the bridges do cop the most wear but unless you seized it really really bad (you didnt) i would move on. Good point about ring gap. KTM does not specify the min ring gap! See if one of these knowledgable peers here can tell you the min gap fot 2st 300cc ring. I cant remember off the top of my head. Wiseco writes it on the install guide. To file the ring gap you draw the file through the gap from the centre outward NOT up and down. Measure the ring 10mm+ from top lip of bore. Read that manual off Rocket first before we repeat it word for word, then we can help further. Its good stuff. One tip with X is your straight edge/rule can be positioned across the top of bore, use the rear wheel to rock the piston on its TDC. Use less gasket until piston stops ta tap tapping on the rule. My last rebuild required .4 + .2 = 0.6
As for the exh flange i only use copper gasket maker there to form a gasket. Follow its instruction. Supershit Auto had a special on that range last week. Theres black blue and copper. Copper is for highest temp. I also clean out the exp chamber “port” and cure a thin layer of this stuff to help the exp chamber orings seal and so it doesnt flog out so easily.

[AlexMember]

Good stuff Galey. I wonder how you remembered all that.

[AlexMember]

See if you can source a V4. They seem to be hard to get still but some are raving about them for 300s Pete. Are yours damaged?

[Author]

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