KTM Rebuild - How Far?

[Harry525]

I've got an 04' 525 that is stock standard other than a JD jetting kit and motard kit - of course. It's got 50 hrs on it and I've been regularly changing oil (every 3 - 8 hrs, depending on what type of riding I've been doing) and valve clearances have never been a problem. I've got a Hot Cams cam to install in the next few weeks along with new cam bearings and I'm not sure how far I should go on the rebuild. Should I change the piston and rings too? Crank bearings?

[Flash]

Measure the clearance and go from there! You may find that it's all good or in dire need of replacment.

[Wobbly]

Yep. I'd be doing ring for sure, and having a look at the piston for wear.

[SMC690]

I would just replace the cam.
50 hours on a 525 is not enought to warrant a top end rebuild.
I would do the ring whilst you have it apart just to freshen it up if you can.
What type of cam are you sticking in it for interest sake?

[Harry525]

I've got a "Hot Cams" cam. I'm not really sure which one as I believe there are two types for the KTM. I got it from Munn Racing in Waco and took his advice on which one I needed. Hopefully it will go like a cut cat when it's finished but I can see myself going too far - Ti exhaust, 540cc kit :D

[discobob]

You can never go to far !

[Harry525]

You're right. Since my first post, I have ordered a high compression forged piston to match the cam.

When my wife complains I'll just tell her the boys from VSMR made me do it.

[Wobbly]

We are the debil :lol2:

[SMC690]

How about Nitrous Oxide too? :)

[Harry525]

Believe it or not, I have a bottle of Nitrous at home. My brother-in-law works at a gasses distribution centre and dropped off a bottle of med O2, Nitrox and Nitrous. The O2 is great for hangovers, the Nitrox is just great :D and the Nitrous is still waiting for an application. :twisted:

[77]

Guy I know bought a cheap aluminium blue water bottle(750-1000ml), put a nox sticker on the side and bolted it to his frame (has a ZX10 or something) has a little braided line coming off it and going into nothing.....................one of the funniest things I've ever seen on a bike.

I liked it so much I nearly did the same for the DRZ :rofl: it would add 10%..............................more...........la ughs. :D

[77]

Of course I would only use it when racing Sibbo..............or Flash! Not that I would really need it! :lol: :lol:

[Harry525]

:rofl:

[Sibbo]

Too funny. I have thought about doing the same thing and selling them.

NO2 is not going to help you if I buy what I test rode last night........

[Wobbly]

Come on then, fess up.... :?:

[Sibbo]

Not until I actually own it.

Could be this weekend.

[Flash]

Of course I would only use it when racing Sibbo..............or Flash! Not that I would really need it! :lol: :lol:

You obviously using it now if you thinkyou can beat me!! :lol:

[agent34]

I've got an 04' 525 that is stock standard other than a JD jetting kit and motard kit - of course. It's got 50 hrs on it and I've been regularly changing oil (every 3 - 8 hrs, depending on what type of riding I've been doing) and valve clearances have never been a problem. I've got a Hot Cams cam to install in the next few weeks along with new cam bearings and I'm not sure how far I should go on the rebuild. Should I change the piston and rings too? Crank bearings?

harry525,

50 hours is still a lot of time being thrashed, i assume this is running time ? on a hour meter ?. It really depends if it has been held flat for long periods at high revs. A highly tuned lc4 motor that is producing over 60 hp needs a re build at 60 hrs. This advice came form Schnider in Germany. I know a guy who raced a 525 and he was experiencing cam and top end ware, due to it being road raced and thats why he switeched to a lc4 motor, less horse power more reliable and lower maintenance cost but heavier bike. With the addition of the cam and high comp, you shoud consider not only the immediate parts but also the other areas that may either be connected to the pistion and cam. like cam chain, cam bearings, the wisco will have a new ring and check that bore out.

It;s just tooo muchh monney to pull it apart again when it GOOOOes BANG due to the increase load, and you didnt change the 2 dollar part !

good luck with the works.
The cam should bring the power is at a different time in the curve, there is a very good article in AMCN ( australian motorcycle news this month ) about the suzuki that they are building for the track and the comments on the cams and compression and how thay suit different tracks where power is needed at different times for drive out of corners. :D
2 cents!

[Wobbly]

Of course I would only use it when racing Sibbo..............or Flash! Not that I would really need it! :lol: :lol:

You obviously using it now if you thinkyou can beat me!! :lol:

Nah, he just knows all he needs to do is paint a mural on the side of his bike like this so you can't make it past him :lol2: :D

http://vsmr.net/files/pizzashop.jpg

[Harry525]

Thanks for the advice Agent. I have ordered everything you mention - cam chain, cam bearings, etc. I sort of felt I was going overboard but also didn't want my bike to look like the Honda in one of the more recent posts here. I also understand the reliability issues you speak of. But, huge dyno figures come at a price!

Shit, I hope the bloody thing is still ridable when I finish... :shock: OMFG :shock:

[Flash]

Nah, he just knows all he needs to do is paint a mural on the side of his bike like this so you can't make it past him :lol2: :D

http://vsmr.net/files/pizzashop.jpg

Feel the love :cry:

I ride past that same Pizza shop every day and no full offy. I guess I'll never live that down. Beware it will come back to you :twisted:

[Wobbly]

You should feel pride in being an integral part of the VSMR folk lore! :)

[Flash]

Mmmmm [-(

[Sibbo]

:snigger:

[Wobbly]

Not until I actually own it.

Could be this weekend.

Well :?:

[Sibbo]

No go. Dude wanted too much $$$ for it. I had to consider the conversion costs and it just did not add up to paying more than I wanted to. And some fool actually payed more than I was willing to.

It would of been nice to have a cr500E, but, shit happens. For all the trouble that I would have to go through and the cost of it all, the cr500e did not actually excite me all that much.

No shit, it was like riding a 4 stroke. Well inbetween a ktm 360exc and my yz, but closer the the ktm. Plus it did not like to run with no revs, it was very unhappy. It lofted the front in every gear, but it did not throw the front into the air like the YZ does.

What I really want is a v-twin yz500, c'mon Yamaha, make one and it will sell.

Also, I think I am too anal to buy second hand crap. So now I am looking for a brand new 4 stroke. Got to save up a few $$ more and then time for shopping.

[Flash]

Alright Neil I owe you $10 you were right!! :lol:

[Sibbo]

Argh, Neil thinks im a piker. Thanks for the support Ash.

I'll show you bastards, if the weather is good tomorrow I will be test riding a......not saying. I will just rock up at south morang and shock you all.

[Wobbly]

You could shock us by actually buying something :)

[Flash]

Yeah mate it's time to buy one! :D

[Harry525]

Also, I think I am too anal

Selective quote = Yes!




I can't believe I was the first onto this... :lol: :lol: :lol:

[Flash]

He is! and no you weren't the first we just humour him, he needs encouragment :lol:

[dicky]

What he really needs is a kick up the arse.
If a financial planner can't figure out how to scrape up the dough for a new bike then he should be looking for a new job.
Look at the shining example set by nmilne.
He blows his bike up, leaves it parked on the side of the road, and goes and buys a new one.
We can all learn from him.

dicky.

[Wobbly]

Never underestimate the power of lazyness :up: