Motorcycle Top End Rebuild for 4-Stroke (Part 2 of 2)

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Motorcycle Top End Rebuild for 4-Stroke (Part 2 of 2)

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Күн бұрын

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.
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@rmatvmc Жыл бұрын

Not sure if you have all the right tools and parts for this job? No worries, we have you covered. www.rockymountainatvmc.com/Sales/1710/Top-End-Rebuild?

@ZmanAdventurez88 2 жыл бұрын

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.

@rmatvmc 2 жыл бұрын

Thanks, we're glad it helped!

@krisomalley2653 4 жыл бұрын

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.

@rmatvmc 4 жыл бұрын

That is so awesome to hear! Thank you for the support and we're glad the video helped you out!

@anthonyshanklin8910 18 күн бұрын

Best video on any RFS or KTM period.... thank you..

@rmatvmc 18 күн бұрын

Glad you liked it! Thanks for the feedback and views.

@hiteck007 11 жыл бұрын

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.

@3131960dan Жыл бұрын

Just did a rebuild on a 2007 XCW - this video is still HELPING US!!!!!!!!! THANKS

@user-ct1ks4gj7n 3 ай бұрын

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.

@rjwebs 11 жыл бұрын

This made my entire day. Kids with two strokes.... Has the world really come to this?

@sikspaksocal 7 жыл бұрын

Great video. Just seized my BETA 525 a couple days ago. Engine is basically a KTM. This video sure has helped me out. Thanks

@InTheDogHouse3DPrinting 10 жыл бұрын

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.

@rmatvmc 10 жыл бұрын

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.

@6bolt_Z 8 жыл бұрын

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!

@rmatvmc 8 жыл бұрын

You're welcome! Thanks for watching our videos.

@nickgroen89 8 жыл бұрын

Thanks, this video pushed me over the line for doing my own head gasket repair!

@rmatvmc 15 жыл бұрын

you are right. I am finishing the editing on it now. I should have it done soon. thanks

@nickclarkuk 11 жыл бұрын

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.

@rmatvmc 11 жыл бұрын

Thank you! If everything goes smoothly you can do this in an hour or two depending on experience and how smoothly the job goes.

@MrKinghuman 12 жыл бұрын

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

@rmatvmc 11 жыл бұрын

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

@rmatvmc 15 жыл бұрын

We will be doing a CRF soon and then a YZ a little later. Just need to find the time. thanks.

@arminlucasbombardier9721 3 жыл бұрын

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

@rmatvmc 14 жыл бұрын

@juoj8 - thanks. We will keep that in mind on our new videos.

@juoj8 14 жыл бұрын

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!

@rmatvmc 14 жыл бұрын

@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.

@rmatvmc 12 жыл бұрын

assembly lube. We offer 3 brands. Belray, PJ1, and Pro Circuit. All 3 work great.

@liquidktm 4 жыл бұрын

Thanks for the Video , very useful and to the point, thumbs up, love the RFS bikes.

@rmatvmc 13 жыл бұрын

@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.

@rmatvmc 15 жыл бұрын

I have a CRF250 video, but I have not had time to finish editing. I will get to it soon.

@rmatvmc 15 жыл бұрын

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.

@rmatvmc 12 жыл бұрын

- 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.

@markr66 15 жыл бұрын

You guys always put together great vids! Thanks!

@rmatvmc 13 жыл бұрын

@kraden18 - refer to the manual. there should be a mark on the flywheel that matches up with a mark on the cover.

@rmatvmc 14 жыл бұрын

@mycat8urskidoo - they are pretty much identical kits. The tusk works great.

@rmatvmc 12 жыл бұрын

- 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.

@rmatvmc 12 жыл бұрын

@londonTown1989 - a few cycles of letting it heat up and then cool off.

@rmatvmc 11 жыл бұрын

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.

@rylaneddie7435 3 жыл бұрын

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 :)

@pedrotucker191 3 жыл бұрын

@Rylan Eddie Yup, been using Instaflixxer for since november myself :)

@rmatvmc 12 жыл бұрын

@HondaRider342Q - you would need to pull it apart and inspect it. then go from there.

@rmatvmc 11 жыл бұрын

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.

@EHROCK1 9 жыл бұрын

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

@rmatvmc 13 жыл бұрын

@2hot4you369 - yep. 2004 EXC 450. not real clean anymore. It has been used and abused by one of our employees!

@rmatvmc 13 жыл бұрын

@SoobaaSteve - You need to call a shop in your are to find out. But why not do it yourself?

@rmatvmc 14 жыл бұрын

@zobel929 - it could be the problem. you shouldn't have needed yamabond on the o-rings or the base gasket though.

@beluga420 15 жыл бұрын

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!

@rmatvmc 11 жыл бұрын

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.

@rmatvmc 11 жыл бұрын

You bet! Thanks for watching

@rmatvmc 13 жыл бұрын

@ridinhonda4life - There is no real relation between the two; however, You should check the valves and adjust them.

@seasonedtoker 13 жыл бұрын

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

@xicosmx6649 4 ай бұрын

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?

@rmatvmc 12 жыл бұрын

@PureN3WZ3ALAND - a lot of factors play into that. regular instection is a good idea.

@rmatvmc 14 жыл бұрын

@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.

@qwikyking 14 жыл бұрын

@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

@zobel929 14 жыл бұрын

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

@rmatvmc 11 жыл бұрын

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.

@EarthTrauma 15 жыл бұрын

Very well done. Clear video and precise instructions.

@rmatvmc 12 жыл бұрын

@MrAhkmed - You are correct!

@rmatvmc 15 жыл бұрын

Good job!

@rmatvmc 11 жыл бұрын

Thanks for the tip!

@coshyno 14 жыл бұрын

wow thats a huge tank

@rmatvmc 14 жыл бұрын

@rama6maiden - i suppose you could say that about any part inside of an engine.

@lodi7777 15 жыл бұрын

very nice vid the best i seen on youtube so far

@rmatvmc 14 жыл бұрын

@acraze21 - there are certainly similarities. Your XR should be a lot easier.

@rmatvmc 11 жыл бұрын

Which cap are you referring to? because two strokes don't have valves

@mmfv1000 10 жыл бұрын

thanks for uploading this

@shanedoyle677 5 жыл бұрын

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.

@rmatvmc 5 жыл бұрын

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!

@rmatvmc 11 жыл бұрын

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

@rmatvmc 13 жыл бұрын

@emoskater1212 - refer to the manuals recommendations for replacement. Don't wait till something breaks!

@rmatvmc 14 жыл бұрын

@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.

@rmatvmc 12 жыл бұрын

- because the belray works great!

@Martin1519 2 жыл бұрын

On the valves is that between .004 - .005 for all the valves, or just the exhaust valves, or just the intake valves?

@jozzilion 15 жыл бұрын

Very well done and very-very informative. Thanks Guys.

@Accidentalouttake 11 жыл бұрын

whoah readjusting valves on ktm looks easy compared to other brands :O

@emuexportep4601 8 жыл бұрын

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?

@rmatvmc 8 жыл бұрын

+Liam Chalk Very true, nice catch. His wording could get a little confusing, but do as shown in the video. Top and bottom.

@emuexportep4601 8 жыл бұрын

+Rocky Mountain ATV MC thanks

@rmatvmc 14 жыл бұрын

@qwikyking - I have no idea what you are looking to buy. Are you talking about a cylinder (that is below the head)? What machine?

@beluga420 15 жыл бұрын

Well thanks a lot as soon as it is out i'm gonna check this out :)!

@penc5use3 14 жыл бұрын

Awesome piece of work! It seems incredibly confusing to me. How come you know which bolt goes in which hole! Which brand's engine is easier to go for this kind of rebuild? Honda, KTM or Husky? Very best to you!

@rmatvmc 12 жыл бұрын

@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.

@zobel929 14 жыл бұрын

ya i replaced the outside one because the tusk kit had two different oring sizes and one seemed to big for both grooves. do the orings need to be a real tight fit around the two grooves?

@rmatvmc 13 жыл бұрын

@sk8perez2 - Most likely not. The steps are similar to those is this video.

@rmatvmc 12 жыл бұрын

one of these days i will get to it:)

@fordf22raptor 12 жыл бұрын

ok and how long will a yz450 last me if i do take care of it? I will only ride once or twice a month on the bike and its only trail/woods riding. Also how long would my yz125 last compared to the 450? I do the same amount of riding on it as well and always clean hear and maintain everything. I"m VERY OCD on maintaining and cleaning my bike and cars. So last question....Should i stick with my yz125 and learn how to it or trade it for a 450 based on the style/time i will put on the bikes...

@charlesbell1355 12 жыл бұрын

i have a 2010 honda crf50 its actually pretty fast but i had to rebuild the engine

@tacokiller101 11 жыл бұрын

check ebay if its a powervalve cover than you can find it but 2 strokes dont have valves for the piston

@fengluzon 14 жыл бұрын

Great videos. Thank you very very very much. Why can't i see the valve replacement video? Do you have a video for a wr250f or a yz250f? (450 will be great to). Thank you very very very much for all the videos.

@nordyk2 14 жыл бұрын

Thank's for video. You very help me !!! Thank's

@skaaltel 12 жыл бұрын

aaaaaaaaaaah great video but man.. I wanted to hear it run!

@RM250D8rzr 13 жыл бұрын

when or how often should the head be re done and valve seats cut? when the valves need a second shim? and replace valves and cut valve seat or? thanks

@rmatvmc 13 жыл бұрын

@171apples171 - yes, i bend mine all the time!

@egar1m 4 жыл бұрын

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

@pauliecash266 11 жыл бұрын

great info you explain nice and clear tanks pal . dublin ireland

@burningsociety 13 жыл бұрын

Great video guys very informative

@agoutdoors53 Жыл бұрын

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.

@hdidane00 13 жыл бұрын

i look on ur web site for an appropriate torque wrench but only dounf the spoke wrench can u provide a link for the appropriate torque wrench?

@rmatvmc 14 жыл бұрын

@9139475 - you certainly could, but this one was fine.

@rmatvmc 14 жыл бұрын

@zobel929 - no, you just need to get them in there.

@londonTown1989 12 жыл бұрын

so what would you say running in time is with a new top end is how many miles ? very nice tutorial allso helped alot with the rings as im used to 2stroke.

@rmatvmc 14 жыл бұрын

@penc5use3 - I think the KTM is harder. a few more steps than the Japanese bikes.

@keyostein 12 жыл бұрын

hello! I make you a question, did u put some kind of glue to the cylinder head gaskets and cylinder base? or they didn´t need that? sorry for my english, i don´t speek it very well..

@rmatvmc 14 жыл бұрын

@zobel929 - did you replace the O-rings around the water pump? It sounds like they may be bad.