Rebuilding a KTM RFS Engine in 2020 (THOUGHTS)

[@EMFRocks]

I have a RFS 450 too, i bought with 90 hrs a year after I lost my leg when I determined to ride bike again, it now has around 15k miles on it, over 2000 hours, it smokes intermittently, meaning it would start with no smoke, but every now and then it just burns oil. Not sure why this is so, but it still soldiers on. I can see the economics of not repairing your customer’s but I know I’d fix mine, purely from a sentimental point of view. It kind of deserves to be maintained due to it never leaving me stranded ever. One of the best motors to have come from KTM, and as a package the bike makes for a mean dual sport far superior than any XR, TT, KLR or whatever, just my 2 cents.

[@christian-yz6ev]

2000 hours ? suppose 200 is,t it ?

[@brkix]

@@christian-yz6ev yeah..sure he made 15k miles in 110 hours. Rfs goes easily 1000 hours, never heard 2000 but for sure is possible, if you dont do extreme enduro stuff every day. Mine was open after 500 hours, replaced valves didnt even change piston only rings..now at 810 hours fells like new. Only reason i will bot buy any newer bike even with better suspension, lighter, and so on. Rfs is unbeatable.

[@pinarrioqwer2933]

new intake valve and keep it rolling i got one from 2003, it makes lot of sounds like all rfs but its a rock

[@danielreinhardt937]

I did my piston, rings and a valve job thru millenium technologies back in 21 for an 96 exc 450 with 400 hours on it and it runs fine. Didnt plate the cyllinder, fuck with the cams or tear open the lower end. Riding without wrenching is only half the sport.

[@danielreinhardt937]

*06 not 96

[@liquidktm]

I say put a new Vertex piston, rings do a good hone job new valves, Find a local machine shop to check or repair head and slap it back together if crank and big bearings are good and within specs. The RFS is a proven engine. My 02 520 exc is still running strong on the Original RFS engine. Most Damage I did was let my bike setup for a few years while riding Atv's after my Armature racing career retirement. I love this bike it rips and pulls hard. Its easy to maintain and work on. I'll be tearing mine down soon for kicks and giggles. Ive got way over 500 hours and maybe closer to 1500 hours Bought it new in 2001 went straight to FL after first oil change and ran the GNCC and raced local Hare scrambles and GNCC races in NC/SC this was my only bike it got ran every weekend every race I could hit every trail I could find. The entire bike is tuff. Mines completely stock except for Suspension setup. Love it. I'm sure some one would like this bike the 450 makes a great super motard . Hope it don't wind up in the bone yard. Bikes worth fixing. New bikes are 10K 😁

[@mxgryan]

Haha, many great points here! Stay tuned for results. While i agree the motor is proven, the rest of the bike, although solid, is not nearly as good as a 16 or newer generation than can be found for around 4k. While sad, sometimes its just not logical.

[@liquidktm]

@@mxgryan I might jump on a newer FI 500 at some point, I completely understand. Around here that 450/520/525 RFS engine is bringing 2K or more for Micro midget Carts its a very sought after engines. The newer bikes are lighter and more agile for sure. Will be interesting to see what happens with the 450 ..👀 I have no plans to shed mine gonna be checking the valves soon so far they been very minute adjustments made over 19 years and its had a hard life.. Gonna tear down soon for inspection and may do a complete rebuild and hopefully get another 20 years on the old hammer. My friends on there new bikes don't know what to think when the older 510cc rfs blows by them a good suspension guy can really do magic to the handling. Its amazing at the HP these new FI engines are making. Very cool technology on the newer bikes for sure.

[@recoil2952]

2004 450 exc with 11k miles going strong

[@riderktm16]

exc 450 2007 is a brilliant bike!!!

[@mxgryan]

Sure, just not as brilliant as anything produced after.

[@riderktm16]

@@mxgryanfor the year (2005-2007) it was a very good bike. Sure the news bikes are better in many ways. But the old exc follows them with no problems

[@kaytme5915]

Cool, I didn't know about the Lock bolt. 😃

[@wokinit]

I am in the exact same boat right now with a 2004. I don't think I will have 2k into it though. I am wondering who I should send the cylinder and head to for the service.

[@mxgryan]

I can answer that. Send the head to Fastheads and send the cylinder the Powerseal. Tell them Ryan The MX Guru sent ya.

[@sanderjoosten3254]

Seeing sand almost dropping in the engine makes me nervous😖

[@mxgryan]

I wouldn't worry. It runs great.

[@scottc4433]

Used head off eBay and a gasket kit and put it back together . Can’t just quit on the old girl

[@mxgryan]

I'm usually pretty skeptical about used heads off ebay! Haha

[@Buddha-ci8fz]

I'm debating a new top end for my 2004 525exc with about 140hrs but I've never tore a motor down. I was told a top and bottom end costs between $3500-4500. Do you still work on RFS and do you agree on pricing?

[@kaytme5915]

I wish he would reply to you!

[@ianpearce5745]

Omg only 140 that's nothing you might just need a set of rings and at the extream a set of valves as long as you change oil and clean the 2 screen filters 1 underneath and the other just underneath the stator you shouldn't need a rebuild until we'll over 200 or more hours.

[@scraggsds]

You should part it out. How much for the inner and outer clutch cover? Lol

[@mxgryan]

We fixed it...haha

[@ducaduke]

Awesome 😎 video. Thank you for that it’s funny I’m in the same situation. I have a lc4 625 smc. It does have a spot to lock the crank so it doesn’t move. Ktm has the locking bolt on back order. So my question could I use a clutch holder tool to hold the front sprocket to keep it from moving when I go to take the cam gear nut off ? Anyways hope you could help love the content keep it up 👍🏼

[@emilianosironi236]

congratulations for the video! I wanted to ask you something, for valve adjustment, is the top dead center (TDC) the same if the piston is in compression or 360 degrees after in the exhaust? (always at the highest point)

[@ktm_65region18]

Good afternoon, I wanted to ask you, the motorcycle is the same as yours, the same engine. There is one problem, you can help me out if it's not difficult to explain. Drops go on the engine on the left side, and drain to the bottom, but the oil level is fine, the antifreeze is fine. And another problem, I can't find a cold level, and after warming up and running the engine, there is a level. Please help.( Vladislav from Sakhalin)

[@JohnHowerton137]

Pretty bomb proof. Not even sure I’ve ever seen one blown up. I know people who beat the piss out of them for years. Sad, but it’s probably worth more parted out. If the owner loves it, fix it. Probably last him the rest of his life. Only real drawback is fuel consumption.

[@mxgryan]

I agree with you, but he does love it and so we ended up fixing it. He now has $3k in the repair with a stock bottom end still...haha!

[@cuerammer]

@@mxgryan And now he's got ANOTHER 1-2,000 hrs of fun and smiles, as long as he changes his oil regularly. RFS,....BEST motors KTM have ever made! You couldn't even GIVE me a new 2008 - 2021 bike! Dead battery = dead bike stranded miles from help!

[@mxgryan]

@@cuerammer lol, you're so far out in the moon and clueless it's not even worth arguing with you. Keep riding your dinosaur buddy.

[@cuerammer]

@@mxgryan Why the personal insults? Did I hit a nerve by merely stating MY opinion? Then you're admitting my opinion is TRUE! I could have stated all parts you replaced with new parts that were totally un-necessary had you really known what you were doing, or had ANY real experience with RFS engines!!!

[@mxgryan]

@@cuerammer I didn't personally insult you at all, but now I wish I would have. Your "opinion" about a new generation KTM motorcycle is pathetic. Is the RFS motor durable? Sure. It's not even remotely in the same league as the current 450 powerplant...and the rest of the bike is even further behind. People like you are the only bad part about posting KZbin videos.

[@spencerepps3287]

Is that the same motor on a Polaris outlaw 450??

[@mxgryan]

Good question, I have no idea Spencer haha

[@mikehawk9617]

You didn't break the cam chain?

[@mxgryan]

Yup, sure did

[@ethanjoseph3504]

U do suspension?

[@mxgryan]

Sure.

[@dasatom3060]

Do you know where i can get an rocker arm exhaust for an 2002 EXC-f 250 Racing 4t?. Has the RFS Motor....

[@mxgryan]

I think i have an extra one!

[@dasatom3060]

@@mxgryan Really?!?! That would be awesome! How can i come in touch with you? Where can i buy it? Thanks, Bela

[@mxgryan]

@@dasatom3060 you can message me on FB or IG, I can verify tomorrow morning if I have one

[@dasatom3060]

@@mxgryan Wrote you on IG. 😉

[@percivalgooglyeyes6178]

Why wouldn't you just send the head out to get re-valved, new gaskets and call it good? New rocker arms? Come on. Obviously the oil was changed correctly, owner just didn't kept up on exhaust valve adjustments. Sheesh.

[@mxgryan]

A good head job is $1500, just to start with.

[@creteking23]

So $2000 for 16 more years of riding/bragging rights of one of best motors made...no dilemma here.

[@mxgryan]

I prefer to ride bikes from this quarter of a century, for the most part lol