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

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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]

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]

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]

Thanks, we're glad it helped!

[@krisomalley2653]

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]

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

[@3131960dan]

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

[@hiteck007]

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.

[@sikspaksocal]

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

[@nickgroen89]

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

[@6bolt_Z]

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]

You're welcome! Thanks for watching our videos.

[@rmatvmc]

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

[@nickclarkuk]

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.

[@markr66]

You guys always put together great vids! Thanks!

[@liquidktm]

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

[@user-ct1ks4gj7n]

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.

[@rmatvmc]

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

[@EarthTrauma]

Very well done. Clear video and precise instructions.

[@InTheDogHouse3DPrinting]

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]

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.

[@mmfv1000]

thanks for uploading this

[@lodi7777]

very nice vid the best i seen on youtube so far

[@juoj8]

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]

Thanks for the tip!

[@rjwebs]

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

[@burningsociety]

Great video guys very informative

[@zuluflight5467]

Really great work, thanks a lot for your video.

[@jozzilion]

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

[@rmatvmc]

Good job!

[@likhwadube5937]

Very informative, thanks.

[@pauliecash266]

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

[@beluga420]

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

[@arminlucasbombardier9721]

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]

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

[@samyadeher6461]

super les vidéos et tout autre chose

[@rmatvmc]

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

[@782000]

Hi on the video you say please refer to our video on the valve replacement instructions ...I cant seem to find the video , do you have a link to the video please?

[@EHROCK1]

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

[@xicosmx6649]

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?

[@Bellonez]

thanks for your exellent video.

[@nordyk2]

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

[@JoeGorse]

Does the Crank Lock Bolt for TDC have any play in it (slotted) or does it locate and prevent the crank from moving at all (hole)?

[@rmatvmc]

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

[@davise8852]

Hello, I must say thanks for this useful video! How much oil do I have to order to my bike? I have a exc 125 2004. I know that the air chamber is 120 mm. Do I need 3 or 4 pieces of 500ml bottle?

[@beluga420]

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]

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

[@rmatvmc]

@MrAhkmed - You are correct!

[@shotox21]

THANK YOU

[@rmatvmc]

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

[@MrKinghuman]

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]

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

[@zobel929]

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?

[@wannabetricker4080]

Hmm i own a ktm 560 from 2006 and i went to a long rod setup just like the 525. Got the oil line, timing chain and rod from a 525 in it so it's the long rod setup. I had 0.040" valve to piston clearance so i add to add another 0.025" gasket to it, but now my timing chain is to short? It's still a 96 roll chain but a 0.05" to short.. any fixed for this? Thank you in advance! btw: The reason i went for a long rod setup with cometic spacer gasket is because the 560 is notorious for ovalizing the lower part of the cylinder.

[@rmatvmc]

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

[@rmatvmc]

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

[@armandosanchez951]

Hey how do I position piston rings on 04 trx450r I need help

[@agoutdoors53]

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.

[@Martin1519]

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

[@rmatvmc]

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

[@rmatvmc]

one of these days i will get to it:)

[@rmatvmc]

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

[@rmatvmc]

You bet! Thanks for watching

[@matthewmihalic3978]

Did you squeeze the piston rings with your hands to fit on the cylinder? Its tight and I find it hard to do.

[@fengluzon]

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.

[@Accidentalouttake]

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

[@ch0l0sk8r]

i was wondering if your susposed to put silicone on a 96 kx250 head gassket, need to no asap thsnkd

[@rmatvmc]

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

[@mulishaswag]

hey i have the same bike and did a top end rebuild and put everything together like in the video and it starts and runs really good but theres a ticking noise in the top end. any idea what it might be?

[@rmatvmc]

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

[@kraden18]

Hey i am messing around with a motor from a ltz250 atv and i am having trouble with the timing. Do they all have some way to find tdc with using a notch in the crank? or are all bikes diff or most?

[@j58400]

super

[@rmatvmc]

@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.

[@londonTown1989]

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.

[@hdidane00]

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]

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

[@Hommyful]

Exellent tutorial 👍🏼

[@rmatvmc]

+Hommyful Thanks!

[@rmatvmc]

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

[@just1lifexx11]

mann.. i want to take motorcycle engine, make agood snow blower out of it.. great and kool video

[@mycat8urskidoo]

Will the Tusk Chain riveting tool do the trick on the RFS motors or would you recommend the motion pro

[@zobel929]

I just rebuilt the same engine as in this video. It starts up and runs great but out of the bottom cylinder gasket it is driblling oil out and the top has anti freeze seeping out. Ive used new gaskets and installed them correctly with yamabond. Could the 4 cylinder bolts not e tight enough? what do you think is causing this?

[@shanedoyle677]

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]

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!

[@NZDIRT]

@RockyMountainATVMC i have an 07 kx250f and i heard that your supposed to have it rebuilt ever 40 hours is this completely necessary or would i get away with just getting the valves done?

[@keyostein]

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..

[@AbraMakudabra]

hi, i've got a question :) how fits this la sleeve for ktm 4 stroke? does it warm too much? can i use this into my cylinder or better is a nicasil ? sorry for my english :)

[@qwikyking]

i'm unable to find the bottom part of the cylinder head on online sites, would i be able to get it from a dealer? would it be under $400?

[@171apples171]

so can can i bend a feeler gauge at the tip so i can get it in between there to adjust the valves on my GS300? I have the bladed feeler gauges but they are straight and wont clear the top of the head where the valve cover gasket surface is.

[@rmatvmc]

@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.

[@mikser-boris]

Чел Ты крут!

[@rmatvmc]

благодаря

[@rama6maiden]

is it possible for me to just buy the piston rings?

[@BowHunt1229]

do you think that just plain ol seal maker would seal up a split case sufficiently if its already bolted together?

[@_jkanderson]

Could you be able to upload the CRF top end video some time?

[@zobel929]

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

[@MASLEX35]

How long should I do a break in period on my warrior 350 new top end. (rings)

[@KevDoesStuff]

when you install new rings does it matter where they sit on the piston? like where the gap on the rings are on the piston?

[@jayinla228]

How much was the cost to get it sleeved?

[@londonTown1989]

@RockyMountainATVMC thats for the reply :) once again great vid

[@mikeschoeffter7420]

nice vid, but why would the 2strokers go by the wayside, simple & powerful

[@johndevinaspre676]

hey so this is probubly a stupid question but i dont know it do you have to like do anything after you empty you radiator or can you just fill it back up with coolant like i dont know if you see what im asking its hard to explain.

[@egar1m]

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

[@synergy224]

what sealant is that? (black)

[@penc5use3]

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!

[@coshyno]

wow thats a huge tank

[@rmatvmc]

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

[@kasenut12]

what type of grease (lube) did you use on the lobes?