Vlog : KTM 530 Top End and Clutch

How do you put a top end in a 530 KTM? We have that answer for you!
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[@brendonchase9460]

Really appreciate you running through clutch instalment process and things to look out for, as you do for everything but sometimes you forget to film or the camera is just a pain in the butt! So then the next clip is it back together. I get it, but I do appreciate it when you do follow through with the process. I'm not as savvy as most on here, so your tips and advice means a lot. 👍

[@geebopbaluba1591]

I’m a retired mechanic and I still do some stuff at home but yeah you know what you’re doing so it’s a really nice job.

[@highlandcycles]

Thanks

[@marctobey5408]

11 thou ring gap ! Wow thats tight

[@ericingulsrud7280]

Great tech video. I have the 450EXC version of this bike and will refer back to this video when it is due for a piston. I would have like to seen the process on timing the cam. Subscribed a few months ago after watching your FCR carburetor video helped me tune my bike. Keep up the good work!

[@highlandcycles]

Eric Ingulsrud thanks. I’ll do the timing video the next time I get one in. Glad we can help

[@paulveucasovic5397]

love it

[@manolourquizo3900]

Thanks my friend!

[@highlandcycles]

You bet!!

[@bradl45]

I bought a Harbor freight Bauer impact driver(not the big 1/2 lug nut one) this year, I tried to remove the 4 head bolts with it, my 09 530 just laughed at that tool, KTM puts those bolts in with a purpose, lol. ya 3 foot breaker bar I needed( I was shocked how snug they were, I didn't know they had thread locker on them). I was watching intently when you had the camera in one hand, and tried to remove the head with the other, heck, I needed 3 hands, it was a puzzle. I was shocked my bike at 250 hours, the cylinder still had good cross hatching, good stuff KTM. I put in a new clutch, now when the bike is not fully warmed up, when I put the bike in gear it stalls, or it has some good clutch drag. My clutch lever doesn't have enough adjustment to take it out, but will see in time if it gets better(less drag). It's a new tusk clutch lever, maybe a KTM lever has more adjustment, (old lever had a custom bend in it, lol. Thanks for the video!!

[@highlandcycles]

Brad Lu thanks for watching and commenting, it means a lot. Yeah, those bolts were SUPER tight!

[@nwyoda8792]

Please do a video of ktm 530 fork seals! complete please!

[@blakehuntington5612]

great video, i would like to know more about the bottom end seal that mixes engine and trans fluids

[@highlandcycles]

Right on. I’ll try to remember to do a vid on that.

[@glenndavis2762]

LOVE YOUR VIDS - Thanks a bunch Could you tell me the make and model of the valve spring compressor you are using on the KTM head by chance?

[@highlandcycles]

Motion pro. Not sure if there is a model number

[@foe_ali23]

Man I’m glad I found this page! 🔥 I have a 2010 KTM 530 and I’ve lost compression. This is my first bike so idk what to do.. any advice?

[@highlandcycles]

Probably need to take it apart to see what you need to replace

[@bradlittlejohn6008]

Morgan, I have this exact same bike. I sent the cylinder off to a machine shop with a new piston. Got it back, did a leak-down test and it was at 4%. The bike started. But, I just ran the motor for 5 mins without riding it. Then the next day it would not start. Did leakdown and it was at 20% leakdown. The sent the cylinder back to the shop and they said the cylinder and piston were fine. But, since I did not ride the bike after first start. The rings did not seal. They said that the bike needs to be ridden for 15 mins for the compression of the cylinder to force the rings against the cylinder walls. They said I needed new rings. Got the new rings and it ran like a champ. Have you seen this issue?

[@highlandcycles]

I’ve not seen that exact issue but these 530’s are known to have lots of issues with burning oil (which is a “leak down” problem). I have a friend who has rebuilt his numerous times. It’s always good for a while (couple thousand miles) then starts to burn oil. Have no idea why to be honest

[@marcossoto3960]

Thanks for your video, is very helpful. After do the same job i have oil coming out from the valves cap vent hole, any idea about that? Maybe valves? Cylinder??

[@highlandcycles]

Huh. Not sure

[@nathanchalecki4842]

thanks for the video- just about to do a clutch on my '08. Do you always replace the frictions and the steels? I see some cheaper kits come without, some of the other kits come with both, and looks like heavy duty springs are also available. Everyone here in NZ seems to sell Premier brand clutches, hope they are OK

[@highlandcycles]

I always replace everything. It just doesn’t make sense not to. I’ve never heard of those but I’m sure they are good.

[@bholway223]

Good video! Does the timing chain stay put on the crank without falling off?

[@highlandcycles]

It does. The plastic "cage" around it holds it on there really well.

[@ronik1974]

Hi Great video, I just porchase a cylinder to my 530 2008, it got damage in delivery, it has few scratches inside, how can I Sent you the picture? Ill appreciate if you will take a look, and tell me that all is good and the scratches are not so big deal.

[@highlandcycles]

Sure man. Email the pics to [e-mail]

[@VincentCastilloux]

hi ! thanks for the nice video i just rebuild my ktm 530 exc . i put the vertex piston but hight compression .do i have to jet it ? my 530 is not exc-r thanks in advence

[@highlandcycles]

Should be good

[@marcoveltre3014]

Great video! I have the 450 version of this bike and am considering doing a top end soon as im starting to burn oil. How much of this stuff other than the piston and rings should I replace? How can you tell if you need to replace the valves and valve springs as well? Thanks in advance!

[@highlandcycles]

I would plan on valve seals at least. Need to inspect the valves before you can tell if you need to replace

[@marcoveltre3014]

@@highlandcycles is there anything in particular I should look for? Would it be a bad idea to re-lap the valve seats even if I end up sticking with the original valves?

[@highlandcycles]

@@marcoveltre3014 yeah. The are ti I believe and lapping them will ruin them. Just look to make sure that the valve faces are flat and not cupped

[@marcoveltre3014]

@@highlandcycles sounds good. Thanks for the help!

[@scottylstra6310]

I have an 2008 ktm 530. I have already started my tear down and forgot to put piston at tdc. Can I keep continuing with tear down and sort out tdc once barrel and piston is off

[@highlandcycles]

Yes

[@huitemarick]

Great video! I tink my KTM 530 burn's oil. After 7 hours of riding I needed to refill 0.1L. But there is no smoke coming out of the exhaust and the bike only has 170 hours. So will a new piston solve the problem? Or am I missing something? Thanks in advance.

[@highlandcycles]

Ugh, that is the curse of the 530. I can’t tell you how many I have seen do that. It seems that a full rebuild (piston and valves and all seals) will take care of it. But make sure you check the valve guides too. I don’t understand why those motors do that honestly

[@huitemarick]

@@highlandcycles the problems don't stop with this bike. the oil consumption problem has now been resolved. only what happens now is that oil flows from the gearbox to the engine. Also known as the oil transfer problem. would you have any idea what i can do about this?

[@highlandcycles]

@@huitemarick yeah man. That isnt KTM’s best engine. You can replace the seals (pretty easy) or you can do the single sump mod which requires splitting the cases and some machining.

[@huitemarick]

@@highlandcycles thanks for the quick response, which seals should I replace?

[@highlandcycles]

@@huitemarick all of them in the bottom end

[@thetrailwaychildren]

How do you know which size piston/rings to order?

[@highlandcycles]

You can measure the cylinder and get the piston that has the correct clearance. But honestly, any of the pistons will fit as long as the cylinder is in good shape. The difference is only .01 of a mm and that is really small.

[@michaelwebster2416]

on this 530 when do the clutch cush rubbers need replacing?

[@highlandcycles]

When there is too much play. I like to do it when you can wiggle it by hand

[@michaelwebster2416]

@@highlandcycles thanks for the reply , how many miles have seen on the cush rubber before they need replaced? I haven't seen much on the fourms about the topics,,thanks

[@peteclaudio3854]

My kick starter locked up what do you think it could be?

[@highlandcycles]

No good for sure. Probably motor

[@peteclaudio3854]

@@highlandcycles thank you!