We FIXED the KTM RFS Motor... (Final Conclusion)

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We FIXED the KTM RFS Motor... (Final Conclusion)
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[@Danman1972]

AT 350 hrs on mine I replaced the piston, replated the cylinder, replaced the intakes and had the head cleaned up with new guides, as well as replaced the camshaft, cam chain sprockets, cam chain guides. What a great motor it has.

[@ktmtravels3727]

I've an '04 525EXC. I paid over the odds but now it's sorted I love it. There are not many left so I'm glad I got in when I did. Great to work on, and ride!

[@Buddha-ci8fz]

Can I ask how much you paid to get it sorted and what kind of work it needed? Last summer, I got the same model for $2900 w/134hrs. Compression at 150psi.

[@ktmtravels3727]

I spent about £300 on essentials, the rest was cosmetics and getting it legal for road use( I'm in the UK). It needed a small repair to the head, so while it was open I did cam bearings, cam-chain and guides, water-pump seals and piston rings. Although a bit rough I was pleasantly surprised to find the piston and bore well within spec but the rings were tired. Coolant, oil, filters etc are included in that figure. I did a 700 camping trip last year and it was great, never missed a beat. Hope you're enjoying yours👍

[@stevenmulkey3572]

I have a 2005 KTM 525 supermotard. An old racebike. Ran great till 2 seasons ago it abruptly stopped running. On further inspection the alt case had cracked because the valve lock nuts somehow made there way thru the engine. It chewed most of them up real good. I've flushed the engine. it had tones of metal shavings....replaced the case ect and now it starts and runs like nothing ever happen. But I'm afraid to ride it and cause anymore damage so I've just been storing it saving up to rebuild the engine (I'm sure it's due anyway). But now hearing you can't get the heads and probably other parts soon should I just button it back up while it still starts and runs and sell it for a newer one like you were talking about or should I tear into it hoping it's not a complete rebuild just a freshen up. What would you suggest. Side note: Supposedly the bike has an interesting history. It was one of Mitch Hanson's race bike. It's raced all over the world. Ended up as a team racebike for a Santa Fe ,New Mexico shop where a fellow race buddie sold me the bike as I was racing at the time looking to get into supermoto. I don't really buy into hype of who raced what but it might make the bike worth more...the Hanson race team added lots of cool one off parts....brakes... different trans..6 speed...ect. just some background on the bike.

[@gnagsaar_]

I picked up a 525, plan was to just sell the engine. And use the frame and bike for a 1100cc supermoto project🥱 But Suddently I got a chance to race my first motocross race, and the EXC 525 was the only bike even close to race ready i had 😆 so I prepped and raced with the 525. And It was a blast 🤘 So lets say I'm dreaming of building the KTM'est KTM, the coolest mind blowing KTM motocross bike in the world.(from a EXC with pds shock system) whats the COOLER engine? 250 EXC (big flywheel and shit for torque) sxs 300 kit and cdi for overrev and way more power than you need. Or a tricked out RFS 525 ? It would be either a 2014 exc chassie if 300sxs or 04 chassie with RFS. And even if it's the 14 or 04, it would get 2017 restyle with carbonfiber tank/subframe. Aer48 shock (ofcorse) pds rear shock with titanium spring. And about any titanium part you can think off. Because weight reduction 😝 Ps I have already tried 500 twostroke. They are boring when all comes to it 😅 Rly hope you will answer me on this one, been following you on tiktok for a while, U seem to have strong opinions 💪 so I'm curious what you would consider the COOLEST, not nessesery the best or most practical.

[@wv4life375]

This is the saddest part of the sport. When your beloved bike cost more to maintain than buy another used bike with unknown history or very expensive new one. I hope my 2013 lasts a lot longer just so I can keep the kickstarter.

[@joey011582]

facts, they are goofy for removing the kick start

[@kaytme5915]

2 years later & I see your video 😃 so I want to mention I have a 2007 also! Only 3,000 miles! Been collecting dust many years!

[@KORR805]

Got a 01 520exc, sucks getting parts sometimes, selling it once I replace the stator

[@maggiepaden5779]

Where did you get that cluch cover

[@evansautomotive307]

I just picked up a 2001 400 exc where did you get the timing chain? Thanks.

[@mxgryan]

From KTM.

[@9morrical]

rocky mountain atv has a wonderful oem part section and they keep a lot of parts in stock.

[@GRIANMEDIA]

Also do not forget about aftermarket parts. We may not see a head but there are a ton of aftermarket mechanical parts for these bikes. I would not worry much about it. Just need to dig deeper and perhaps order parts from Europe. Bikes still be shredding out there.

[@JohnHowerton137]

Kind of a happy story though 🤣 Outside of that radiator, nothing looks that beat. A good deep clean and she’d look pretty legit. This bike looks like a diamond compared to the ‘09 I redid last year.

[@mxgryan]

Yeah, I kind of felt bad about my first thoughts after I finished the job...but I also feel bad that he has so much invested in the bike. Oh well, if he's happy then i'm happy! :)

[@JohnHowerton137]

@@mxgryan yeah, those are tough decisions, but it has many years of service left. It’s not like it’s $2k into a 1984 XR 500. The new stuff might be better, but it’s a totally capable bike. Hell, it’s more modern than the 2021 YZ250! 🤣 Not even that far behind the RMZ450... and even more advanced in many ways 🤣

[@mxgryan]

@@JohnHowerton137 those a very good points for sure. My thinking was that for 4k he could have scooped a 16 model...and 16-21 generation 450 is a work of art.

[@JohnHowerton137]

@@mxgryan not anywhere I live/d. If you could even find one, more like 7+. I had people waiting in line for my ‘12 350EXC at 6k.

[@mxgryan]

@@JohnHowerton137 that's wild! We had a 17 450 sell for 4k here this summer with Kreft setup...a buddy of mine picked up a 19 450 for 5k lol

[@KnowItAllHVACRTech.]

I plan on doing this to my bike as soon as I get the parts I just ordered. The problem is I want to do it myself but no one will help me do it myself, they want me to take the engine or the bike to them and let them do it. I said I would pay for their time to help me because my problem with taking something somewhere is that I did that with my truck and the the guy switched the high pressure oil pump with somebody else's I don't know if it was a mistake or it was intentional but I was not happy about that. And I know that that doesn't always happen at every shop, but I'm not going to have that happen with my bike. So my question is what do I do?

[@ktmtravels3727]

I have a workshop manual for my '04 525, they're not difficult to work on. I would have to pay if I needed machining done, otherwise it's DIY👍

[@apemanfool]

i got an 07 that was rebuilt in 2014 and lightly used since

[@9morrical]

Just finished a full bottom end rebuild on my 03' 450SX got the cylinder and crank rebuilt at millennium tech. ordered all the bearings from a bearing supplier saves 50%. also added 5th and 6th from the exc. I previously had head rebuilt at a local machine shop using all kibblewhite hardware arround 30 hrs ago. all in all yes I am into it around 3k but I also have a brand new engine, not one with an unknown history. Definitely not feasible to have someone else do but not bad if you are doing the labor.

[@mxgryan]

Agreed! You'll have a good one.

[@GRIANMEDIA]

I rebuilt my RFS 05 last year. Bottom end and top end, carb, and everything in between. dropped an oversized piston, stage 3 cam, 6 speed conversion. The only way it makes sense is if you do all the research and do the work yourself. Otherwise paying a shop is a financial disaster. Dont get me wrong, its just as mentioned at the end all the expenses could buy a newer model. I love RFS and plan to keep shredding for another 10 15 years. I am only missing an electric start since my bike is an SX, parts alone would run close to 1k so it could be expensive, but learn to wrench and def can save thousands.

[@mxgryan]

He paid us to fix it. It was sad. Lol

[@xolus7003]

I have an 05 rfs 400 and has started smoking where did u get your rebuild kit from?

[@ianpearce5745]

My bike had done 17,000 miles before it needed rings abd valves and still going today on original bottom end bearings as long as you change oil often the rfs motor will continue on fir many years btw I was only using 10/40 semi synthetic for trail riding and enduro events maybe full synthetic for super moto events. 😊

[@kaytme5915]

Yes for real! Sits lower than my 14 690 & 16 500 EXC F.

[@lannybackes1053]

The low end torque on these 450's or 525's just isn't matched by anything out in today's lineups. Makes it such an easy to ride bike. Valve adjustment is a snap too. It would be great to see an air cooled lightweight trail bike version. But it probably wouldn't make the sales numbers that KTM would want to see.

[@GordysGoodworks]

The valves are the achilles heel of these motors. If you fix that, the rest of the engine is a real workhorse.

[@GRIANMEDIA]

That is an easy fix, there are many very strong stanley steel options,,after some proper machine work on the heads and new valves it is solid. I think you refer to the magnesium valves, which are high performance racing valves but the lifespan is short.

[@9morrical]

@@GRIANMEDIA Yeah I've upgraded my head to Kibblewhite SS valves, springs, seats and guides. Have 30 hrs on head since rebuild. Recently checked valves. The adjustment hasn't moved one bit vs the titanium valves that came stock in it.

[@ianpearce5745]

​@@9morricalwow only 30 hours and you valves needed replacing 😢 my rfs done 700 hours before my valves sunk .

[@harding1986]

I have an RFS bike with a ton of money into it in somewhat of similar situation. If you're interested in it I'll cut you a hell of a deal MX Guru.

[@mxgryan]

Haha thanks man but I wouldn't touch one of those with a 10 foot pole knowing that so much is on backorder...and with the virus, much of it may never be manufactured again.

[@purebloodheretic4682]

Offer it to Gabe from "Torture Test Magazine" I'd love to see him Rip on a Actual Fast Bike!! He got 2nd Place in a 24hr Race on a Dr200🤨 He'll fix it up! Imagine him on a 525😁👍

[@andycote2135]

I have a 04 525sx I just finished rebuilding. Took me a year to do. Sent the motor out to be done, costs way to much to do but I love my bike. Next bike i want is a 360 2 stroke.

[@mxgryan]

Dang Andy, you're WILD!

[@riderktm16]

Sad news, i’ve got the same bike and it runs soooooo good with 700hours

[@mxgryan]

Not as good as the new ones...haha!

[@riderktm16]

@@mxgryan yeah, don't blame me xd I want to preserve that bike, it's very special for me

[@mxgryan]

@@riderktm16 Nothing wrong with that...that's a different situation for sure .

[@purebloodheretic4682]

Start collecting 2nd parts off Craigslist or Gumtree ect, you can still pick up bargains if you look hard enough! I just picked up a Mint 2003 525exc 2 Owner with 160hrs All Original with Books for $3k Aus -But some want Double that $$ for bikes in Rough Condition! I waited a while for the Right Bike -Cheers👍😁

[@ianpearce5745]

​@@mxgryanif new bikes where half as good as a rfs that would be really something. 😂

[@billywright8606]

I bought a 2001 400 before Christmas . This video makes me upset lol 😂 I struggled to get a exhaust they are also discontinued. I didn’t pay allot for the bike but one day I won’t be able to get parts I’ll cross that bridge when it comes to it .. sad times

[@mxgryan]

Well to be fair the bike is almost a quarter century old...what did you expect?! haha. Hopefully it lasts you a long time though Billy!

[@billywright8606]

@@mxgryan yeah should be fine thanks haha and I just wanted a field basher it’s crazy how exc hold there money . I’ve bought a brand new pro circuit t4 silencer sounds good, also just had to buy a water pump rebuild kit lol 😂 hopefully that should be enough for a while . They still do most parts for rebuilds etc so should be okay atleast the frame could still be used . Just the motor and all components may become extinct lol 😂

[@casmitherz]

Don't worry, that thing should run forever. My 400EXC won't die. Just don't neglect oil changes.

[@kaytme5915]

I bought the 525 new from Sam (KTM OF MOJAVE) first one in USA & street Legal from the factory! IT'S MORE COMFORTABLE THAN MY OTHER KTMs I should sale the 525! Somebody wants it?

[@tonyrichengod9280]

I have a friend who's put more than 200,000 kms on his.

[@creteking23]

Yeah pick up a 17-19 needing same shit or more, weigh your options...06 exc 4 life.

[@mxgryan]

LOL no. And a 17-19 CRUSHES this bike. Get real.

[@creteking23]

@@mxgryan just sayin, seen alot of people pick up "clean" few year old bikes that are railed but "look" nice and affordable but also cost $3 grand or more also to fix. Also I've owned my 06 450 exc since new, capital i smoke ALL my friends still and most their kids 😄 no matter what bike they got. 45 years on planet too! I'm about things that last not throwing away good shit for other shit. It's about smiles per $$ yen euro etc

[@joey011582]

@@mxgryan also that's including your labor and markup. I can do the same job for 900 lol

[@mxgryan]

@@joey011582 pardon me?

[@joey011582]

@@mxgryan pardon what you see what I typed. I CaN Do A tOp EnD fOr WaY LeSs. It's not a difficult task. I priced all the parts out including new valves, guides, springs and getting valve seats cut/replaced.

[@danielreinhardt937]

3k for a top end? Sounds like somebody needs to learn2wrench....

[@mxgryan]

Oh yeah?

[@danielreinhardt937]

@@mxgryan Not to insult your business, I work in automotive and understand that the price is the price. Power sports are a hell of a lot cheaper if you diy though.