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I found this video in 2024 after screwing up the valve adjustment on my KTM 2003 540 SXS. Causing my engine to loose compression & the bike to not start. I just gave up & found this GEM. Used your method to find TDC. Performed the adjustment with the 1/6th method & VOILA the engine popped up with one kick & roars like a beast. My gratitude to you. If you are ever in Suriname ,I got the first round.

Good stuff!!! Easy explanation and thorough! Thank you!

Great video. No yacking, right to the job.

What the video doesn’t show is the valve cover isn’t tightened down to the head. I’ve tried this method and I can officially call bull shit on doing without taking the valve cover off. Carrier will not seat on the back oring.

I just did the same job on a 2004 KTM exc 525 got it all back together and was instantly weeping coolant any ideas

Is there supposed to be a space between rear oring and backing spaceer

Thank you. I still won one this early 2003. This vídeo really helped me to diagnose and fix my water pump. God bless you.

Bonjour l’ami et merci pour ta vidéo bien utile ! J’ai cependant une question importante. Quelle produit mets tu sur le joint ? C’est du loctit ? J’ai trouvé sur amazone le même flacon que toi mais il existe plusieurs référence. Peux tu me donner un exemple similaire ?

Yo you the man just did my water pump thanks for your help love this bike

Thanks a bunch! Seems to be working. I did have to press both seals in the keeper with a brass rod and a hammer. I used blue painters tape to wrap around the end of the shaft so it didn’t Knick the seal. Your kit at this time was unavailable.

amazing..thank for learning by doing my bike 400 exc too...thank again bro

Why would you only do the outer O-rings of the carrier and not the seals that go around the shaft? I’m confused that’s how I’ve always done it and you might as well while you’re in there

Does replacing the carrier stop oil leak? Or just coolant leak? Ive got an oil leak do i need to replace the inner seal?

thanks broo :D Gretings from Poland

I see this is 14 years old but hope someone can help, doing my 520exc 02 and would like to replace the carrier also, I can't find just the carrier anywhere.....

Bout to do this to my 520

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)KTM XC 450 2006

Poor camera work.

Love the video! Question...I have radiator fluid weeping out of the little hole to the right of the water pump impeller. It appears as though this video shows all that I need to do to fix the problem, correct? Next question...so I don't need to take the cam cover off, break the cam chain to remove the cam to take care of this weeping leak that is getting worse? Last question, you sell the kit with the sleeve protector? I have the 2003 525 exc and I have a 500 mile ride coming up in two weeks. When I buy it, can I get it by this Friday so I can follow your video? Thanks.

Do u work on dam pumps Harleys

My bike has been down for weeks because I've been having trouble locating shim sizes..... JOKES ON ME! 🤣🤣

I over thought this whole process and you made it look simple. Thank you

Why is the drain / indicator hole installed oriented on the top? It seems to me like if the coolant o ring leaked it would run down the second channel and out the weep no problem. However, with the hole for the internal, shaft seals installed vertically overhead, it seems the space between the seals would have to fill before coolant could run up and out of the drain hole and then out the weep hole... My manual is poorly worded on this too. I may be overthinking but might as well try and do this right the first time

Thanks once again brilliantly executed tutorial from here in 🇬🇧

Thanks so much, from here in 🇬🇧

This is the best how to still to date. Thanks

Hola i gracias por el video tengo un pequeño problema con la misma moto i el tema del agua, Ami con la moto encendida me pierde agua por el sobrante de debajo de la bomba de agua justo en la culata, sabes si el problema puede ser la bomba de agua? Gracias de antemano 👌🏾

Can the coolant make its way into oil if the seals are bad?

Do you still happen to have these kits?

you rock dude, thanks for explaining tdc and overlap

At 4:05 my 2004 450 doesn't have those 3mm holes. How do I go about getting it out?

4:00 "an easy way to do it.......". I wish. After an hour with 3mm screws, multigrips and a heat gun, yanking and twisting, the carrier was reluctantly in my hot sweaty hands.

I'm getting coolant in my oil. I rebuild my water pump twice already and I'm wondering if its leaking some place else. Should I try and rebuild the pump again or look elsewhere for the problem?

awesome video, cheers from New Zealand

It was hard to find correct TDC for me. Also the 1/6 turn method gives less than 0.10mm clearance to me, which should be 0.12mm. I guess 0.02~ mm is not an issue?

Mui bien

thanks for the vid. Excellent tips and tricks

***FOR EVERYONE ASKING WHATS DIFFERENT FOR 03+ MODELS***** he said- The proceedure is no diferent for the 03 450sx and 03+ 525sx. The thing with those years and bikes are the spring retainers are different and puts a bind on a feeler gauge. So on those years and models-- or any year with the conical valve springs The 6th turn method works better

My friend I've got a trouble with that. The intake valves are too tight. Screw down hit the valve and screw up hit the limit of the rockers. What should I do?

When I try this my wheels won't turn unless I pull the clutch. Then with clutch pulled the engine doesn't rotate? 450 atv

iv watched this 10 times and still dont get how he got to the rignt location

Thanks for the video! I will be using these tips!

Hi, Great Video! I have a question, I can perform this work with the mounted head? or do I have to remove the cylinder head

hi i wanto buy parts of you but i cant find your website

hi there i need help can you contact me on joshiewraithking@gmail.com im in australia im interested in buying off you

Camera guy and light guy fail

The part about TDC doesn't make sense, can't see what the valves are doing.

Why won't this work on a 03 525sx? Or will it?

Much thanks

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