Motorcycle Top End Rebuild for 4-Stroke (Part 2 of 2)
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- เผยแพร่เมื่อ 2 ต.ค. 2024
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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.
Watch Part 1 Here:
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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?
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.
That is so awesome to hear! Thank you for the support and we're glad the video helped you out!
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.
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
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.
Thanks, we're glad it helped!
@londonTown1989 - a few cycles of letting it heat up and then cool off.
@mycat8urskidoo - they are pretty much identical kits. The tusk works great.
very nice vid the best i seen on youtube so far
@2hot4you369 - yep. 2004 EXC 450. not real clean anymore. It has been used and abused by one of our employees!
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!
@SoobaaSteve - You need to call a shop in your are to find out. But why not do it yourself?
thanks for uploading this
@ridinhonda4life - There is no real relation between the two; however, You should check the valves and adjust them.
maybe it's irrelevant but I was taught that circlip gap orientation should point either up to the piston top or down to the crankshaft. just a thought
btw thanks for your videos
Which cap are you referring to? because two strokes don't have valves
Thank's for video. You very help me !!! Thank's
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
@penc5use3 - I think the KTM is harder. a few more steps than the Japanese bikes.
THANK YOU
aaaaaaaaaaah great video but man.. I wanted to hear it run!
@qwikyking - I have no idea what you are looking to buy. Are you talking about a cylinder (that is below the head)? What machine?
check ebay if its a powervalve cover than you can find it but 2 strokes dont have valves for the piston
@ed563 - it doesn't exist yet. My hard drive failed and I lost the video. I will make a new one someday. sorry about that.
Hello friends from Rocky Mountain ATV MC, I'm from Brazil, São Paulo and also motorcycle mechanic'm here, I have a youtube channel (vba bikes), like many of his videos and try to be organized the same as you guys, thank you for the videos and hug here from Brazil.
@9139475 - you certainly could, but this one was fine.
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.
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!
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!
no we didn't, but it isn't a bad idea.
I'm sure your dad could manage the rebuild. Anyone with the correct tools, a service manual and some basic knowledge of motors would be able to manage a rebuild. As long as you do everything in the right step you should be fine. We also have these videos for you to follow through the rebuild.
you probably dont give a shit but if you are bored like me during the covid times then you can watch all the new movies and series on Instaflixxer. Have been binge watching with my girlfriend these days :)
@Rylan Eddie Yup, been using Instaflixxer for since november myself :)
@coxboyentertainment its a short skirt piston
all newer performence 4 strokes are like that
Oil Starvation was ultimately the cause. This damaged cylinder was bored and sleeved slightly larger than stock. Most resleeving companies will restore your cylinder back to stock specifications.
@BowHunt1229 - Already bolted together? no. Some case halves use a liquid gasket maker instead of a gasket, but it has to be pulled apart. If your bike requires a gasket you must use one.
yamabond 6B
sure you can - I am not sure why you be be taking it out though.
@njpaul78 - no locking screw. just timing marks on the cam gears and flywheel. Easier than this KTM.
turned out to be to much slack in the decrompression cable tightend it up and it works perfect now
@sk8perez2 - Most likely not. The steps are similar to those is this video.
We're not sure, there wasn't any oil in the bike when we fixed it
@acraze21 - there are certainly similarities. Your XR should be a lot easier.
We are also putting one together for a crf250, but not a kfx250. The process is about the same though. It will be done in a few weeks.
- I would guess the nikasil is better - that is why the OE's do it. However, I have never had a problem with a sleeve. The one we did in this video is still running strong 3 years later.
- you can look up pricing on our website. 4-strokes cost a lot more; more moving parts! If you take care of a YZ450 though, it will last a long time. In my oppinion it is the most reliable 450.
@ch0l0sk8r - a new gasket doesn't require it. It may not hurt though.
Not unless my WR bottom end fails me.
We will be doing a CRF soon and then a YZ a little later. Just need to find the time. thanks.
@RockyMountainATVMC thats for the reply :) once again great vid
- we lubed the cylinder wall with motor oil.
@bmxty82 - Nope. most 4-strokes don't.
send me a vin # and I can look. otherwise, I have no idea what you have.
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
Well thank you very much! but no, not at all. Any motor that is maintained regularly and taken care of correctly is going to last you. Obviously all the manufacturers are striving to to improve their design and to be the best and so in my opinion any modern bike is going to be a good quality bike for you . . . it all comes down to maintenance now
you say to put the 2 smaller rings on top of the oil scraper ring. do you mean on either side of it. or both on the top side of it?
+Liam Chalk Very true, nice catch. His wording could get a little confusing, but do as shown in the video. Top and bottom.
+Rocky Mountain ATV MC thanks
@hdidane00 - any auto store will sell them.
I have a CRF250 video, but I have not had time to finish editing. I will get to it soon.
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.
how much more is it to buy a top end for a 450f yz compared to a yz125 top end? this is a new cylinder, piston, rings, bearings, but no bottom end work at all I really wanna know cuz i might have to get a 4 stroke, and am worried about the cost on the 4 strokes. Plus how many years or hours would i get on a 450f that i will just baby and trail ride it?
are the head bolts new ? or can these be reused ?
@lastaferyn - I lost the file and have to make a new one. sorry
@PureN3WZ3ALAND - a lot of factors play into that. regular instection is a good idea.
It depends on what "all of this" means. Check out our website for prices specific to your model.
@zobel929 - it could be the problem. you shouldn't have needed yamabond on the o-rings or the base gasket though.
@juoj8 - thanks. We will keep that in mind on our new videos.
assembly lube. We offer 3 brands. Belray, PJ1, and Pro Circuit. All 3 work great.
super
@171apples171 - yes, i bend mine all the time!
@kraden18 - refer to the manual. there should be a mark on the flywheel that matches up with a mark on the cover.
I'm not sure on this bike. You shouldn't have to and it should just about be like any other bike. Remove cylinder head and then slide the cylinder/s up off and you're at the pistons... I would suggest investing in a service manual to complete this job.
@rama6maiden - i suppose you could say that about any part inside of an engine.
@HondaRider342Q - you would need to pull it apart and inspect it. then go from there.
@zobel929 - did you replace the O-rings around the water pump? It sounds like they may be bad.
@zobel929 - no, you just need to get them in there.
do you think that just plain ol seal maker would seal up a split case sufficiently if its already bolted together?
your CRF is much easier than this KTM. I actually filmed a video on one, but never have had time to edit it.
@emoskater1212 - refer to the manuals recommendations for replacement. Don't wait till something breaks!
@hdidane00 - No locking screw on your WR. you needto line up the timing marks on your flywheel. Pull both caps off the cover to do this. Your WR is much easier than this KTM.
you are right. I am finishing the editing on it now. I should have it done soon. thanks
- because the belray works great!
Replacing the top end on a bike isn't hard so long as you've got the correct tools such as a service manual and some other common hand tools and then you would need a valve spring compressor if you plan on replacing the valves. We are actually working on a YZF Top End Replacement Video right now that would help you out but you are going to need to refer to your service manual mostly for this job.
@sejlefrew - this 4-stroke is by far little more work than most I must admit.
@spruland - not usually
Did you squeeze the piston rings with your hands to fit on the cylinder? Its tight and I find it hard to do.
what would happen if you only place on ring instead of two on oil ring expander ??
@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.
@importmac - i suppose it could be that.
Ha Ha Thanks! 2 Strokes are definitely a little easier to work on but 4 strokes aren't bad as long as you've got the correct tools and you get all the steps in the correct order.
You bet! Thanks for watching
@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.
one of these days i will get to it:)
Did you use lube on the cyclinder and rings when you installed them or was it dry?
Just did a rebuild on a 2007 XCW - this video is still HELPING US!!!!!!!!! THANKS
@MrAhkmed - You are correct!
Could you be able to upload the CRF top end video some time?
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.
Good job!
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 :)
Thanks, this video pushed me over the line for doing my own head gasket repair!
Thanks for the tip!
Thanks for the Video , very useful and to the point, thumbs up, love the RFS bikes.
Best video on any RFS or KTM period.... thank you..
Glad you liked it! Thanks for the feedback and views.
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?