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Old 01-11-2009, 08:05 PM   #61
Mudguts OP
when in doubt GAS IT
 
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Location: Some were in , lostralia
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Stage Two

Stage 2 525-540 kit rebuild by a noob

, I have had the 540 kit sitting in my bedroom for few weeks now

And it time to install having never done a top end on 4\St just want to know the tricks of the trade as some you seem to pull you bike down because you think it is funn

1) I have the thumper 540 kit with gaskets
2) I have the cam chain tool
3) Have all new cam chain & guides
4) Head will been sent out for new valve and seats
5) I have check ring gaps) all good
6) I have the service manual .
7) Have a 3 torque wrenches ¼ 3/8 ½ inch.

What other things do I need to know , tip and tricks

My plan is get the head & barrel off tonight , drop the head off tomorrow
Pick up head and cam chain & guides weds and reassemble.

Disassembling is the easy part , putting back together is tricky bit ,

I’ll need to check the deck hight , don’t know how to change it if I needed to thou

I think I’ll be fine up until the cam and TDC I know the theory just need the practice. I suppose it is just a matter of lining up all the indicators and going for it . and to double checking my work.
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Old 01-12-2009, 01:16 AM   #62
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So i got home and got right to it

a quick pressure wash before pulling the motor down



start stripping parts off


some springy bits that go up and down




and a shiny new thing that goes up and down



and this it where it stops for tonight, gotta drop the head off in the morning for new valves



old V New
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Old 01-16-2009, 05:43 PM   #63
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Well got pick the head up last night then hurried home , to start reassembling , 3 hours later she was together , after checking and double check valve gap , & cranking the motor by hand , i felt it was time to drop the spark plug in , and her a kick ( battery is rooted )

so wheeler outside flip out the kick starter , and give a boot full
the first thing i thought was ......SHIT this has compression

forgetting to turn the fuel on and 10 kicks later ,
i turn the fuel on two kicks and she fired up Oh what a lovely sound
of HI-comp 540 KTM EXC , big and meaty but sharp and crisp

I excitited , I have to take her around the block
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Old 01-16-2009, 06:01 PM   #64
OldDog
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Well done Mudguts, there are few things sweeter than the first bark out of a newly rebuilt motor, hope you enjoyed the ride.


Oh and don't worry about the fuel thing, we all do that
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Old 02-09-2009, 04:40 PM   #65
vallarian
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Running in

Well done with kit install Mudguts. Must be satisfying seeing it come together. Can't remember which thread I read, but there is some good info around on running-in theory if u can find it (basically slowpoke vs WFO) J
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Old 02-12-2009, 09:16 PM   #66
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next time u buy wheel bearings just get them from a bearing shop rather than a bike shop and you'll save lots of $.
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Old 02-14-2009, 04:16 AM   #67
teti
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Quote:
Originally Posted by Mudguts








the nab bracket mounted ( with new bracket on trilpe clamp )




road book mounted




All finsished stage one


mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

saludos atte

y gracias

teti
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Old 02-14-2009, 04:22 AM   #68
nevgriff64
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Quote:
Originally Posted by teti
mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

saludos atte

y gracias

teti
So what`s your reply to this one Mudguts??

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Old 02-14-2009, 04:36 AM   #69
teti
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Quote:
Originally Posted by nevgriff64
So what`s your reply to this one Mudguts??

perdon pero no entiendo , yo uso google para traducir y algunas cosas las traduce mal,

el q tenga las medidas si le las puede pasar

gracias

teti
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Old 02-14-2009, 04:39 AM   #70
nevgriff64
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Quote:
Originally Posted by teti
perdon pero no entiendo , yo uso google para traducir y algunas cosas las traduce mal,

el q tenga las medidas si le las puede pasar

gracias

teti




















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Old 02-14-2009, 04:43 AM   #71
Sylvia
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Originally Posted by teti
perdon pero no entiendo , yo uso google para traducir y algunas cosas las traduce mal,

el q tenga las medidas si le las puede pasar

gracias

teti




pardon but I do not understand, I use google to translate and some things translate them bad,
the q has the measures if him teti can
pass
thanks
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Old 02-14-2009, 04:45 AM   #72
Sylvia
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Originally Posted by teti
mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

saludos atte

y gracias

teti



mugguts good day, serious so amiable to pass the measures to me of the support of road book?
whichever centimeters develop forwards, upwards, always taking like reference the pivot from the direction, I am about to to copy anchorage q tenes put in your moto, and if tenes a photo of how you anchored in the chassis
greetings atte
and thanks
teti
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Old 02-14-2009, 04:51 AM   #73
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Quote:
Originally Posted by teti
mugguts buen dia, serias tan amable de pasarme las medidas del soporte de road book ?

cuantos centimetros desarrolla hacia adelante , hacia arriba , siempre tomando como referencia el pivote de la direccion , estoy por copiar el anclaje q tenes puesto en tu moto , y si tenes una foto de como lo anclaste en el chasis

saludos atte

y gracias

teti
I think he`s saying,

Hello Mudguts,

Would you please pass the measurements of the support for road book.
how many centimeters develops forward, upward, against the direction of the pivot, I am copying the anchor post in your bike, and if you got a photo as anclaste in the chassis.

greetings and thanks atte Teti.

Well thats how Google translates it, he basically wants to do the same as you i think, spanish is the language.

Mezo.
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Old 02-14-2009, 05:50 AM   #74
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Correct.

Hes after the measurements of the nav post, to copy it. (Teti is argentinian and imported stuff there is very expensive - so hes trying to do a DYI job)

Mudguts, how did you get on with a possible clone of the fairing?
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Old 02-14-2009, 12:50 PM   #75
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Yeah cool I'll get the basics .If any one has a CAD program they can lend me
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