ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 06-12-2013, 01:09 PM   #1
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
Cool2 Back2Orange - NooB '02 400 EXC owner le questionies...

...looks like I'll be picking up a spankin' old 2002 KTM 400EXC'er this weekend from an inmate if all goes right. (props to Joel and ConTeacher)
130hours per the PO.

I'm gonna need to go through it stem to stearn.
All in all evidently a decently maintained bike that needs some LUV.

I figure I'll do:
valve check
wheel bearing check
swingarm bearing check
head bearing check
new tars
and a general scrubbin' an' spiffin'

Been reading all the EXC threadness, but still a few things to sort.
I'll have a few questions as well as I go along since there's no owners manual, like:

Recommended sparkplug? Should I use Iridium?
Oil weight?
Who's got a Scott's stabilizer I can buy from ya...

She looks like a real narsty dirtybike...







__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-12-2013, 02:42 PM   #2
bobfab
Beastly Adventurer
 
bobfab's Avatar
 
Joined: May 2009
Location: Westminster CO
Oddometer: 1,267
my good friend just bought the same exact bike im
__________________
Project Labor of Love: 1972 CT90 Rebuild
Current Stable: VFR800 | CRF250L | KTM200SX
bobfab is offline   Reply With Quote
Old 06-12-2013, 03:15 PM   #3
Droptarotter
Beastly Adventurer
 
Joined: Jul 2007
Location: Cloverdale
Oddometer: 1,152
Hey Randy;
Make sure the chain adjuster are not seized. I drill a 1/8 hole in the bottom rear of the swing arm for a water drain.

The chains like to run what looks like really loose on these bikes......best way to adjust the chain for the first time is to remove the shock (it's easy) and raise the swing arm in line with the countershaft/swing arm pivot to get the proper tension.

There is a oil filter screen under the engine that needs to be torqued properly.......most guys do them too tight and bugger them up the next time they try to take them out.
If yours is buggered get a new screen with a bolt head.

Run 20/50 oil........I like Chevron Delo 400.......

Have fun!!
__________________
HP2 Sport, R1200S, R100S, KTM 640 Adventure, KTM 520 EXC/Motard, Yamaha RZ350, Hodaka 125 Wombat
Droptarotter is offline   Reply With Quote
Old 06-12-2013, 03:39 PM   #4
Baja Dad
Beastly Adventurer
 
Baja Dad's Avatar
 
Joined: Jan 2011
Location: Norco California
Oddometer: 1,851
here is my 01 400 rebuild
__________________
2014 support: GPR,IMS Aurora Rally Kriega, Raiden LS2,100Goggles,SIDI,Seat Concepts, Rally Raid Products UK,Precision Concepts, MX1West,Dunlop
Baja Dad is offline   Reply With Quote
Old 06-13-2013, 08:15 AM   #5
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
..hooyah! Frame off resto...nice.
I promised myself I'm not going overboard on this one.
Gonna be a get dirty trailbike I can drop and not fret about.
Low budget but well maintained.

I do need a Scott's stabilizer'n some stuff though...
__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-15-2013, 05:50 AM   #6
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
...soon come...
__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 07:01 AM   #7
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
....got 'er done...





__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 07:04 AM   #8
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
it starts

first a scrub down, she's a dirty bitch but runs fairly well.
Needs huge TLC...
The PO move the ECU to under the seat. Some sort of mod I don't understand. I mounted back where it belongs on the steering head.
Questions to come...




__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 07:10 AM   #9
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
...there, that's better. Cleaned up pretty good.
Managed to get the valves set.
Intakes were tight
Exhausts were loose...

Turnsinals and brake light don't work
Turnsignal switch has been buggered.
It's got the TrickDualSport Light kit. Not sure how that's wired, much to sort there.



First question, is the adjuster knob on the carb (bot left) fuel mixture or idle?


__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 07:13 AM   #10
MotoChris521
Studly Adventurer
 
MotoChris521's Avatar
 
Joined: Aug 2007
Location: SoCal
Oddometer: 531
Idle speed
__________________
dreaming of moist soil
MotoChris521 is offline   Reply With Quote
Old 06-17-2013, 09:13 AM   #11
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
Thanks Chris.

Here's another:

Bike runs good but when running and you let it die, there's a top-end rattle ...noise during the last couple rpm's.
Sounds like a cam chain noise.
Not sure this is normal or a sign of something 'else'.

I have set the valves already but not run it yet.
Intakes were tight, exhausts where loose.

Over at KTM Talk someone suggested...
Quote:
You are probably hearing the auto-decompression kick in.
This bike has the decompression cable disconnected..for what I do not know...
__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 10:42 AM   #12
bobfab
Beastly Adventurer
 
bobfab's Avatar
 
Joined: May 2009
Location: Westminster CO
Oddometer: 1,267
My buddies is the exact same way. Decomp cable disconnected and a slight rattle at low "Shutoff" RPM's. Im all ears here!
__________________
Project Labor of Love: 1972 CT90 Rebuild
Current Stable: VFR800 | CRF250L | KTM200SX
bobfab is offline   Reply With Quote
Old 06-17-2013, 11:56 AM   #13
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
me2

__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Old 06-17-2013, 12:25 PM   #14
GR0NK
Got some screws loose!
 
GR0NK's Avatar
 
Joined: Sep 2006
Location: In the Valley of Bomb Runs...
Oddometer: 1,720
The decomp is auto, makes no difference if the cable is connected or not. The noise is normal. About the decomp on pre 03 bikes though, is the stop on the cam gear. It's a bolt with a nylock nut on it. In 03 they changed it to a riveted pin. If the nylock nut comes loose and the parts fall out, it's not pretty. Very rare to happen but it has. The fix is a new cam gear which isn't terribly expensive, under $60 IIRC. You'll need a new cam in 200 hours or so as the water pump seal will groove the end of the shaft. I would just wait and do it all later.

If you follow the 400 discussions anywhere, you'll surely come across the mention of the 453. The 453 is the best RFS motor KTM never made. Basically it's the 400 crank (short stroke) with a 525 cylinder (and a special piston from Thumper Racing) and it bumps the displacement to 453cc. You toss the anemic 400 cam and use the 5521 cam (stock cam on 450 and 525 EXCs) and that gives you a great all around motor for low bucks. It's still docile on the bottom but it comes alive on top and revs out good due to the short stroke and the better cam.

At 300 hours you're going to start running out of adjuster as the intake valves get tighter and start knife-edging. Send your head to Dave Hopkins and have him do his stuff. Stainless steel Kibblewhite valves at the very least. If you are going to bump up the displacement, get the intake valves oversize by 1mm and unshrouded. You're then only an 806 (or my fav an 833) cam away from serious fun.

I love these motors. My favorite is the 540 but that's a long stroke crank so not quite the snap and smoothness of the short stroke crank. Ride it stock and enjoy it for now, it's an awesome bike.



Sean
__________________
Team Valley Bomb Squad

Nullus Vereor ex Terra Incognita

GR0NK screwed with this post 06-18-2013 at 05:07 AM
GR0NK is offline   Reply With Quote
Old 06-17-2013, 01:15 PM   #15
Rapid Dog OP
bikes, booze, broads...
 
Rapid Dog's Avatar
 
Joined: Oct 2003
Location: Strangel Living West of Hell
Oddometer: 9,054
yaeh baby! Now that's some relative info!
Thanks for that.

Quote:
Send your head to Dave Hopkins
Who is he. How does one contact him, eh?
__________________
'09 450 EXC Nani Roma Limited/'08 R1200R-Gone to the Hipsters/'02 Dirty lil KTM400EXC-gone to a good home/'10 WR290X/R buhbye!
'81 R100RS Rattlecandy Red/'06 950 ADV Orangeboom/91 R100GSPD Derelict

Rapid Dog is online now   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 01:22 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014