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Old 08-17-2012, 08:30 AM   #18316
dieselcruiserhead
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Pretty sure it is a broken ring.

Did a compression test, 50psi at best...

And then I started thinking to the moment "it" happened. Bike was upright just idling away up against a log and then it made a noise and smoke started coming out of the exhaust pretty much never to go away.

Such is life...

I'm pretty mechanically handy (I'd done a ton of heads on cars and all sorts of various jobs on cars) but I'll say that these Austrian engines are quirky and I'm just barely starting to learn how 1 cyls work. I watched the "how to rebuild your top end" vids from Rocky Mountain ATV which are super helpful so it doesn't look too hard.

Can anyone recommend which kits to use and other items \I should order? Otherwise I'll start pouring through some of the KTM threads for advice...

As always if I'm repairing some of these items I'm thinking maybe I'll update if there are any opportunities. My biggest complaint with this 02 is that it has jobs of high end power but seems to be lacking on the torque from idle unlike an '05. It stalls easily so I was hoping to be able to increase that for the tough rocky technical areas.. Not sure if there is a way I could do that via a cam or some sort of different piston kit? I am already more than happy with its power otherwise and don't need/want any more.

Otherwise, This '02 is kind of old but is completely dialed and really well set up with custom valving and the suspension dialed and almost every possible gizmo and doodad available. I ride with guys on '09s and the newish bikes and this one completely hangs and actually feels really good to get back on, so I think it's worth investing into. So I'm all ears on any additional mods...

dieselcruiserhead screwed with this post 08-17-2012 at 08:35 AM
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Old 08-17-2012, 08:45 AM   #18317
dieselcruiserhead
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Is there someone who really knows their RFS engines that wouldn't mind 20 minutes of conversation and would be willing to PM me their phone number? I can read and read but I would love some guidance if possible...
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Old 08-17-2012, 09:58 AM   #18318
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Quote:
Originally Posted by dieselcruiserhead View Post
Pretty bummed, first went on a crazy adventure a couple weeks ago trying to find the end of a trail that connect Brighton Estates (up in Guardsman's) to the midway/AF canyon trails. At the end the trail disappeared and we basically had to hike a bike for a mile or two and it was steep as hell and the bikes went over probably a dozen times or so in the process.

Then after a dump there must have been some oil that got into the cyclinder somehow and it appears I lost my rings I guess. Bike starts and runs, but... 50 PSI on the cycl. Oil was coming out of the exhaust. Bummer because there aren't a whole lot of miles on this motor, maybe 2000 or so since the last rebuild? Oddly still starts and runs but definitley burning a ton of oil too..

Anyway, questions are:

- Does anyone have the top end KTM RFS tools I could borrow.

- Carb also seems to have stripped out its fuel screw because a POS aluminum Tusk knob. Do not buy a Tusk aluminum air/fuel knob for your KTM, always buy brass.

- This is an 02 which is good but has less top end than the later ones. Anyone have a '03 to '07 525 engine lying around, even if it needs a rebuild?

- Not sure if I should upgrate to a 41mm carb in the process, I have a '39 on this 02 but the later ones had the 41.

- Not sure if folks have recommendations on parts and/or where to machine locally. I'll def be finding some stainless valves at bare min and imagine the head and cyl will need some work.

- Considering pulling the bike completely apart and possibly repowdercoating the frame. Not sure if that is overkill...

All ears on recommendations...
If you need a carb mknight has a bunch and is selling them to help Josh get to germany for the isde. http://advrider.com/forums/showthrea...7#post19346667 Just bought one and its in great shape

Pm'ed my number I have two rfs engines pulled apart now.
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Old 08-17-2012, 10:49 AM   #18319
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Nobody likes a broken bike. I'm going sit back and bite my tounge on this one.

Let us know what it ends up being. Is odd how it happened. Still could be a valve issue
the way it made a noise and lost compression. The oil burning sounds like rings.
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Old 08-17-2012, 11:16 AM   #18320
dieselcruiserhead
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Just talked to frog for a while and it definitely helped a lot. Theres a chance it's fine, didn't know I needed the thottle open for the compression test. It doesn't feel like it has 50 psi of compression on how it starts/rides. Feels fairly normal other than blowing oil though... Four likely options:

- oil in the airbox and/or exhaust that keeps recycling so this is where the burned oil came from. Lost about a 1/2 quart that day.

- oil scraper ring broke so it will have decent compression but burn oil.

- original guess that rings are bad

- or a 4th option of something messed up in the head or a decomp issue or something like that.


Time to dig in, I'll report back... If its not #1 above then I'll pull the head..

Im also trying to figure out the carb air fuel screw mixture strip (need a new carb) and lack of low end that I haven't figured out yet either thats plauged this bike since i got it. It's not jetting or a dirty carb. My thinking is its this odd custom header the bike has and the super free flowing loud as hell muffler, that I want to get rid of...


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Old 08-17-2012, 11:28 AM   #18321
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I'm going sit back and bite my tounge on this one.
Hell has truly frozen over.
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Old 08-17-2012, 01:03 PM   #18322
pluric
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Hell has truly frozen over.
Don't you have a fuel pump or regulator to replace... or something???

Always nice to hear from our NE lurker.
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Old 08-17-2012, 01:50 PM   #18323
trackhead
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Originally Posted by Ryman View Post
Send a pm to frog, fano, trackhead........they have all done work on this motor.
Talk to the guys at lindsy. Something tells me they have done many RFS rebuilds.
The guy rebuilds and converts truck engines to hppy diesel. He'll figure it out.

I did my RFS over a year ago. Memory is shot. Simple motor though. Just buy a good cam chain rivet tool.
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Old 08-17-2012, 01:58 PM   #18324
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Brake light

So, there's no little switch like the one that Pluric posted, and the right amount of fluid is in the reservoir. ideas?
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Old 08-17-2012, 02:09 PM   #18325
ScottG
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Originally Posted by GISkev View Post
So, there's no little switch like the one that Pluric posted, and the right amount of fluid is in the reservoir. ideas?
have you checked the Stromtrooper.com forum? I'll bet someone over there has already been through this same problem. Greywolf is a great resource over there he knows those bikes backwards and fowards. Good luck.
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Old 08-17-2012, 02:46 PM   #18326
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brake light fixt

oops... the little switchy thing was just hiding.
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Old 08-17-2012, 03:27 PM   #18327
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?

Quote:
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Geeeeez. What does it take to get a bunch of moto heads excited about a mountain bike ride. It's like crickets in here.
You mean like pedaling and stuff, right?
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Old 08-17-2012, 04:51 PM   #18328
trackhead
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Geeeeez. What does it take to get a bunch of moto heads excited about a mountain bike ride. It's like crickets in here.
I ride every day........Monday-Thursday off. If you want to ride, let me know.

When it's hot, my rides start before sunrise and end before it's too high in the sky.
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Old 08-17-2012, 08:39 PM   #18329
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Our fellow Utard Kanook finished vegas to reno about an hour ago. His first long solo race and he killed it.
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Old 08-17-2012, 10:47 PM   #18330
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Our fellow Utard Kanook finished vegas to reno about an hour ago. His first long solo race and he killed it.
Awesome!
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