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Old 02-11-2014, 06:40 AM   #1456
HellSickle
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Quote:
Originally Posted by Toadady View Post
anyone know how to put these things back together?

Insert pin A into slot B....

I may have a service manual if you don't. What year?
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Old 02-11-2014, 09:25 AM   #1457
Toadady
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it's a 99. but i've got a service manual , but thanks for the offer!
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Old 02-11-2014, 10:09 AM   #1458
DougZ73
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I can see on this bike(300 EXC) why someone might disable the powervalve. When I rebuilt mine, the rear brake was not working yet, as a master rebuild was needed. Of course I still wanted to ride it around the block once I got it all back together.

Friggen thing scared the hell outta me...bikes does care what gear it is in..it will wheelie. Got to the point I had to sit on tank and practically monkey hump the bars to keep it down....try and keep it down I should say. When the "hit" come on pipe...watch out.
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Old 02-11-2014, 10:15 AM   #1459
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Quote:
Originally Posted by AWM View Post
You boys better get to it!!!!![Dougy]Winters gona be all over before your done.





Studded tire must be nice......heck, winter riding must be nice.
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Old 02-11-2014, 10:20 AM   #1460
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Toaddy...you probably already know, but this is where those four orings I mentioed go....beautifully drawn in by me.

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Old 02-11-2014, 11:02 AM   #1461
AWM
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Quote:
Originally Posted by DougZ73 View Post
Studded tire must be nice......heck, winter riding must be nice.

Any time you get available pal.


This bikes screwed,



Theres another one or two in the garage that can get Treliborged.
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Old 02-11-2014, 03:59 PM   #1462
RozzyCat
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Quote:
Originally Posted by AWM View Post
You boys better get to it!!!!![Dougy]Winters gona be all over before your done.:loll
I did my part. Here in the midwest we've got a mix of ice/snow that makes for interesting traction. Studs - you bet.

FILE0470-2 from Randy Block on Vimeo.

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Old 02-11-2014, 04:05 PM   #1463
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Nice!





Think of the gas you'd save with a couple hundred of these.



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Old 02-11-2014, 06:22 PM   #1464
zig06
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Quote:
Originally Posted by DougZ73 View Post
PV cover does not get a gasket..silicone per manual. there should be 4 little orings in there though.

no wonder why you got such a deal.
Don't use silicone, use Three Bond (it's is good stuff) or (GASP!) Yamabond 5. I personally use Yamabond anytime there's no gasket.

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Old 02-11-2014, 08:59 PM   #1465
Toadady
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Quote:
Originally Posted by DougZ73 View Post
Toaddy...you probably already know, but this is where those four orings I mentioed go....beautifully drawn in by me.

actually, your drawing looks better than the O-rings did when I took it apart

permatex moto seal #1 is what I've been using, I've used yamabond, and the threebond also ,the permatex MOTO seal#1 acts just like the other two do, and I can get it trough my work
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Old 02-12-2014, 04:53 AM   #1466
DougZ73
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Quote:
Originally Posted by zig06 View Post
Don't use silicone, use Three Bond (it's is good stuff) or (GASP!) Yamabond 5. I personally use Yamabond anytime there's no gasket.

LOL..I just used what my manual said. I'll try the other stuff this time around.

Quote:
Originally Posted by KTM manual
Place preassembled control flap in cylinder, engage gear segments in
control rollers in such a manner that, when the control flap is ,open
(pivoted right to the top), the markings of the gear segments and the
gear rollers coincide. Please check that the two control rollers do not
block the cross-section of the port when the control flap is open.
Coat sealing surface thinly with silicon and mount intermediate flange
bs with 4 O-rings (11,3x2,4 mm).

Mount exhaust flange bt and spring hangers. If you are dealing with
a throttled version, do not forget the exhaust throttle.
Finally check smooth running of exhaust control system.
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Old 02-12-2014, 07:54 PM   #1467
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Alright, now here's my question. Why has no one here built a KTM 300 Rally? Seriously, top picture is a 500exc rally kit, middle is a 300xcw, bottom picture is a 150xc that finished the Dakar. Wouldn't the 300 lend itself to Rally style useage just, if not better, than a 150? Aren't these the bikes with top ends that can last 100+ hours?
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Old 02-12-2014, 10:32 PM   #1468
RideFreak
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Mileage

Because with that tank the 500 will go almost 200mi, a 300 with the same tank will go a little over 100mi at a rally pace. A 150 is better, probably closer to 150mi on 4 gal.
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Old 02-13-2014, 04:11 AM   #1469
AWM
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Quote:
Originally Posted by RideFreak View Post
Because with that tank the 500 will go almost 200mi, a 300 with the same tank will go a little over 100mi at a rally pace. A 150 is better, probably closer to 150mi on 4 gal.

I know they use big,big 2 strokes in some buggies.I wonder what kinda mpg they get?





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Old 02-13-2014, 06:50 AM   #1470
DougZ73
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Buddy brought over a good impact gun* last night and we got the primary drive gear off....which allowed me to take the crank out and make sure the little piece of metal that caused all my cylinder damage. It was ofcourse not in there....which was good to see.

* My cheap impact gun that came free with compressor...along with free air chisel and air ratchet....was not up to task. Tools cheap, compressor works well though.

Now I can start cleaning all the parts and putting the motor back together, and rebuilding the powervalve, and then rebuilding the carb and getting it cleaned out again.
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