Well, I got myself another project bike! A little more of a project than I was hoping for, but thats the way these things go! While I am new to KTMs and singles, I am not new to riding (17+yrs) or to building motors (4 or so moto, 5 or so small car). My reluctance comes from not knowing where or who to source parts and such from, and also never having a KTM or single open. I have been trying to collect info from ADVRider and now from here. I did get the owners books with the bike and I also ordered the KTM Repair Manual. What I know from previous owner: -unknown mileage, guestimate of 15,000 kilometers; the IMO has a loose wire and resets itself, soon to be fixed, I believe -piston ring broken and shut engine down immediately, approximately 2 yrs ago; sat for a few months before getting replaced; owner rode bike roughly 1000 miles and was hearing a noise that made him nervous and the bike has sat since June 2009 What I have found: -carb orings were dried up and leaking; could be the reason or one of the reasons I couldnt get the bike to start; I sent a message to MotoLab for a titanium needle, orings, stainless bolts and other bits and ordered the Mixture Screw from Stenhouse. I also contacted Boyesen and unfortunately they do not make a SuperBowl for the BST40 -head gasket was leaking, but from the water jacket to the outside of the cylinder; so it was probably tightened down without proper torque, but close -the thrust washer between the cam and the large cam bearing was broken, looks like the retaining clip next to it was damaged and cause the thrust washer damage -the cylinder wall has aluminum embedded in the nikasil, most likely came from the previous piston; hoping to find a local machine shop to work with -the piston is scored on the skirt, matching where the aluminum is embedded into the cyl; also the bottom is badly burned; so time for a new piston! -the piston pin is a lil bit sloppier in the small end of the rod than I'd like to see, but I haven't really looked into whether or not its the pin, rod or bushing, does it have a bushing? I am on the line as to whether or not I should just do the topend or do a full tear down and at least inspect it thoughly. I'd like to get the bike up and running ASAP, but on the other hand I want it to be the best it can be and last a while, so I am leaning towards a teardown. I intend on using the bike for daily riding as well as long distance trips (ADVRider WestFest in Montana, [1100 miles one way] in July 2010]. I want reliability and longevity vs hotrod, I have the Ducati for that! I intend to take the time to make the motor as efficient as possible. What I would like to know is: - One of the camcover bolts has a locating bulb/knob on the tip. It was located on the left side just in front of the water pump. Where does it belong? - What improvements and upgrades should I be considering? - Are there weak points/issues to look for? - Should I put a High Flow head on it, if the price is reasonable? - Should I put larger valves in it? - Better cam to consider? - I've found a few missing bolts, washers, dowels and misc parts that I will need to order from a dealer, who has good pricing, stock, shipping, etc? Stateside would be faster I assume. - I've read of Engine Dynamics, who is a short drive from me, so I will be calling them on Monday to see what they can help me with. Who else should I get in contact with? - What else have I missed that I should consider? Is there anyone in the Nor Cal area who has experience with these motors, that wouldn't mind taking a look from time to time? I can come to you. Thank you all!