2007 450 KTM EXC Rejuvenation August 2015

[carlrf]

Yes. It stays up perfectly fine w/o the pin in.

I did a google search, come to find out it's pretty common for these lifts not to work right.

[carlrf]

Wanted to spend some time on the KTM last night but didn't want to get too involved in anything so............

Thought I would lube some pivot points, woohoo!





And protect some electrical connections.



And reinstall the stator with the new gasket.

[carlrf]

OK, gets a little messy. First oil change on a new bike is often a bit awkward to say the least.
I had puled the two filters and two strainer screens prior to beginning this post so you will just have to use your "mind's eye" as they say for those details.

Anyway, Troy gave me a heads up to fill the oil filter cavities before starting the bike to reduce the time the engine runs without good oil pressure so.............



Woops, bad picture, sorry.


Yes, I got oil everywhere. next time the oil first then the filters.

[carlrf]

Let's clean a little underneath and put the skid plate back on.










More bolt threads to ant seize!



I put a couple of washers on each bolt on top of the skid plate to fill the recess in the plastic canister mounting tabs so the skid plate isn't putting undue pressure on the tabs when the bolts are tight and/or the plate impacted with the terrain. Washers are not shown.
It's an aftermarket skid plate. I am pretty sure the bike didn't come with one originally.


Oh, I replaced the cotter pins in foot peg pivots last night. Wouldn't want to lose a peg you know!

[carlrf]

OK, back to the rear inner fender.
Earlier you saw the dilapidated old one and the new one I purchased.
Now I am ready to mount the turn signals on the fender and the fender on the bike.

It was a challenge to finally decide where to put the signal holes and get them the same on both sides since there are so many different angles and irregular surfaces. Not much to measure from.



Not only do I need the signal mounting holes but......



............but I also need rotation locator holes.
The Mounting holes look a little rough because I had to open them up with a rattail file. The two bits I have one was a little too small and other was too big.



And they need to be close enough to the pre-drilled wire pass through holes as the pigtails on the blinkers are very short.





Cool!


I think they came out ok for blinkers on a dirt bike!

[troy]

NICE WORK, Carl!

[carlrf]

Troy gave me a tail bag too!
Maybe a little beat up certainly functional.
He even gave me the bolts to mount it with!

Before I did anything with it.



I turned it inside out removed what was left of a water resistant liner long since gone most of it, and trim up the frayed seams. The seams actually are still in good shape.


I used up an old tube of modeling glue on the seams to possibly reduce further fraying and strengthen the existing seams.




Throw it in the laundry with some old towels I use for various jobs.



Looks better but you can see where the glue worked it's way away from the seams.

[Ed M]

I see you are using WD-40 to clean the electrical connectors. I also open the connectors and cram in dielectric grease to prevent water intrusion and corrosion.

[carlrf]

I see you are using WD-40 to clean the electrical connectors. I also open the connectors and cram in dielectric grease to prevent water intrusion and corrosion.

Yep.

[troy]

I see you are using WD-40 to clean the electrical connectors. I also open the connectors and cram in dielectric grease to prevent water intrusion and corrosion.

And Carl should have found most of the electrical connectors were packed with dialectric grease. Slightly less than 2 years ago, I took them all apart, cleaned, and packed with dialectric grease before reassembly.

[carlrf]

Well it's time to pull the exhaust and see if I can get it cleaned up a little.

Muffler looks ok but I may put the OEM muffler back on cause it's more Purdy!


It looks like something (or more than one something) may have melted on the head pipe.
Here I am trying to get it out from between the frame, engine and shock, not going so well!


I am thinking the shock needs to come out to accomplish the head pipe removal.



Bolt was tough, had get out the breaker bar.






Got it!





Got my work cut out for me!




More on this later!

[carlrf]

I got to have a new crankcase breather hose!

Here is the original, a little kinked.


I think I will go with this setup.


And here it is installed.

[carlrf]

Enough of that, let's move to the cooling system.

Drain it.
Yes, I do leave it out for the cat!



Every hose and clamp comes off to be inspected and cleaned.




This is as far as I got this weekend.

[HanesAnizer]

I'm admiring your progress....I bet the 450 doesn't miss it's old neglectful owner

I wish I had the time to do this to my bikes.

[troy]

I'm admiring your progress....I bet the 450 doesn't miss it's old neglectful owner

I wish I had the time to do this to my bikes.

Seriously. When Carl started this, I was like, OK, so he's going to clean up a few things, fix the oil leak. Who wouldn't? ..but now this is getting ridiculous! That 450 is going to be show-ready in another couple weeks!

I'm starting to feel bad about the sawdust I threw in the oil to quiet down the fact the motor is ready to explode.

[Rick]

I don.t know carlrf but I admire his patience and attention to detail exhibited during this process. That said, I can't help but wonder what his reaction will be when faced with that first big mud bog out on the trail??

[carlrf]

I don.t know carlrf but I admire his patience and attention to detail exhibited during this process. That said, I can't help but wonder what his reaction will be when faced with that first big mud bog out on the trail??

MUD? NOoooooo!

[Savage]

Good work!
I don't like tearing into stuff as far as you're going, because if it's not broke I don't want to fix it. I'd probably end up creating a radiator leak. But I do enjoy cleaning and working on my bikes just as much as I do riding them.

Now put that thing together, load it on the trailer, and go ride it for an afternoon!

[carlrf]

"Now put that thing together, load it on the trailer, and go ride it for an afternoon!"

I am trying!!!

[carlrf]

I'm admiring your progress....I bet the 450 doesn't miss it's old neglectful owner

I wish I had the time to do this to my bikes.

Taking care of kids = 0
Lawn care = 0
House maintenance/repair = 0
Appliance/HVAC maintenance/repair = 0
Elder care (other than myself) = 0
House cleaning = 0 almost
Grocery shopping = 0
Girlfriend maintenance = 1
Full time employment = 1
Other current hobbies = 0

I am looking for a part time retirement job!