2007 450 KTM EXC Rejuvenation August 2015

[carlrf]

Thanks to Troy's generosity I have a spare, clean and oiled air filter to install!
I don't think I messed that up.

[carlrf]

I had to adjust the position of one of the hand guards to fit the turn signals. Bolts had been in there a while. I decided to take them all out, apply anti-sieze and reinstall.

[carlrf]

The right hand guard didn't seem too happy. When I took the inner mounting bolt out with some difficulty it sprung out a few inches, having been in a stressed position from an apparent drop.



So I decided to take it all the way off and do a little persuading.
I will replace the lever and swap locations with the kill button so the whole lever will fit in the hand guard, hopefully.

[HanesAnizer]

I'd recommend installing these when you put the guards back on...never come loose.

https://www.bulletproofdesigns.com/prod ... d-tap.html

[carlrf]

Found I had somehow blown the 10 amp fuse when working on the signals.




This broken connector may have made contact with the frame during my manipulations.





Oh well, it gave me motivation to clean up the battery/relay/fuse area.

[carlrf]

I'd recommend installing these when you put the guards back on...never come loose.

https://www.bulletproofdesigns.com/prod ... d-tap.html

Awesome, I like it!

[carlrf]

Rehabbed left frame protector and mounting components.



Trimmed damaged rubber insert.
Replace rusty nylock nut with non-nylock nut.
Anti-seize bolts and run nuts down entire thread to thoroughly coat threads.
Add small washer to help expand the rubber piece in the swing-arm pivot bolt. Had to grind perimeter of washer to reduce diameter so it would fit in the pivot bolt.



Did I mention the Armor All to improve the looks of the faded black plastic?

[Jamee]

Wow, looking good!
I really like how much attention to detail your putting in here!

[carlrf]

Wow, looking good!
I really like how much attention to detail your putting in here!

Thanks, I am a trainer at work and it feels like I am working on a training Powerpoint, but no audio.

[carlrf]

Wow this forum has been busy today!

Anyway, I thought I would try to clean up the orange rear fender the way i have cleaned white plastic before. That is with SOS pads and/or Comet and plastic scrub pad.




Well darn, it left a dull white haze.
That didn't pan out so well.
It's going to have to do for the time being.

[carlrf]

Well the main rear fender fastener looks important and unique enough to deserve some special attention.

How about a little cleaning with WD-40, and couple of brushes?
Finish it up with some antiseize and run the nut all the way down the threads.


Now let's put it in place.






I know, boring for most of you. It is actually entertainment for me.

[carlrf]

I tried to salvage the inner rear fender and tail light but I could not get the brake light circuit to work in the light itself. Also you can see the broken mounting tabs but I could have made those.




I did considerable research on just replacing the light but none except one in England were the right size and/or had the correct mounting dimensions. The one in England was pretty steep plus shipping so I decided just to replace the entire assmbly and be done with it.



They are proud of these things!

It's not mounted yet.

[Jamee]

Not bored here - This is great.. Although the SOS and cleaner, soon as I saw that I was wondering about the shine and the tiny scratches. Probably not see it on the white, but any other color might produce a bit of dulling..

Still though, they don't call it learning without being burned once or twice.

Looking forward to seeing this bike in person at some point.

[carlrf]

Not bored here - This is great.. Although the SOS and cleaner, soon as I saw that I was wondering about the shine and the tiny scratches. Probably not see it on the white, but any other color might produce a bit of dulling..

Still though, they don't call it learning without being burned once or twice.

Looking forward to seeing this bike in person at some point.

(I am working on it!)

It was already plenty dull and scratched. Didn't have anything to lose!

[Savage]

I haven't been digging as deep as you are Carl, but I've been doing some rejuvenating of my own.

[troy]

I haven't been digging as deep as you are Carl, but I've been doing some rejuvenating of my own.

Sponsored by Subway I see. Did you buy the bike from Jarrod?

Whoa! I had not heard the scandal regarding Jarrod. [THREAD HIJACK]
https://www.youtube.com/watch?v=0vyRubGqFdA

[Savage]

Its funny that people comment on my Subway decals all the time, but no one ever questions Monster, Red Bull, Race Tech, Dunlop, Fox, Klim, etc, etc. We're all branded posers.
Now where is my KTM branded toast!

[carlrf]

Wow super clean! Nice.

i will back off after i go through it once. It's that initial "get to know it" mode I am in right now.

[carlrf]

I haven't been digging as deep as you are Carl, but I've been doing some rejuvenating of my own.

Is that a Harbor freight stand? I just bought one and it wont stay up without the pin in it.

Did I assemble it wrong?

[Savage]

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