2007 450 KTM EXC Rejuvenation August 2015

[HanesAnizer]

These make wheel bearings so easy. I use it for my trailers and bikes. http://www.harborfreight.com/10-piece-b ... 95853.html

As for the tail light stuck on, it's likely this -
Year/Model: 2007,
Component: HAND BRAKE CYLINDER
Item #: 50
Part Number: 50311050100
Description: BRAKE LIGHT SWITCH FRONT 2002
Retail: $64.69
Your Price: $48.52 (Summer Savings - 25% discount)

Easy to break this when riding in the woods....especially the way Troy rides.

[Savage]

Ingenious work!

[carlrf]

Well I was all happy with myself, I thought I would start it up and work on getting the signal and lights all working the way they should but it would not start and I have lost the half functioning signals that I had before.

Darn it what have I done.
It cranks but doesn't fire a lick.
I am all sad now and had to give up for the night.
I did check the fuse but it appears ok.
Don't even know where to start. Guess I will get out the wiring diagram and try to follow it o the problem.
I am never going to get this thing going.

Again..........to be continued

[carlrf]

These make wheel bearings so easy. I use it for my trailers and bikes. http://www.harborfreight.com/10-piece-b ... 95853.html

As for the tail light stuck on, it's likely this -
Year/Model: 2007,
Component: HAND BRAKE CYLINDER
Item #: 50
Part Number: 50311050100
Description: BRAKE LIGHT SWITCH FRONT 2002
Retail: $64.69
Your Price: $48.52 (Summer Savings - 25% discount)

Easy to break this when riding in the woods....especially the way Troy rides.

There have been many times I could have used that set!
Thanks for the other info too.

[carlrf]

Ingenious work!

Thanks but I think I countered it with something I messed up on the electrical.

[carlrf]

OK, operator or should I say rejuvenator error.

In my haste or laziness I assumed I couldn't get the electrical connectors mixed up.

But when tracing the wiring with a diagram I quickly had the signals and brake lights working as expected but motor still wouldn't start.

A few steps later, including pulling the plug and checking for spark, I realized I had the gas on but there wasn't enough in the tank to use the normal petcock position. When I put it on reserve I got the gas I needed and it started.

What's worse is a week or so ago I already knew it was low enough to need reserve.

I hope these things aren't symptomatic of my age?
Or maybe I hope they are, that way I have an excuse.

[carlrf]

It's ALIVE!






Put the OEM muffler on. The FMF muffler was too loud for me. The OEM I heavier but the sound is worth it.
Had a little trouble getting it on. As Troy had said earlier the subframe has been skewed a bit from drops. I looked up a knew one on ebay but it's not that far off to justify the cost.

Also the FMF points the exhaust gases right at the turn signal, I was afraid I would ride it and come back with a turn signal melted to the bike!









I took a début ride on it today to the get some gas and check everything out before I head to the inspection station and license bureau tomorrow.
The only issue I had was I couldn't shift to a higher gear and got a grinding noise when I did. On inspection I realize I installed the shifter one notch too high and it would hit the chain at the countershaft sprocket. /a quick adjustment and I was on my way.



The only things I have left I want to do is pull the rear wheel for bearing inspection and rear brake pads, just ordered them.
This thing has more power than I expected I can tell you that.

[troy]

Impressive!

[carlrf]

Impressive!

Thanks, means a lot to me.
I am overdue on title. Will be penalized. I could have hauled but I just waited.

[troy]

Impressive!

Thanks, means a lot to me.
I am overdue on title. Will be penalized. I could have hauled but I just waited.

I think the penalty in KS and MO is tiny, as in not enough to care about being late with registration.

[bird man]

Carl , impressive work. As I remember that bike left dead the last time it was at the bird farm trails.....looks like it is ready to come back and give them a try again.

[carlrf]

Impressive!

Thanks, means a lot to me.
I am overdue on title. Will be penalized. I could have hauled but I just waited.

I think the penalty in KS and MO is tiny, as in not enough to care about being late with registration.

I think it's $25 a month with max at $200 but not positive. Guess I will find out tomorrow.

[carlrf]

Carl , impressive work. As I remember that bike left dead the last time it was at the bird farm trails.....looks like it is ready to come back and give them a try again.

Hmmm, I am afraid to ask but.........

[carlrf]

After my first trip North across Paseo Bridge to Antioch inspection station ( I know it's not Paseo anymore but do not know what else to call it), quietly waiting for "the inspection man" to show up for work.







And it passed!
He didn't look at the rear brake pads, although they do still have a little meat on them.

I asked him if he would pass it without signals and he said it's a grey area? but he probably would not. I feel better with them on there anyway.

A call to the insurance company and another 200 bucks at the DMV and it's legal! WooHoo!

[troy]

WOOHOO! There is something magical about a street-legal dirt bike. It's like a unicorn.

[kendall_smith]

Nice work, Carl!

It's always nice to see a machine escape the neglectful hands of an unworthy owner to end up somewhere it really belongs.

[troy]

You can call it abuse, but I was taming that beast in order to allow folks like Carl to straddle such a powerful machine.

[Scott_B]

Just an FYI on the turn signal question...The official MO handbook states something very close to the following:

"If a motorcycle is equipped with turn signals, they must be in working order"

(the actual verbiage starts on page 39 of the state regulations manual (http://www.mshp.dps.missouri.gov/MSHPWe ... Manual.pdf)

I've gotten the DR-Z inspected shortly after returning from a trip to Arkansas sans tail-lights, and the inspector (also a fellow rider), confirmed the regulation...

[carlrf]

Nice work, Carl!

It's always nice to see a machine escape the neglectful hands of an unworthy owner to end up somewhere it really belongs.

Thanks. But in all honesty, after riding it again today to CVS, by the Plaza and to 55th and Troost, I really don't think I have any business on this thing off road. It's just beyond my current abilities to feel any where comfortable (read safe) on it. Hmmm.

Troy, are you sure no "buy backs"?

[KC]

Yep, Troy sure beat the hell out of that poor bike! Uh...just kidding around.
The 450 looks immaculate!! Nice job. With all that torque and knobbie tires, it can be a little intimidating on the pavement, but when you get her in the dirt where she belongs it will feel at home. That bike is a keeper in my book. If you are serious at all about unloading it,I don't think it will take very long to find a happy new owner!!