Dirtbike/4-wheeler guys, come in!!!

**SonofaBish** · 03-31-2007, 02:03 PM

Alright, i need a little help. I'm trying to tear down my KTM to put a new top end in it, and i've ran into a stumbling point. I got everything torn off and the head off, to find a huge chunk of something on top of the piston. However, that's not my problem. The problem is i can't get the engine out of the frame. There is one bolt (or something) that runs through the frame, through the swingarm, through the engine, through the other side of the swingarm, then back through the other side of the frame.
Here is what it looks like on one side:

and on the other side:

on this side, the end is threaded (u can't see that), so i'm guessing there is supposed to be a huge nut on it too.

How am i going to get that rod/bolt/whatever it is out of there, so i can take the engine out??!???!?!?!?

**Inkdcountryboy** · 03-31-2007, 03:03 PM

you got issues, did you try taking that nut off? im sure it'll come out..just gotta work at it

**SonofaBish** · 03-31-2007, 03:06 PM

no didnt even try, b/c do you see how thin-walled of a socket i would need to get that nut off there?

**Domination** · 03-31-2007, 04:18 PM

eh? take the nut off?

**Inkdcountryboy** · 03-31-2007, 05:00 PM

yea that nut has to come off, or youll never get anywhere...shuolda paid someone to do it lol

**2000 Ultra Z** · 03-31-2007, 06:17 PM

use a 15/16 or 1 inch 6point socket it will fit in there i just did that on a warrior a had it was so rusted in there had to beat the heck out of it just put the nut back on not tight and beat it

**INSANELY CRAZY** · 03-31-2007, 06:38 PM

when i pulled mine out there i had to wd40 it then hit it with a hammer,then once it was flush with the hole i used a bolt that was the same size and hit that to push it out the other side.. hope this helps

**SonofaBish** · 03-31-2007, 08:12 PM

the size of the nut is about 7/8 (the metric equivalent), but a 7/8 socket won't fit in the hole...
however, i figured out how to get it... the side that is threaded is supposed to have a nut on it... all i did was take a punch and hammer the rod out... its just a greased rod that is supposed to have a nut on each side... i'll be sure to have a nut on the other side when i get the bike back together

**SonofaBish** · 03-31-2007, 08:12 PM

Originally Posted by Inkdcountryboy

yea that nut has to come off, or youll never get anywhere...shuolda paid someone to do it lol

nahhh... too much fun tearing stuff apart yourself...

**SonofaBish** · 03-31-2007, 08:24 PM

this is the huge chunk of metal i found on top of the piston...

the funny part is... everythign is actually in quite good shape... when i bought the bike, the guy said that it had a very new top end, and he wasnt lying.... i have the engine out, cylinder off, and the piston is in great shape(except the marks that chunk of metail left when i was trying to kickstart the bike), cylinder is in great shape, connection rod, crank, everything is in spectacular shape....

my uncle and I have looked at everythign adn can't find wtf that peice of metal belongs to. only thing we can figure is that it maybe is a piece of the exhaust port... which would mean i need a new cylinder... don't even wanna know what that will cost

**SonofaBish** · 03-31-2007, 08:26 PM

u can see the marks on teh top of the piston from that piece...

pics are blurry b/c i took them before i had the engine out of the bike, so i was trying to push the camera in b/w the frame and engine and couldnt really tell what i was taking a pic of...

**SonofaBish** · 03-31-2007, 08:56 PM

ok, i just figured out what it is....

its the exhaust "valve"... since 2 strokes dont have valves really, i dont know what else to call it, but yea, its the exhaust control flap... was looking at a parts michrofiche, and looked through a bunch and then it clikced.. the one i looked at 20 pages ago was it... so.. looks like it'll be a $75 part along with a new piston of course... so that'll probably be a good 170 or so.. but o well... worth it

**INSANELY CRAZY** · 03-31-2007, 09:12 PM

wow thats a big chunk... good thing it didnt come out while you where riding it.

**chevydad** · 04-01-2007, 12:16 AM

it's called a power valve. what it does is open and close at certain rpms altering the power.

**weareweird69** · 04-01-2007, 12:34 AM

Its about time you get to work on that thing. I got my 250R out the other day lol

Glad you found out what was wrong!

**wick** · 04-01-2007, 11:25 AM

Originally Posted by weareweird69

Its about time you get to work on that thing. I got my 250R out the other day lol

Glad you found out what was wrong!

250 R quad or bike? Any riding out there?

Bish, hurry up and get this thing back together. Lets go riding!!!

**SonofaBish** · 04-01-2007, 11:31 AM

Originally Posted by wick

250 R quad or bike? Any riding out there?

Bish, hurry up and get this thing back together. Lets go riding!!!

Don't worry, I'm doin my best man... my uncle is gonna take everything down to the guy that does the spec-ing for him to have a new piston&rings ordered up, along wtih that valve, and then i'll have it back together asap.

**wick** · 04-01-2007, 11:33 AM

Originally Posted by SonofaBish

Don't worry, I'm doin my best man... my uncle is gonna take everything down to the guy that does the spec-ing for him to have a new piston&rings ordered up, along wtih that valve, and then i'll have it back together asap.

Sweet!! how old is it?

**SonofaBish** · 04-01-2007, 12:02 PM

Originally Posted by wick

Sweet!! how old is it?

its a '92 KTM 300EXC.... not particularly much to look at... i bought it for $250, in about 4 million pieces... guy told me it had a new top end in it, but didnt feel like finishing putting it back together. He thought it was a '94, so bought a '94 subframe for it. I had to do some "convincing" to get that to work with the plastics and all... did a 'custom' shaker-can paint job... lol... biek actually looks pretty decent, but its obvious its not a real late model bike. Engine runs like a mother tho... like i said in a thread somewhere else, i honestly feel it runs better than my nieghbors KX250 that he races under a dealer sponsorship... but i dont think KTM changed teh 300 2-stroke motor in any way(other than the cooling system) until like '99 or something.

**SonofaBish** · 04-01-2007, 12:03 PM

actually, ever since i bought it, i havent had it out in the dry... every time i've gotten to ride it, its either been raining or a muddy mess, so i'm excited to get it out in the dry for once....

only thing i wish is that the front brakes were stronger.... i think it could use a new caliper, but i dont care to spend the money on one since the one it has works... but the bike would never stand up on the front wheel...