New Top End on a KTM 300
  • PaulB14PaulB14
    Posts: 8,012
    AFter 5 years and over 300 hours I think I'll put a new top end kit into my 300 :o
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    Dan (yellow riding fellow)'s thread has some excellent links to top end prices. The $110.00 price range will stick in my head as I vist the dealer today to get their price and availability information.
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • MJP68MJP68
    Posts: 5,591
    PaulB14Dan (yellow riding fellow)'s thread has some excellent links to top end prices. The $110.00 price range will stick in my head as I vist the dealer today to get their price and availability information.
    Hopefully the price will be close, but Id be suprised if it wasnt quite a bit more for your bike.
    looking forward to a build thread!
    image
    Autismspeaks.org
    Mesa AZ
    06yz144,04yz125,95kx125. 07 TTR50
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  • MJP68MJP68
    Posts: 5,591
    PaulB14AFter 5 years and over 300 hours I think I'll put a new top end kit into my 300 :o
    This is the only one I could find on ebay
    KTM 300 piston kit

    doesnt include gaskets or small end bearing though.


    .
    image
    Autismspeaks.org
    Mesa AZ
    06yz144,04yz125,95kx125. 07 TTR50
    Kiwi = cabbage
    Koby = Sausage master
    Chud, I miss Tallboy and Shitbiscut
    ML,OCD posterchild..
    Spiderdud??
    Maple Leaf STFU!!
    I'm not certified
  • PaulB14PaulB14
    Posts: 8,012
    Thanks at $153.00 that was the lowest price for the wiseco piston kit I found all day. I ordered it. I can add on the bearings and gasket kits for about $32.00 The dealer wants $255.00 for the complete wiseco kit, including gaskets and bearings. For the KTM oem kit the cost is $268.00. At RockyMtnATV/MC the complete pro-x kit, gaskets and bearings totals $158.00, but I'm not sure about the pro-x piston. The wiseco kit at RockyMtnATV/MC is $243.00, which includes the gaskets and bearings.
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • MJP68MJP68
    Posts: 5,591
    Glad I could help..did I mention the finders fee?? :)
    image
    Autismspeaks.org
    Mesa AZ
    06yz144,04yz125,95kx125. 07 TTR50
    Kiwi = cabbage
    Koby = Sausage master
    Chud, I miss Tallboy and Shitbiscut
    ML,OCD posterchild..
    Spiderdud??
    Maple Leaf STFU!!
    I'm not certified
  • Smasher.BradSmasher.Brad
    Posts: 3,396
    Ahh Paul, your 300 could keep going! Thats like my uncles YZ125, he went like 4-5 years without a top end job, and finally it went, had 0 compression..he put a new one in :P

    I too, am looking to a build thread, as we all know you are great with pictures and writing! B)
    >Brad
    * * * * * * * * * * * * * * * * * * * *
    img src="http://i25.photobucket.com/albums/c61/myy_sigss/Dirtbiking/DSC00188.jpg">
    Shift Happens
    4 Stroke FTW!

    Ontario, Canada.
    2 2008 Honda CRF 230's!
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    "Life In Balance is Life On 2 Wheels."
  • PaulB14PaulB14
    Posts: 8,012
    Smasher.BradAhh Paul, your 300 could keep going! Thats like my uncles YZ125, he went like 4-5 years without a top end job, and finally it went, had 0 compression..he put a new one in :P

    I too, am looking to a build thread, as we all know you are great with pictures and writing! B)
    True Brad, I could let it go another year or two or three...LOL. :D But if I snapped a ring or broke a piston from fatigue it might mess up the cylinder, or worse, then I'd be looking at a more expensive fix right in the middle of the riding season (odds are) :p So I choose to bite bullet now and take care of it.
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • ridin4liferidin4life
    Posts: 1,245
    yeah good thinking paul. I really neeed to do that to. I have a 04 on the stock piston and cylinder, and thats sketchy on a 4 stroke. Does anyone know the baseline price for a 4 stroke rebuild. If thhere is no damage to the cylinder?
    Adam
    2002 XR 100R
    2003 RM 100
    2004 yz250f
  • bikerdude11bikerdude11
    Posts: 1,351
    Sheesh Paul, you've definitely gotten your money's worth out of that piston!

    Adam, a Wiseco top end kit is $170 on RM ATV/MC plus the gasket kits which are anywhere from $22-$44. A Pro-X kit is $155.

    http://www.rockymountainatvmc.com/HeaderVeh.do?headerPrevMake=8&headerPrevModel=722&headerPrevVehicleType=2&whichPage=home&vehicleId=&headerVehicleTypeId=2&headerMake=8&headerModel=722&headerYear=2004
    ______________________________
    Adam
    Beautiful B.C.
    2007 CRF150RB
    2009 YZ250F
    image
  • NZriderNZrider
    Posts: 5,086
    pro x is good stuff. they actually make alot of pistons for factory assembled bikes. i know for a fact gas gas use prox pistons and cranks from new.
    *********************
    Winning is 90% rider and only 5% bike, the rest is luck
  • gospel truth
    Posts: 1,480
    i just did the top end on my wr450 stainless valves and springs with a big bore for less than a shop wouldve done using oem parts,im pretty sure ive got the pro-x valve set-up,seem fine to me
    i dont get resentments i give um
  • ridin4liferidin4life
    Posts: 1,245
    thanks adam, trying to decide wethere or not to do it myself, sorry for the thread jack paul.
    Adam
    2002 XR 100R
    2003 RM 100
    2004 yz250f
  • Mark47mxMark47mx
    Posts: 1,889
    NZriderpro x is good stuff. they actually make alot of pistons for factory assembled bikes. i know for a fact gas gas use prox pistons and cranks from new.
    ProX is actually a company based in the Netherlands which, as far as I know,doesn't really make anything themselves but purchase pistons, clutches...from the oem providers and then resale them at a price significantly less than oem. If you like oem you will like pro-x.

    Here is the scoop acording to pro-x
    PMI Europe b.v.'s headquarters are located in the Netherlands. In Nieuw-Vennep (area Amsterdam Airport Schiphol) you can find the ProX office and warehouse, where we stock the complete ProX product line, which consists of over 3,000 part numbers. Prox Racing Parts are mainly manufactured in Japan by reputable Original Equipment Manufacturers.
    The latest, state-of-the-art CNC equipment, machines ProX Racing Parts to our exact specifications and high quality standards. ProX Racing Parts can be considered the leading brand in the engine part replacement market for motorcycles (dirt & road), moped/scooter, ATV, PWC and snowmobiles.

    Founded in 1975, PMI Europe b.v. nowadays distributes ProX Racing Parts to practically every continent world-wide. Over 100 official ProX distributors are taking good care of consumer needs in more than 55 countries.
    .
    .
    Colorado

    2006 RM-250
  • PaulB14PaulB14
    Posts: 8,012
    good info Mark, as usual. I have to call the seller of the top end kit to make the payment, but couldn't get through or even leave them a message today (voice mail was full), even though I took 3 hours off work to do it :( Arrggg! I may cancel this order and buy from Rocky Mtn ATV/MC instead...and go with the PRO-X kit :?
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • lfoster29
    Posts: 70
    Ten below this weekend. Snow everywhere. You picked a good time to be working on your bike. I am trying to decide what brand piston to put into my 300 this winter as well, let me know what you think of the PRO-X if you order it.
  • Mark47mxMark47mx
    Posts: 1,889
    Paul, I think I would throw in the ebay towel I have had little actual luck with it.
    It often ends up costing more and unless they have pay pal I don't even mess with them.

    Rocky Mountain can get you a pro-x for less just order the gasket and top end bearing as well it will be less than your ebay supplier.
    You might look in dirt mart in the back of DR KTM Hutt might have some good deals.

    enjoy your winter project I always look forward to the rebuild season not as much as riding but...
    .
    .
    Colorado

    2006 RM-250
  • PaulB14PaulB14
    Posts: 8,012
    lfoster29Ten below this weekend. Snow everywhere. You picked a good time to be working on your bike. I am trying to decide what brand piston to put into my 300 this winter as well, let me know what you think of the PRO-X if you order it.
    where do you live and ride foster? 10 below with snow everywhere sounds awfully close to where I live... :p
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    Mark47mxPaul, I think I would throw in the ebay towel I have had little actual luck with it.
    It often ends up costing more and unless they have pay pal I don't even mess with them.

    Rocky Mountain can get you a pro-x for less just order the gasket and top end bearing as well it will be less than your ebay supplier.
    You might look in dirt mart in the back of DR KTM Hutt might have some good deals.

    enjoy your winter project I always look forward to the rebuild season not as much as riding but...
    consider it thrown in LOL. I just ordered the PRO-X piston kit, gaskets and bearing from Rocky Mountain B) Total cost is $158.13, shipping is free if the order is over $100.00. By the way, I ordered two gasket sets and two bearings, just in case my other order for the wiseco piston kit comes in 8)
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • lfoster29
    Posts: 70
    I live in the Kalispell area. I am re-learning how to ride again after years off and have been riding trail 7 all summer, but alas only ten more months of winter till I can ride again!
  • PaulB14PaulB14
    Posts: 8,012
    Dude, I'm in Fortine, about 50 miles from you. Check out my ride reports from our rides this summer! We need to get together for some riding next spring and summer. In the meantime, haul your bike up to my shop so we can install a new top end in it (I just bought two this week). Where is trail 7?
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • lfoster29
    Posts: 70
    Neat, small world. My inlaws live near Trego, and I was wondering if there were any single track trails up there. Trail 7 is the Alpine trail, along the top of Columbia Mountain and down the swan. It is a great ride and one could explore up there all summer. I'm trying to get better as I am learning this mountain stuff (grew up riding the desert). I have found single track to be more fun in first gear than the desert ever was in fifth! I even ended up switching to a trials tire by the end of the summer. A little help with the top end would be nice! PM me with your email and we can discuss further.
  • PaulB14PaulB14
    Posts: 8,012
    I grew up riding the desert as well, and had to adjust for the single track trails here in Montana. I haven't tried the Columbia Mountain trail yet though I've heard a lot of good comments about it. ...taking this to pm now...
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    anyway, I received the top end kit from rocky mountain, still waiting for a phone call from the other outfit through e-bay...so, my plan to get this thing done over Thanksgiving weekend is still on track...except...it's 16 below right now, probably cost me $200.00 to heat the shop up enough to work out there...
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image

    16 below (brrrr!)
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • pojp58pojp58
    Posts: 10,599
    Just bring the bike in the house Paul where its already heated. Just wait till the wife is out for a while.lol
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    image image
  • PaulB14PaulB14
    Posts: 8,012
    great idea pop! I shoulda thought of that! (duh)
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    It's been about 30 years since I replaced a top end (on my Suzuki RM400) :p

    I took a few minutes to read DL's top end thread here it is to get familiar with the process again, what a valuable read! I made a checklist from that thread, along with a shopping list:

    expansion chamber o-rings
    torque wrench
    oven cleaner (for head, cylinder)
    carb cleaner (for power valve)
    new gasket for power valve (not sure it came with my gasket kit)
    new gasket for reed body
    shop manual
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    Here is a picture of the gasket set, is everything in there?

    image
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • NZriderNZrider
    Posts: 5,086
    oh it has o'rings in the head! thats interesting.

    i see 2 different p/v cover gaskets there, base gasket, head orings and exhaust orings plus a bunch of other orings i dont recognise immediately
    *********************
    Winning is 90% rider and only 5% bike, the rest is luck
  • PaulB14PaulB14
    Posts: 8,012
    left my nest today for a trip to town in search of a torque wrench and shop manual :o

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    image

    image
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image

    image
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    got my christmas shopping done while I was at it B) Found the KTM shop manual at the dealer for $28.00, the torque wrench at NAPA for $19.00. I talked to the mechanic at the KTM shop and he said to make sure I make a note (or take a picture) of the timing settings. The power valve arm has a spring-tensioned clip holding it in, that you have to remove by going into the side case before pulling the cylinder. Sounds simple enough :p
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • ridin4liferidin4life
    Posts: 1,245
    nice paul cant wait to see how it comes out for you.
    Adam
    2002 XR 100R
    2003 RM 100
    2004 yz250f
  • masterlinkmasterlink
    Posts: 9,989
    timing settings?? u mean what time of day u start or when u push the bike though the living room in2 the kitchen just b4 Mrs Paul goes 2 bed?? :p
    image
    herby ur useless. MAPLE 2010
    Suzukidude, shut up. CS 2010
    Yeah der, errone be using no seize CRWOODS 2013

    So forward thinking everything else seems SDRAWKCAB.
  • sanderssanders
    Posts: 9,990
    It looks like u have the reed block gasket anyways have fun take lots of pic!
    Davids
    "im gona' find my freedom brother you should to if you don't find it now you'll be one year older when you do.......

    ___________________
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    People like theonetheycallsuzuki are the reason the general public hates dirt bikes & want to close our trails
  • Kiwi450xKiwi450x
    Posts: 3,635
    Thanks for putting up the celcius temp Paul. For me, fahrenheit is like trying to understand saskratchewanese... :D

    As an aside, if it was -21C here, wild horses couldn't drag me out of the house... That's inconceivable for me. :p
    ########################################

    If you can't fix it with vicegrips and/or a sledge hammer, it ain't worth fixing...
    image
  • PaulB14PaulB14
    Posts: 8,012
    It warmed up to 10 above today (not sure what the celcius temp is). When I got the bike out to ride it to the house there was more traction than (insert Maples Mom joke here) so I decided to make a ride out of it. Besides, the engine needed to be warmed up before I could drain the oil, right?
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    image
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    As I mentioned before it's been about 30 years since I've done a top end, and never one with a power valve, so if you guys want to chip in with your advice feel free to do so. I'm sure I will use it.
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    The very first task was to lay down a drop cloth on the garage floor :D

    image



    That's for Mrs.Paul
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    Step number 2: set up and turn on the heater :D

    image


    Am I getting too detailed for you? :?
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    ...and lay out the tools from my trail kit. Except for the torque wrench and a hammer (!) everything I will need is right here :)

    image
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    Since I will be changing my oil and replacing both engine side cases, I need to remove my skid plate

    image



    :D
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    draining the engine oil on a KTM 300

    image
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • PaulB14PaulB14
    Posts: 8,012
    The drain bolt is magnetized so it picks up small metal shavings. This is normal :p

    image
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    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
  • Smasher.BradSmasher.Brad
    Posts: 3,396
    Looking forward to the rest, Paul! You do a great job at pics and descriptions! :D
    >Brad
    * * * * * * * * * * * * * * * * * * * *
    img src="http://i25.photobucket.com/albums/c61/myy_sigss/Dirtbiking/DSC00188.jpg">
    Shift Happens
    4 Stroke FTW!

    Ontario, Canada.
    2 2008 Honda CRF 230's!
    1 2005 Honda CRF230!

    "Life In Balance is Life On 2 Wheels."
  • PaulB14PaulB14
    Posts: 8,012
    Thanks Brad, it's taking me longer to upload and resize these pictures than it takes to do the work :(
    ///////////////////
    NW Montana - Where the pavement ends and the fun begins
    image

    2005 KTM 300exc
    1977 SUZUKI PE250
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