Mystery Motor 03 FE650

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Thanks bush mechanic for the link. And Taffy, I think I'm going to dig a little deeper in the engine. I want that piece of mind this season knowing the engine was apart I checked and made sure it was all good, or replaced anything I could. :)

There did seem to be a fair bit of metal shavings in the oil pre filter and on the magnet.

need to find what's wearing.
 
Hey Bush, to check these i will need to crack the cases i assume. Being where im at already i suppose thats the route ill need to go.

If the gear sets were looking rough, are these near impossible to replace? Or fairly easy to buy replacements?

I just bought the kibbles. That was a good deal, 188$ CAD shipped with import charges. I called the local KTM dealer down the street, they wants 275 for the same. SO off to a good start.

As for the impellor bearing, what should i look for? roughness and play?

thanks
Tim
 
Heads off and all apart. I suppose I keep my valve spring retainer clips for the new valve springs coming.

Taffy you mentioned intake valve 'tuliping'? I took a picture. Not sure if it shows or not.

Anything to look for as far as valve condition?
 

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gears in the gearbox are current parts except for the close ratio 6th that is sometimes found

the WP bearing just check it rotates nicely when installed in the case

I used ktm valve seals in my 02. guides were not STD though

kibblewhite will make you valves very reasonably priced if you need new ones.
 
What do you mean by not STD?

I'm not sure if I need to replace the valves they seem like they are in great shape. And the seats also look perfect.
 
that is correct Lord Taffwad it is a new hybrid Ebola + gonorrhea mutation brought about by cross breeding with tight arsed Welsh DNA and Aspbergers crocus monkeys

thus named after its inventor and is known as Spotted Taffy Dick
 
Lol I sense a little tension.

I did a little work on the ports this weekend. Smoothed out the casting marks. Which were really bad.
In which direction do the rocker arms press out from? Inside the chain case area outwards?
 

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Hey Taffy, is there a trick to pushing them? Seems awfully tight.
 
yes they are *******s for sure. you know those old fasioned 'L' shaped allen keys? well they are the perfect length to use the back wall and lever them through. if you do that AND ALSO you start it moving by putting a screwdriver through the top hole you can get the first 3mm of movement and then they ususally give up.......

Taffy
 
Well Taffy. I ended up getting the rocker shafts out. They are clean, shiny and free of defects. The brass bushings seem to be in good shape as well. With zero play. So thats sweet!

I ended up taking the clutch basket off, and all the parts. To my surprise i found damage. one of the clutch basket studs mounts must have previously broken, and be welded. Seems sturdy though. My question is, how do i hold the basket from rotating while i remove the large nut. Special clutch basket holding device?

Also is the one way bearing gear suppose to be really loose feeling? it doesnt seem to have a nice seat inside the case. I cant see back there yet. but doesnt feel right.

Thanks!
Tim
 
Few pics.
 

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Are the clutch assemblies from an 04 fe450 and 03 fe650 the same by chance?
 
before i got a proper clutch tool i used an old clutch pack with 2 holes drilled through all the plates and steels, pins in the holes then use an aluminum wedge between the gears to lock the clutch basket to the crank

if you have an air or electric impact driver wrap a rag around the inner hub hang onto it and pull the trigger
 
the clutch assemblies are the same. as long as the 2003 IS a 2003!

they modified the clutch hub twice more after yours though so investing in one may not be a daft idea. the early ones suffer from a shrill sound but nobody is absolutely 100% sure why.

if you have an air gun, just put all the plates back in and press down with one finger while undoing the nut.

I not have a clutch DRUM holding tool for tightening. I've gone posh!

regards

Taffy
 

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