WTB water pump rotor

Use KTM part 59035055144 $3.79

Its slightly larger in diameter. I attached it to a drill and removed a few mm of material by spinning it against some 80 grit sandpaper. Crude but it worked.

I would also get a new pin 0402031780 and circlip 0471100010

I also used the KTM cam 59036010000 and the husaberg 04-08 cam sprocket, autodecompression device and autodecompression spring. You need to install the sprocket back side to the front (flip it over) and omit the bolt that limits the movement of the ADC as the KTM cam is 2mm longer near the cam sprocket buts lines up perfectly with the CFB's.

2 reasons to use the KTM cam. Its a lot easier on the valve train as it has a smoother ramp up and it fits the new style ADC perfectly. At any rate you definitely want to use the new style 04-08 ADC as it the best ADC that will fit your bike.

I do understand that this can really start to add up. I am pretty sure the dual valve spring kit will work but you will have to grind some material from the head with a Dremel tool or similar as the springs are slightly larger. There is a good thread somewhere with pictures showing a cylinder marked up ready for grinding. As far as pistons go the most commonly available is Wosner. They have A, B and C versions of all their pistons, I believe, which add a little more size to them to help offset some bore wear on aged cylinders.

The KTM water pump impeller can be used with the stock cam. It is probably the same as the 04-08 husa impellar but they do have different part numbers.

I have not installed the starter yet. There is nothing wrong with mine but I could not resist ordering the one on Amazon as a suitable cross reference, for the original, to date had not been found. You will probably get to it before I do.

Check your cam follower bearings (on the rocker arms) and see if you can tell if they are new too. They are easy to replace and are the first things to get beat up by the somewhat aggressive Husa stock cam and cause engine damage when they fail. In 03 they went to a slightly different CFB to help with that issue. Unfortunately the 03 CFB will not interchange with older models so it is good practice to keep an eye on them and replace them at maybe around 50-75 hour intervals or something like that.

I think its probably about 3/4 of a turn or so on the spring to pretension it. When you pull out / extend the decomp from its resting position it should snap back nicely when you let it go. If there is any hesitation give it another half turn or so. I have always gone through a few springs trying to get it right as they are delicate and damage easily. You may want to pick up a few spares just in case.

The decomp spring was not attached properly from the factory (the weight would just flop around) on my 97 and I could not budge the kick starter. The electric starter always worked fine though which just goes to show how powerful that starter motor is.

The decomp stopper bolt has been known to fall out as you now know. Many just run without it. If you use the 04-08 steel cam gear the decomp stopper is riveted on from the factory and only comes apart occasionally. Bushmechanic put a spot of weld on his to make sure it stays put.

Where do u live?

I think the KTM impellor design is an improvement.

first of all there's no gap between the hole in the middle and the veins. secondly the curved veins add pushing the coolant along.

so I would re-look at it.

you could always experiment with it? I have a laser temperature sensor and you could try the old and new ones back to back in 30 minutes.

regards

Taffy