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 Chipped piston severe oil leak 
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TRAIL BOSS
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Joined: Sun 05 May, 2013 3:12 pm
Posts: 341
Post Re: Chipped piston severe oil leak
I googled the symptoms ktm 300 noisy power vavles
and theres few articles that seem to be saying its common ?
And the symptoms seem to go away after a rebuild - wierd eh!
bike looks good!

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Wed 17 Dec, 2014 7:10 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
Yeah I did find some similar stuff and a few clips regarding that but nothing that really sounds similar everything in the clips is much louder anyway I'll clean the pv linkage and check the actuator rod and nut see if it quiets down abit.
The head will be coming off over the weekend hopefully I don't find anything to sinister and the rebuild in a couple of weeks.
Thanks all for your help


Wed 17 Dec, 2014 11:25 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
So got the head off the bore looks good.
Piston isent as bad as it looked in pics but still knackered plenty of blow by and a few chips scars etc,

There was no up/down play with the rod just a little side to side which I still have to measure.
The power valve has a fair bit of side to side movement maybe 1mm each side.(see vid)

What I need to ask is what is the chance of bending a rod from taping out the wrist pin with a socket and mullet it was stuck fairly good and needed a few taps to get it out I forgot to hold the rod as I had the socket and extension in one hand and mullet in the other they weren't hard hits probably as hard as you'd tap a nail into a stud on the wall.


https://www.youtube.com/results?search_ ... lve+rattle


Fri 19 Dec, 2014 11:27 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
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Fri 19 Dec, 2014 11:35 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
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Fri 19 Dec, 2014 11:37 pm
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TRAIL BOSS
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Post Re: Chipped piston severe oil leak
little to no chance of bending it - id say if it was just a tap!
but the big end wouldnt have liked the angle nip fulcrum effect of the crank putting angle load on the mains crank bearing if the crank was at TDC or top of the stroke fully extended when you tapped out the little end un suported if it was at the bottom close to the crank with least amount of the conrod exposed you should be sweet!
usually load is only up and down not side to side so really check the main bearing again.
pretty unlikely to damage the lower crank / bearing but its more likley than bending the crank.
shoulda wedged a block of wood in between the lower crankcase and the piston when stroke is at the lowest point nearly touching the crank taking up the side to side when tapping out the little end pin next time!

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Sat 20 Dec, 2014 7:07 pm
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TRAIL PORN STAR
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Joined: Wed 15 Jul, 2009 12:27 pm
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Post Re: Chipped piston severe oil leak
When i did my piston/rings i just pushed it out with my finger.


Sat 20 Dec, 2014 7:58 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
Sweet puts my mind at ease a little will definatly remember the wedge trick next time.
Any thoughts on the movement with the power valve? Normal or not?
http://youtu.be/9yH8iD4Jj0c


Sat 20 Dec, 2014 10:07 pm
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TRAIL BOSS
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Joined: Sun 05 May, 2013 3:12 pm
Posts: 341
Post Re: Chipped piston severe oil leak
measure on to the new piston for clearance. #1
on the movemnt in the power vaslve it wont be the hardened pin thats worn as side to side is ok - its the slop wear thats an issue!
itll be either in the powervalve tongue or pivot point in either
or a combination of both the alloy componants where the wear will occur letting the power valve move closer to the piston. icon_scratch
Cant see any powervalve wear marks on the old piston. icon_thumright
and its supposed to have some loose movement!
a ning ting ting - luv those 2 strokes!

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Sun 21 Dec, 2014 9:15 am
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
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Post Re: Chipped piston severe oil leak
Yeah sweet thanks mate,
Now just to get the bloody thing out to clean the carbon crap from the tongue. Anyway just to wait on the parts now decided to go with a vforce 4 reed and for the price a high comp s3 head should add a bit off kick.
Plenty of wire brushing and polishing till then.


Sun 21 Dec, 2014 4:23 pm
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TRAIL BOSS
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Post Re: Chipped piston severe oil leak
vforce = good choice!
remember ur new reeds changes the jetting - richer at low & leaner at hi revs
get the full jet kit - it might new a few goes to get it right!

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Sun 21 Dec, 2014 9:25 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
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Post Re: Chipped piston severe oil leak
Ok so thought I'd update,
I know it's been a while but a wasn't in a real hurry and parts are super hard and fairly expensive to get for this year as the 95 model has a piston that only fits the 95 and the egs and mx models are different anyway found one through wossner and a gasket kit with athena,

I dident end up getting the vforce as yet just flipped the reed petals over and there sealing good, everything was good through the rebuild didn't find any real nasty surprises besides a rock in the expansion chamber :o and the slow jet been completely blocked I have no idea how the rock got in there icon_scratch anyway checked clearances for piston cylinder and rings the rings came in at 0.013 the wall clearance was 0.007.

I checked deck clearance after install as I forgot to when assembling and the piston rises above the cylinder by 0.007 will this be a problem? Haven't started her yet because I'm waiting for the ultra copper RTV to set around the exhaust I also used this stuff on all gaskets during assembly very easy to work with has great resistance to everything I highly recommend it. I plan to start her up tomorrow going to be very nervous lol but I am sure I haven't forgot anything and it really is a straight forward job

I did find that with the safety pin on the powervalve linkage (the one that holds the rod to the ball) wasn't seated in the grove real well when pulling it apart and Couldent get it to seat on one side properly on install spent over an hour trying it does take a fair bit of force to pull of though so should be ok, what would be the worst damage it could do if the linkage was to come off mid ride?


Sun 25 Jan, 2015 4:11 pm
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TRAIL PORN STAR
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Joined: Wed 15 Jul, 2009 12:27 pm
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Post Re: Chipped piston severe oil leak
Have you taken the spark plug out and turned it over by hand first,by the sounds of it you have.


Sun 25 Jan, 2015 4:53 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
Yeah have done that everything's smooth,


Sun 25 Jan, 2015 5:00 pm
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TRAIL YOBBO

Joined: Tue 09 Dec, 2014 12:24 pm
Posts: 21
Post Re: Chipped piston severe oil leak
Hey just wanted to get some advise from you guys on this rattle it's always been there and gets quieter with the clutch pulled in, but after the top end rebuild it seems twice as loud,
Only thing I changed in the bottom end was the conversion from gear oil to atf maybe the thicker gear oil was masking the sound a little ? I know the clutches in these bikes come factory with a noisy clutch feature but this just sounds too loud in my opinion.
The bike has only had maybe 30-45mins run time (After video) since rebuild with some low-mid revving while tuning the carb checking plugs etc, it has gotten a little quieter but still very concerning.

VID LINK
http://youtu.be/rjIIRtHQe2E


Tue 27 Jan, 2015 9:17 pm
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