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 Rebuild Time KLX 450R 
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Post Rebuild Time KLX 450R
The time has come for a freshen up for the KLX at 130hrs. I 've had a new piston sitting in the shed for awhile now and the time has come to put it in while i have a spare bike to ride. I adjusted the inlet valves at 90hrs but exhaust were still good, meant to check them before stripping down just for interest but got to carried away.. Ripped the head off and stripped down to find the intakes badly worn, not sure on the seats yet, will bearing blue when new valves arrive. When buying the KLX i thought they run s/steel inlets with steel ex with the exhaust being 1mm smaller then the KX (30mm instead of 31mm) but this did not turn out to be the case. They infact run Ti inlets & s/steel ex, as it's the inlets that always wear this did not make sense to me!! Apart from that the Ti inlets are different to the KX Ti inlets meaning i couldn't use aftermarket s/steel KX inlets!! Therefore i'm stuck with running genuine Ti inlet valves as there is no aftermarket ones available. Saying this Kibble White have just made some for a guy off thumper talk but he had to send whole head in and wait around a month so they should be available soon.

Piston, rings and barrel and chain guides are all in perfect condition, if i hadn't already bought a new one i wouldn't have replaced the piston, sticking a high comp one in anyway and a new cam just for insurance while i'm there. Engines done around 80hrs on semi-synthetic as the slipper didn't like full synthetic and the last 50hrs on delvo 400 changed every 10 hrs.

Will post some pics later.


Thu 05 Nov, 2009 2:26 pm
Beerburrum Freak
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Joined: Thu 09 Jul, 2009 5:17 pm
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Post Re: Rebuild Time KLX 450R
Good run down there Craig will be watching this thread with interest hello2

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Thu 05 Nov, 2009 4:45 pm
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Post Re: Rebuild Time KLX 450R
A few pics piston wear.


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Sun 08 Nov, 2009 7:48 pm
Post Re: Rebuild Time KLX 450R
A few more, valve wear


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Sun 08 Nov, 2009 7:51 pm
Pro Dude
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Joined: Sat 11 Jul, 2009 4:20 pm
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Location: Chapel Hill The Good Side
Post Re: Rebuild Time KLX 450R
At least if ya loose any nuts n bolts you wont have to go far to get sum new ones icon_biggrin

good luck with the rebuild Craig hello2

I think the TM is a fast enuff weapon for you atm . cussing that bike hauled over the soft stuff yesterday..

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Sun 08 Nov, 2009 8:20 pm
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Post Re: Rebuild Time KLX 450R
Finally getting around to finishing my thread on the KLX rebuild, had to get mine back together in a hurry so didn't get anymore pics. Doing Wildhorses klx now so will finish this thread off using his.
First up head just came back from being ported.

You can see in this photo how the inlet valve seats have been blended into the port. Std it's just a metal insert pressed into the head and not finished.

Also material around from around the exhaust guide has been removed. In a pro race bike the valve guides would be shortened so as not to protude into port at all, but this also effects reliabilty as minimal support for valve.


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Last edited by LMB on Sat 13 Feb, 2010 9:34 pm, edited 1 time in total.

Sat 13 Feb, 2010 7:00 pm
Post Re: Rebuild Time KLX 450R
In this one you can see where they have cleaned up the casting marks and cleaned up the divider. There was a clear mark where the two halfs of the head were joined.


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Sat 13 Feb, 2010 9:24 pm
5' 4" Haggis Tossing Dwarf

Joined: Tue 14 Jul, 2009 1:46 pm
Posts: 3050
Post Re: Rebuild Time KLX 450R
should flow a fair bit better now craig ! 8-)


Sat 13 Feb, 2010 10:46 pm
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Post Re: Rebuild Time KLX 450R
KX heads are all hand finished from factory to remove casting dags, should be done for all bike i reckon. Anyway, new Ti inlets installed and seats cut, cleaned up exhaust and lapped in, you cannot lap in Ti valves!!!!


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Sun 14 Feb, 2010 10:35 am
Post Re: Rebuild Time KLX 450R
Valves shimmed and buckets installed, bit of assm lube.


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Sun 14 Feb, 2010 10:43 am
Post Whore
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Joined: Sun 12 Jul, 2009 6:18 pm
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Location: Samford Brisbane
Post Re: Rebuild Time KLX 450R
do you worry about the smooth walls in the inlet and exhust?

I know when building the race motors they went away from really smooth walls as the air would not flow well over a smooth surface but dimples works better?

Think about a golfball. a smooth ball will go 3/4 the distance of a dimpled ball this is due to the layering effect (IE a layer of air stics to the bore, and allows the rst of the air to slip off that air) But in a smooth bore or wall there is nothing for the air to sick to so there is no static layer against the wall of the inlet outlet... mind you they were polishing the walls to a mirror finish.

and its not like its a race bike.

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Sun 14 Feb, 2010 11:01 am
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Post Whore
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Joined: Sun 12 Jul, 2009 6:18 pm
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Post Re: Rebuild Time KLX 450R
bloody good thread mate thanks for posting!

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Currently on the Bench @#$^@# But Normally an 09 WRF 450.
BMW F650 Dakar


Sun 14 Feb, 2010 11:03 am
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Post Re: Rebuild Time KLX 450R
Can polish up the exhaust as much as you like only need to worry the intake, fuel condensing into droplets on mirrored finishes seemed to be more of an issue then the air speed from what i understand, pimple finish would be ideal just don't know how to achieve, suface is rougher then you may think just no square edges.


Sun 14 Feb, 2010 5:25 pm
Post Re: Rebuild Time KLX 450R
Shinny new Wiseco high comp piston.


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Sun 14 Feb, 2010 5:37 pm

Joined: Sat 07 Aug, 2010 4:03 pm
Posts: 4
Post Re: Rebuild Time KLX 450R
Mate,not being rude but that's a rough porting job.
Hope you didn't pay strong money for it?


Wed 11 Aug, 2010 9:54 pm
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