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cobra46

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About cobra46

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    California

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  1. cobra46

    replacement motor

    I get where you're coming from that some, including those in my world of engineering, say motors are electric and engines burn fuel but this is not 100% accurate according to the Oxford dictionary. They define motor as: NOUN 1A machine, especially one powered by electricity or internal combustion, that supplies motive power for a vehicle or for another device with moving parts. So that said, his KX450f has a motor.
  2. cobra46

    2003 KTM 450 EXC won't start

    A loud crack could be any number of things but the valve train is high on the list. I would start by taking off the head/valve cover.
  3. cobra46

    Full KTM exhaust

    PM sent
  4. cobra46

    KTM 525 Clutch Issues

    I wasn't aware of this change. From a end product material standpoint there isn't any difference between the two processes. The biggest differences are that die cast parts can hold better tolerances which would be required with thinner walls. Die cast parts can be made with more complex shapes. Die cast is cheaper if the production runs are high enough.
  5. cobra46

    Full KTM exhaust

    They are dirty but I think they will clean pretty good the two into one section is cracked.
  6. cobra46

    KTM 525 Clutch Issues

    I can only guess as to what grade of aluminum the cases are made from. If I had to guess I would say A380. The properties are: A380 Tensile strength 324MPa 6061 Tensile strength 310MPa 7075 Tensile strength 570Mpa There's a lot more to this but I'll keep it simple. In general, yes cast aluminum is weaker than wrought aluminum. That's a interesting though about someone busting it out with a press. I can't imagine why someone would've been in there at just 88 hours. Maybe it isn't really 88 hours. @Hai Karate Is there any evidence of a sealant bead near the oil filter housings where the case half's meet? This would be squeeze out from the factory which would be one indicator that no one has been in there before. Although, someone could've used sealant there during reassembly but if someone is careless enough to bust the case, I doubt they would use sealant. I would be pissed at the previous owner. If there's no big chunk of the broken bits in the case indicating it happened after you bought it, they had to have known about this issue.
  7. cobra46

    Registering away from home in the military

    I never paid California state taxes when I was in the Army.
  8. cobra46

    Full KTM exhaust

    The one I have is the two pipe version from the early models. I'll snap a pic when I get home.
  9. cobra46

    Registering away from home in the military

    I was stationed at Ft. Eustis Virginia....twice but it was back in the 80's. I had a California licence and drove a Virginia registered, inspected and insured car. Like I said this was a long time ago so things may have changed. Jeff's advice to ask folks on base would be great option. You may even go down to the police station and ask them.
  10. cobra46

    Full KTM exhaust

    What year? I have part of of one.
  11. cobra46

    KTM 525 Clutch Issues

    I was thinking about your issue. Changing the case is only fixing the damage. You really need to investigate why the case failed in the first place. Something caused the main shaft to shift axially with enough force to break the case. Maybe something to do with the shift drum or shift forks. Although I would expect the shift forks to bend or break before the case.
  12. cobra46

    KTM 525 Clutch Issues

    I use the $40 Tusk Chain Riviting Tool from Rocky Mountain ATV. It's for sure not as good as the KTM tool but it can give you an acceptable swage on the pin. For chain removal it works great. This is the same tool as the Motion Pro with different labeling. I've used my tool on cam chains and main drive chains.
  13. cobra46

    KTM 525 Clutch Issues

    You're going to need a few special tools some of which can be sourced cheaply at Harbor Freight or Rocky Mountain. 1. Cam chain splitter/riveter. 2. Flywheel puller. 3. Lower cam gear puller. 4. Primary gear puller. If you plan to change main bearings you will need some means to remove the races from the crank. You will also need a dial indicator to set crank end play. If you change other bearings you may need and ID bearing puller which can be rented for free from auto parts stores. Overall the job isn't that hard.
  14. cobra46

    KTM 525 Clutch Issues

    This is one engine I really want my hands on as this is a very interesting problem. Were you able to isolate what exactly moves out when you press the clutch? No surprise it rubbed the cover. There's not much clearance between the clutch and the cover. In fact, some Recluse Clutch installs require a thicker cover gasket. to avoid an interference. Th kick started idler post is held into the case with a socket head cap screw from the outside so no need to split the case to repair it. This idler is only for the kick starter.
  15. cobra46

    KTM 525 Clutch Issues

    I agree with SM. That amount of play on the main shaft looks reasonable. Can you take a video of multiple clutch squeezes with everything all torqued down properly with the gears aligned? Setting the camera on something steady could aid in showing what exactly is moving out of place.
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