KTM 530 Top End Rebuild

Rommpy's 530 has 200+ hrs so we decided to freshen up the top end before our upcoming desert trip this summer. After getting the bike torn down we were both surprised to find everything still within specs, even the ring end gap was still in spec. The piston and bore looked/measured great as well....religious air filter maint and oil changes! Since it's already apart we are going to install a Wossner piston kit, updated camshaft, new cam and roller rocker bearings, counter shaft seal, water pump seals etc.

Normally you can do the top end in the frame...but we had a slight issue with the last head bolt when the allen socket head stripped out. Long story short we had to pull the engine and grind the head off the bolt to remove the head/cyl. But as long as the bike is completely stripped down Andy decided to do some deep cleaning and polishing on the removed parts.

Here's a couple pics of the project.

Pretty Bare!




Stripped out head bolt socket.....and it's recessed in the head




Bolt removed, parts cleaned up and ready for re-assembly




Valves after 200 hrs




And after a bath in the Harbor Freight ultrasonic cleaner




More to come....

Hodakaguy