As a 22 501 owner I am so glad I have found a great well priced mechanic because he would get a rebuild done in less than a qtr of the time it would take me. When considering the price of these bikes it’s a small price to pay for peace of mind. The amount of things that could go wrong and the amount of swearing and frustration just does not make this make sense to me. do a few extra hrs of my day job to cover the rebuild with no stress and we’re sweet.
Great video thanks for making it I don’t do any maintenance myself on my 701 other than oil &filters ect but found this video fascinating thanks agin I’m binge watching all your videos today enjoying them all here from the UK 👍👍🏍
THX for sharing your know how and patriotic video! Curiously, Beta 4 strokes have this same plastic oil pump drive setup. Can you verify that it is indeed plastic? I’d feel much better if it was nylon, just saying. Beta parts offers an oil pump drive “upgrade” kit containing steel gears. In the past I’ve stripped out 2 stroke oil injection plastic drive gears. This can leave you stranded in the woods/dessert etc. I consider this to be a real biscuit a manufacture leaves it’s customers. Keep up the great vids.
When doing the piston replacement did you just stick the piston slightly in the bottom of the cylinder before putting it in the engine? And do i have to adjust the valves when doing piston replacement? I have a 2020 model😅
Yes that is how I did it although I put the piston in from the top of the cylinder and then pushed it down. I did use a piston ring compressor when I did it and gave it a light tap. You have to be careful not to snag the ring. Your valves should be fine for a long time. Honestly you're piston should be fine too. How many miles are on the bike? I've heard of guys going tens of thousands of miles on the original piston no problem
Awesome vid thanks. Only thing i noticed is i think the shift locking lever (7:45) should be flipped. There is a notch in the arm that the spring sits into. I don't think it will make much of a difference though.
Great vid bro! - I've got a 13' 500 and a 16' 501 - Where are you buying your parts for your rebuild? You didn't mention what parts you had to replace - did you have to change out any of the bearings? Thanks and subscribed. Glenn
Thanks man! I appreciate you watching.. feel free to check out the other FE 501 stuff I have a ton of different content on here with it. I ended up getting away with only having to do a couple transmission bearings and the upper cam bearings, I also ended up having to do the valve seals and while I was in there I just put new exhaust valves in. The guides were fine, the piston was fine, the crank was fine..
I have a 18’ fe 450. The pcv tube is routed from the valve cover and goes into the air box. Is this safe from the issues you had? I’m assuming this is the factory routing and sad but I bought if preowned. Thanks. Great content
Thanks dude! The dualsport playlist I have has tons of info and mods applicable to your 450 as well. Check it out if you have any mods you desire or want to see what these things can really do. Subscribe if you like what you see🤙
Thank you. Quick question, after new cam bearings, how tight does the cam fit? I just changed my timing chain and noticed my cam has 1 to 2 thou movement up and down, do you know what the spec is? big thanks
I like the tool you made, I looked at my cam bearings today and see how my blind bearing puller won't work, I'm going to order the bearings(little over $20) and make a tool like in your video. I don't know actual hours, used bike, no meter, guessing 150 so changing the bearings can't hurt. My intake rocker is worn where it meets the shims(deforming the shims), I'll replace that(over $200, lol), and see those 2 items help the ticking. Previous owner said about 20 hours ago new piston and timing chain, my fingers are crossed. Huge thanks for you taking HOURS to share this video with us!! I hear a tick, I think it a bomb ticking, I'll do a tear down in January to prep the bike for 2023!
How did you get sand was it a PCV delete and it got sucked up tube ? I just deleted my 501 and it's just a bare hose no filter silicone tube routed down by spring
That's exactly what happened change it back immediately lol. I did that exact same mod and ran the 450 air boot. The crankcase vent goes down by the linkage. I went through a puddle and water and sand went up the crankcase vent and into the engine seizing the rocker arm shaft on the exhaust, among other things. Turns out having the crankcase vent up high and behind filtered air isn't such a bad thing. Thanks for watching! I will be posting another video soon about what happened and the teardown
It's a 2020. I had a bad feeling about the delete because it's a four stroke there are time the tube may be under vacuum ? Thanks this is perfect timing I'm just gonna reuse the old routings with new silicone hose.
@@smacnee3278 nice. Yes in my opinion particularly when the exhaust stroke is happening. There is no blow by because the gasses are going out the valve. The piston is going up and requires air to displace the void. Keep in mind that I had a reputable husky KTM dealership Tell me that this would be a non-issue. When I told them what happened they said they've never heard of that. Ha! I had a bad feeling about it too as I couldn't believe it was just an open vent but I followed the advice of someone else and learned my lesson. And to be honest I noticed really no power difference between the air boots and crankcase vent mods. I have 2,000 mi on mine and I've never seen any oil in the air boot.
Great video! I had the same thing happen, got stuck in a sandy mud puddle and shut the bike off to re position and it sucked a bunch of sandy mud in it. didn’t realize until i got home and all screens and filter were clogged. Still runs but smokes now so time to tear it down. Will be running my PVC back to the Airbox nipple that comes out under the filter.
hello I have a 2021 ktm 500 xcf-w, the weekend I was in the mountains and my motorcycle turned off in the mud, more than half of the motorcycle was in the water the motorcycle did not want to turn on immediately then it turned on and it is coming out smoke, today I wanted to change the oil and what I see is that water comes out, mud together with the oil. I wanted an opinion on what can be done in this case. Thanks
Unfortunately sounds like you’re in for a rebuild. I had to replace a few transmission bearings in mine, along with valve seals. If it’s oil smoke it’s probably the valve seals. There is no true way to get all the water and mud out without a rebuild.
@@DualsportDisport i cant send a picture I guess but if you look at a top end gasket kit there is 4 small round things. Not like O rings , they are maybe 1/4” tall or wide however you want to say it . I can’t figure out where they go.
As a 22 501 owner I am so glad I have found a great well priced mechanic because he would get a rebuild done in less than a qtr of the time it would take me. When considering the price of these bikes it’s a small price to pay for peace of mind. The amount of things that could go wrong and the amount of swearing and frustration just does not make this make sense to me. do a few extra hrs of my day job to cover the rebuild with no stress and we’re sweet.
How much does he charge for top end?
Great video thanks for making it I don’t do any maintenance myself on my 701 other than oil &filters ect but found this video fascinating thanks agin I’m binge watching all your videos today enjoying them all here from the UK 👍👍🏍
Really nice vid, at 1.2k subs you sound like a natural! Liked & subbed and I don't even ride a 4 stroke ;-)!
Thank you! Glad you enjoyed just getting started on this journey!
THX for sharing your know how and patriotic video! Curiously, Beta 4 strokes have this same plastic oil pump drive setup. Can you verify that it is indeed plastic? I’d feel much better if it was nylon, just saying. Beta parts offers an oil pump drive “upgrade” kit containing steel gears. In the past I’ve stripped out 2 stroke oil injection plastic drive gears. This can leave you stranded in the woods/dessert etc. I consider this to be a real biscuit a manufacture leaves it’s customers. Keep up the great vids.
Thank you. As far as I know the gear is plastic, not nylon
What’s the whole rebuild cost you ?
THANK YOU …SUPER DUPER HELPFUL
When doing the piston replacement did you just stick the piston slightly in the bottom of the cylinder before putting it in the engine? And do i have to adjust the valves when doing piston replacement? I have a 2020 model😅
Yes that is how I did it although I put the piston in from the top of the cylinder and then pushed it down. I did use a piston ring compressor when I did it and gave it a light tap. You have to be careful not to snag the ring. Your valves should be fine for a long time. Honestly you're piston should be fine too. How many miles are on the bike? I've heard of guys going tens of thousands of miles on the original piston no problem
great video thanks for putting up , make me think hang on minute i could do that . cheers
EXACTLY huh !!!! Just ordered my piston kit 👍👍👍👍👍
@@jasonking1623 where did you order your kit? Also, maybe a link to it? thanks
@@glenndavis2762 parts giant
Wow awesome...thanks for sharing
Awesome vid thanks. Only thing i noticed is i think the shift locking lever (7:45) should be flipped. There is a notch in the arm that the spring sits into. I don't think it will make much of a difference though.
If you look at a parts diagram or have a manual you will see the lever and spring situated exactly the way it is in the video. Thanks for watching.
As well as how long did the whole process take ?
Great vid bro! - I've got a 13' 500 and a 16' 501 - Where are you buying your parts for your rebuild? You didn't mention what parts you had to replace - did you have to change out any of the bearings? Thanks and subscribed. Glenn
Thanks man! I appreciate you watching.. feel free to check out the other FE 501 stuff I have a ton of different content on here with it. I ended up getting away with only having to do a couple transmission bearings and the upper cam bearings, I also ended up having to do the valve seals and while I was in there I just put new exhaust valves in. The guides were fine, the piston was fine, the crank was fine..
LOVE It!! Greta video 🤝
how did you mount new cam bearings? by tapping them in or pressing?
I believe I pressed them can’t remember
Thanks for making the video. What year was this particular engine?
2019 FE501
I have a 18’ fe 450. The pcv tube is routed from the valve cover and goes into the air box. Is this safe from the issues you had? I’m assuming this is the factory routing and sad but I bought if preowned. Thanks. Great content
Safe* not sad
Correct. Stock routing is good as long as it goes into the air boot! Filtered air in your engine is key! LoL thanks for watching! How's that's 450
Dualsport Disport thanks for the response. Absolutely love it. Feels like an extremely solid bike. Best of luck with yours. I’ll be watching your vids
Dualsport Disport just subscribed. Love watching my bike specific videos/fixes. Keep it up, love learning from knowledgeable people
Thanks dude! The dualsport playlist I have has tons of info and mods applicable to your 450 as well. Check it out if you have any mods you desire or want to see what these things can really do. Subscribe if you like what you see🤙
Is that oil pump gear plastic plastic? Why is it plastic? Can u get metal ones?
Yes it is plastic. They do make a metal replacement I don't know what manufacturer though. Thanks for watching
Thank you.
Quick question, after new cam bearings, how tight does the cam fit? I just changed my timing chain and noticed my cam has 1 to 2 thou movement up and down, do you know what the spec is?
big thanks
I’m not sure what the spec is. But I know they were cheap. How many hours do you have on it?
I like the tool you made, I looked at my cam bearings today and see how my blind bearing puller won't work, I'm going to order the bearings(little over $20) and make a tool like in your video. I don't know actual hours, used bike, no meter, guessing 150 so changing the bearings can't hurt. My intake rocker is worn where it meets the shims(deforming the shims), I'll replace that(over $200, lol), and see those 2 items help the ticking. Previous owner said about 20 hours ago new piston and timing chain, my fingers are crossed.
Huge thanks for you taking HOURS to share this video with us!!
I hear a tick, I think it a bomb ticking, I'll do a tear down in January to prep the bike for 2023!
How did you get sand was it a PCV delete and it got sucked up tube ? I just deleted my 501 and it's just a bare hose no filter silicone tube routed down by spring
That's exactly what happened change it back immediately lol. I did that exact same mod and ran the 450 air boot. The crankcase vent goes down by the linkage. I went through a puddle and water and sand went up the crankcase vent and into the engine seizing the rocker arm shaft on the exhaust, among other things. Turns out having the crankcase vent up high and behind filtered air isn't such a bad thing. Thanks for watching! I will be posting another video soon about what happened and the teardown
Check out my playlist man I have a ton of other 501 videos.. mods, racing, trails, etc. Subscribe if you like what you see. What year is yours?
It's a 2020. I had a bad feeling about the delete because it's a four stroke there are time the tube may be under vacuum ? Thanks this is perfect timing I'm just gonna reuse the old routings with new silicone hose.
@@smacnee3278 nice. Yes in my opinion particularly when the exhaust stroke is happening. There is no blow by because the gasses are going out the valve. The piston is going up and requires air to displace the void. Keep in mind that I had a reputable husky KTM dealership Tell me that this would be a non-issue. When I told them what happened they said they've never heard of that. Ha! I had a bad feeling about it too as I couldn't believe it was just an open vent but I followed the advice of someone else and learned my lesson. And to be honest I noticed really no power difference between the air boots and crankcase vent mods. I have 2,000 mi on mine and I've never seen any oil in the air boot.
Great video! I had the same thing happen, got stuck in a sandy mud puddle and shut the bike off to re position and it sucked a bunch of sandy mud in it. didn’t realize until i got home and all screens and filter were clogged. Still runs but smokes now so time to tear it down. Will be running my PVC back to the Airbox nipple that comes out under the filter.
Doesn’t the last clutch plate have to be a fibre one?
If you look on the OEM parts diagram you will see that they are steels on the outsides. Thanks for watching
hello I have a 2021 ktm 500 xcf-w, the weekend I was in the mountains and my motorcycle turned off in the mud, more than half of the motorcycle was in the water the motorcycle did not want to turn on immediately then it turned on and it is coming out smoke, today I wanted to change the oil and what I see is that water comes out, mud together with the oil. I wanted an opinion on what can be done in this case. Thanks
Unfortunately sounds like you’re in for a rebuild. I had to replace a few transmission bearings in mine, along with valve seals. If it’s oil smoke it’s probably the valve seals. There is no true way to get all the water and mud out without a rebuild.
Also, if your bike crank case vent is down low make sure you change that to where it vents up high under the gas tank or something
Thank you so much for help
@@DualsportDisport why that advicIe about the crankcase vent? What's wrong with being under the airbox?
Which torque wrench is that ? I saw one that brand but it only goes down to 10ft pounds
I'm not sure it was some cheap one on Amazon that went to inch pounds
@@DualsportDisport found it ..thanks again 👍👍👍👍👍
@@jasonking1623 what happened to your bike? Are you doing maintenance or something go wrong?
@@DualsportDisport just maintenance
Whats the 4 little round things in the gasket kit for ?
What are you referring to?
@@DualsportDisport i cant send a picture I guess but if you look at a top end gasket kit there is 4 small round things. Not like O rings , they are maybe 1/4” tall or wide however you want to say it . I can’t figure out where they go.
what is the diameter of the piston?!
95mm. Thanks for watching
thank you🌹