First rebuild been on 1 ride have ??'s

[Andrews250]

For starters i own a 2004 ktm 250 2-stroke exc and have just rebuilt the entire top-end. First run or two went well. I notice a huge increase in power and the compression is alot more too just by the feel of the kickstart. as a bcak note i run amsoil and mix 60:1 br8es spark plug used. I noticed that it cuts out a bit on the high end of each gear and after 1 ride these are my main issues that concern me.
The bushing that goes on the motor case that has a hole in it for the front drive sprocket is leaking pretty marginal.(I have replaced this once when i got it and it didin't leak till now again) the clutch cover gasket is now leaking as well.These two things are minor and can be easily fixed wich ive already purchased one gasket . But does the increase in compression cause these to prematurely wear out for some reason or maybe another issue caused this or just dumb luck on my end.

My other Issue that REALLY concerns me is that the bike is starting to smoke after one ride i repacked the silencer as well when i changed out piston and rings and also the spark plug... what might cause this. could it just need to be jetted ? not sure what to do and i am getting scared something might go wrong just looking for some advice from anyone that can help

Thanks Guys
Andrew

[Andrews250]

Originally Posted by Andrews250

For starters i own a 2004 ktm 250 2-stroke exc and have just rebuilt the entire top-end. First run or two went well. I notice a huge increase in power and the compression is alot more too just by the feel of the kickstart. as a bcak note i run amsoil and mix 60:1 br8es spark plug used. I noticed that it cuts out a bit on the high end of each gear and after 1 ride these are my main issues that concern me.
The bushing that goes on the motor case that has a hole in it for the front drive sprocket is leaking pretty marginal.(I have replaced this once when i got it and it didin't leak till now again) the clutch cover gasket is now leaking as well.These two things are minor and can be easily fixed wich ive already purchased one gasket . But does the increase in compression cause these to prematurely wear out for some reason or maybe another issue caused this or just dumb luck on my end.

My other Issue that REALLY concerns me is that the bike is starting to smoke after one ride i repacked the silencer as well when i changed out piston and rings and also the spark plug... what might cause this. could it just need to be jetted ? not sure what to do and i am getting scared something might go wrong just looking for some advice from anyone that can help

Thanks Guys
Andrew

Latest update is that I looked on the repair cd that i got from the dealer and it says if you have white smoke coming out of the exhaust that it could be a head gasket or o-ring leak. looks like im tearing it down again.... ughhh
when mounting the head on the lower end i was given like 5 different thickness of gaskets i just put one on that looked similar to what i took off does the thickness of those gaskets matter really? should i have put silicon sealant on that as well cause there wasnt any on there before, amd the o-rings that came for the kit for the top cover of the head seemed to be small for their spots so i used the old ones there can you stretch these to fit and if the thickness doesn't match to the old ones do these expand with heat or over time cause these that came with the gasket kit arent the same (thats y i used tie old o-rings) Seems to be my luck

[bajadog]

I always used yamabond when I assembled the jug to the lower end.

http://www.yamaha-motor.com/outdoor/...60/detail.aspx

Although I've never used this, a lot of guys on KTMtalk and Thumpertalk say
this yamabond product works great a the head mating surface.

http://www.yamaha-motor.com/outdoor/...71/detail.aspx

Good luck, and keep us posted.

[Andrews250]

Originally Posted by bajadog

I always used yamabond when I assembled the jug to the lower end.

http://www.yamaha-motor.com/outdoor/...60/detail.aspx

Although I've never used this, a lot of guys on KTMtalk and Thumpertalk say
this yamabond product works great a the head mating surface.

http://www.yamaha-motor.com/outdoor/...71/detail.aspx

Good luck, and keep us posted.

sounds good Ill head to the local Yamaha dealer and ask for some ... Sounds funny buying a yamaha product for my KTM but w/e we know who gets the job done on the track and woods anyway right thanks man ill keep everyone posted. Ordered a few more things today the seal ring for the front sprocket and what not so well see when that comes in Bikebandit seems to be killing me on Lead times might take 2 weeks or maybe even 3

[bajadog]

Originally Posted by Andrews250

Bikebandit seems to be killing me on Lead times might take 2 weeks or maybe even 3

I always get faster shipping with Chip Munn.

http://www.munnracing.com/

[taps]

Originally Posted by bajadog

I always get faster shipping with Chip Munn.

http://www.munnracing.com/

Same here. I ordered an assortment of parts from Chip today, and everything was in stock. I should see it tomorrow.

[Andrews250]

OK,
So ordered my parts from munnracing.com you guys were right on the money ordered on a wednesday and recieved them friday.
Replaced all the stated above and bike still seems to smoke alot more than i would think. and im seeing a leak still from somewhere around the shifter maybe the seal ring there its very small only like 1-2 drops overnight not much more but i am kinda weird when it comes to my bike I know it needs to be jetted or at lease tuned as well it cuts out at full throttle opened wide up so im taking it to a friend that knows about this could this cause it to smoke too though? let me kow what you guys think.

[Andrews250]

So bike is running well but not like it should i have eliminated all problems down to the point where it is a jetting issue i need to have the carbs adjusted/ maybe jetted to make it run better it bogs down at full throttle and seems to hesitate. Gonna see if i set it back to stock settings and tweak from there to see if i can work it out.