An engine rebuild is in the pipeline for 2025.
BHPian Dhruv Shetty recently shared this with other enthusiasts.
As I reduced my usage on the bike, cleaned off the switchgear contact points, changed the long due starter motor cable and during the switchgear cleaning, it came to my notice that the throttle cable is going to fail at any given point, the point which connects to the throttle body was down to two to three threads of cable. I was bored at home the day I was doing the switchgear. Before deciding to open and clean the switchgear, I was inclined to change both the switchgear but then decided to open and check, clean and decide whether to change or not.
A lot of patience, cleaner (deodorant) and q tips were consumed, but the results were satisfactory and no damages were done.
Gave the stalk which holds the indicator switch a fresh coat of black paint.
Left the bike like this for five days under the cover, as I had to go to Udupi for a family function and the job interview and deal with it once I returned.
After coming back from Karnataka, the very next went to KTM SVC, picked up a throttle cable, starter motor cable and normal brake pads
Valve clearance job
As I’ll be moving to Udupi for a job in February, I preponed the valve clearance job before I move. The reason to do this was to check the condition of the camshaft, and the timing of the engine and discuss the engine rebuild. During the process, it was observed that one of the intake valve shims was out of spec, so the camshaft assembly was removed, and inspected for any damage, replaced the damaged shim.
Got the Timing chain checked, and replaced the o-rings of the spark plug area. The timing chain is in good condition up till now, once the bike is in for its rebuild the entire engine will be taken apart and inspected properly.
For the time being changed the brake pads to organic ones till I recover some funds for sintered pads, changed the brake fluid from the racing DOT 4 to a budget DOT 4, as the racing one has a life of 8 months max, got the fluid checked by a fancy brake fluid moisture tester, it showed 100% moisture. The reason I went with DOT 4 and not 5.1 is during the engine rebuild I will be getting the callipers fully rebuilt also, so do not want to waste good DOT 5.1 fluid.
Bike cooling off and staring at the 790.
On a side note, somebody bought this neglected 790 and is doing a complete overhaul of it, the throttle of this bike is not working and even KTM does not have a solution to it. As of now, the small amounts of parts ordered have already touched 1.3 lakhs and there is still more to come.
Up till now after the valve clearance job, it is for sure that the block piston is gone for sure. The parts which will be getting replaced are the block piston assembly, Crankshaft and timing chain.
Till then, ride it gingerly and keep topping up the oil every 300 to 500 kms.
Current ODO reading 35211
The next big update will be the engine rebuild and brake calipers, in early 2025.
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