FastCletus552
Well-known member
I have a 03 KTM RFS 450. I just did a whole new top end. Piston, rings, honed cylinder, valves, and valve guides. I put it back together and did the 1/6 turn out on valve adjustment. I tried to start it and it wouldn't fire. I could smell fuel burning while I was kicking so i know its firing, but i couldn't get it to start. I decided that maybe I was off a tooth of timing so took it back apart and triple checked timing marks and all was correct. So had to be valves clearance. I tightened the head cover and did the valves. Had to take head cover off as I needed to install gasket sealer. did that and put head cover back on and decided to to double check valves. got to TDC and valves were tight. feeler gauge wouldn't fit. Also so tight that I couldn't unscrew them out all the way. I thought maybe I was not at TDC so I put a dowel in spark plug hole and checked. got TDC and checked both rockers are moving so to my knowledge thats confirmed TDC. Valves still tight. When piston is at bottom valves are loose and I can unscrew them out all the way, but back at TDC they are tight. What have I done wrong?