I have had several people email me for pointers on adjusting the valves on the KTM 510 cc engine. You will not believe how easy it is. Here is a very brief explanation with a few pictures.
First go here and read this write up.
paying attention to the 1/2 open 1/2 closed method. After reading this, watch this. http://www.youtube.com/watch?v=hWS9RuEQzc8
The lock down bolt in the front of the engine they talk about when adjusting the valves using the TDC method does not work on the quad since the case is bigger and the bolt is not long enough. But if you want to do the TDC method the Polaris part number for the longer bolt is Polaris part # is PA-48677. I use the adjust the intake when the exhaust is 1/2 open and adjust the exhaust when the intake is 1/2 closing method used in the video and the detailed explanation. This method is quick and cleaner since you do not have to drain the oil. The 1/2 closing 1/2 opening method does work best with a helper!
1. First take off the front plastic, 3 torx nuts on each side and 1 torx under the headlights, then the 2 10 mm bolts on top of the gas tank and the 2 larger torx nuts on the back plastic on the gas tank. The tank is held on by the 2 10 mm bolts at the back.
2. Then put the quad in 5th gear and jack up the rear end.
3. Pull the valve covers 8mm bolt. The gaskets can be reused, but if you rip one buy a new one from here, this is also where I get the oil filters. http://www.cyclezonektm.com/eshoppro...T_FOR_KTM_.htm
4. You need a small bent feeler gauge. The specs are for a 0.12 mm / 0.005 in gap. I use this feeler gauge. http://www.motionpro.com/motorcycle/..._tool_for_ktm/
5. Now rotate the bike tires in the forward dircection a few times to get the feel of watching the intake and exhaust valves open and close. The 2 intake valves are towards the carb and the 2 exhaust valves are towards the front of the bike where the exhaust comes out.
With the engine rotating its correct direction, tires going forward, the exhaust is adjusted when the intake is closing and the intake is adjusted when the exhaust is opening!
When you get to the point of the valves either half open or half closed, depending on which valves you are adjusting, have your helper stand on the rear brake. More than likely the first time you adjust your valves they will be too tight. So loosen the 10 mm keeper nut and turn the slotted adjuster up so you can get the feel of where the guage should be and adjust the gap. The 1/6 turn method in the video and instructions actually works out very well. The torque spec on the valve jam nut is 7.2 ft/lbs
6. You are done, put it back together and ride. Remember the 525 engine is a noisy engine but most of the sound is coming from the tranny area.
Any questions just ask.
Quad plastic off and wash off any loose dirt or mud.
Looking at the top of the valve covers after taking off the gas tank. You do not have to disconnect the gas line, it is long enough to just set the tank on top of the air filter.
Now with both valve covers off. Remember the Exhaust valves are on the exhaust side and the intake are the ones close to the carb.
Checking the intake valve.
****"The torque spec on the valve jam nut is 7.2 ft/lbs"*****
When I did mine I did not even mess with the feeler gauge way, I just did the 1/6 turn thing and it works so easy you don't even need to do it any other way.
I only wish every bikes valves could be done as easy.