05 TE450 rebuild time

Its time- 300+ hrs and its never been apart. I cant seem to "search" and find any real data- does anyone make a high CR drop in piston? Can I use a 510 cyl and piston and net an increase? Or am I stuck just going OE replacement parts?

I'm not aware of any higher CR pistons, check Athena, any higher than 12.9:1 would almost surely demand high octane. I hear most would prefer a bit lower compression.

The 510 is the same bore, but longer stroke. You'd need the 510 crank and rod, plus jug and timing chain, plus more I'm sure to make it a 510, probably cheaper to buy a 510 instead.

No listing from Athena - looks like Im building a stock 450!

Thanks fro the help!

Take pictures and let us follow your progress once you get started.

The original OEM has lasted well don't worry about a replacement oem.
I am going to do the same but have 20 thou shaved off the piston to lower the comp a tad. The detuning is slight but will allow for more tractoring, lower operating temp and tollerate lower octane gas if necessary

FBF has some but they are not cheap.http://www.ferracci.com/store/cart.php?m=product_detail&p=169

I live and ride between 5,000 and 11,000 feet. The 13:1 piston will not be a problem for me- Im going to think that one over once I get it apart and check tolerances etc.

If you're just going by hours alone, you may not have to rebuild that 450 for quite some time, unless there is an obvious issue like burning oil, low compression, etc, due to some sort of an 'event'(ie. watered out with dirty water, severely overheated.......).

The 450's and 510's can easily go well over 500 hrs. with no issues.
My 250 has almost 300 hrs. on it and should see 400 or more before rebuild time.

Well I do believe its time for my beloved Italian goddess of the forest to be rebuilt. My 07 510 has accumulated 435 hrs . The last time I rode her, she was pinging when under a slight load in 5/6th gear, quarter throttle on highway at 50mph. When we pulled off the road to checked to see how much coolant I would need,I emptied most of my camelback. \
The last oilchange before my overheating issue, I have some found some fine metal shavings in the 2 steel prefilters. I have not had any shavings other than after the break-in rides.
Should I have the cases split and really get her done up right, or should I just do pistons and rings.I am so happy with the reliability of the 510 and dont need more power, I just need another 400hrsl.

I have an 05 te450 and i am gonna keep it forever. I ride it every fortnight or month and give it heaps.

I have no idea how many KMs its done (speedo is in the shed) or how many hours. How else can you gauge when the piston is due?

My bike is so reliable and so easy to start and makes heaps of power i am reluctant to touch it, on the other hand i dont want excessive wear. I dont need more power, just years of reliability.

Also whats your range on the 05 510? on my 450 its about 80kms and i am totally out.

The little metal shavings were steel, I used a magnet and pick to clean the metal filters. There was some smaller shavings on the oil drain plug as well.

I have not done a compression test or a wet/dry test. Whats a wet/dry test? Does that mean if she bogs when on stream crossings? If so, the last time I blasted a stream crossing and made too much fun, the bike did die. Now these are not easy hours on the 510.:smashpc:

I have an '04 TE 510 that I just put through the rebuild process-piston, rings, main bearings and rod. Heard a little knock when accelerating at low RPM's. We have some great support up here in the North West, so the price was right turn around time was awesome. Turned out very good to say the least. If you are happy with your bike, it's money well spent. I did find all the rivets in my clutch basket were loose, and one was actually missing! Found it stuck to the drain plug, (Whew). I'm looking into upgrading the basket to a bolt on to get rid of the rivets. If I can't find a solution, I'll just rivet it back together and check the basket once a year. If you have an '04-'05, check that basket once in a while!