Engine problems 08/09!

[pjg351]

A lot of the Ktm boy's over here are not happy with there 450/530's, it seems it's a world wide problem not just isolated, so beware if your thinking of going orange! here's a post from a rider here in AUS. Iv'e since found out some 09's are the same


08 450 & 530 Oil Transfer Problems KTM DESIGN FAULT!!!

Unfortunately KTM have a major design problem with the 08' 450 & 530. I hope they've got it right for the 09' bike.

The oil transfer from gear box into engine is a major design error. I have an '08 450 & 530 EXC. The problem is not isolated to just one thing. The first problem is the oil seal on the primary drive out of the engine is failing. KTM are trying to blame some poor bastard on the production line for faulty fitting, which can contribute to the problem. The second part of this problem is the primary drive shaft is a two part component. The join of this shaft is right where the seal is place. Any movement (thrust) will also amplify this problem, this is why the factory race teams weld the two parts together and machine it.

The second part to the problem is with this two part system the primary drive gear hanging off the end of this shaft has a design fault. This gear is a twin drive arrangement which works its way apart and starts grinding into the outer clutch case. For those who are wondering why am I getting a fine silver trace when you change your engine oil, this is the answer.

This problem is real and everyone should take it on board. I'm not saying all the motors are faulty as it has not happened to my 530 (Yet!). My 450 is being fixed under warranty even though it ran out 6 months ago and for this I take my hat off to KTM. Unfortunately my concern is for the riders safety and this mechanical problem could cause a major malfunction with a gear box seizure or engine locking up due to too much oil in it.

My 450 has had that many problems with it that I've ridden it twice in six weeks and it is still in the shop. The shop was told by KTM how to fix this problem and the fix lasted less than 55km. When I was riding I could hear the engine churning/chugging and when I stopped at camp I gathered my mates around and said watch this. I removed the plug above the engine sight glass and about 400ml shot out of the motor like a fountain to everyone's disbelief. This is the second time it has happened to me and I'm pissed off that I didn't film it & placed it on You Tube.

This bike is now back in the shop waiting for new cases, the new improved oil seal, new primary gear drive and external clutch cover (again!). I would like to know what damage the gear box is taking with the low oil levels and will find out when the new cases arrive. Problem with KTM is that their spares take so long to get hold of (probably the demand is extremely high) and their decision making some times takes longer. This is not an isolated case as my mate had the same deal with his 450 which resulted in a new cases fix.

KTM should save face and recall the '08 450 & 530 motors as it is a serious safety problem. I race enduros and rode the Finke Desert Race at over 180km/h on the same 450 with all these problems, I have lost faith with it & will sell it as soon as it is fixed. Jeez I wish I kept my '07, it was faster but didn't handle as good as the 08.

I'll let you know how the gear box has held up once the shop pulls it down, I don't think it will be all roses.

Oh, by the way the factory blokes & the shop confirm that 700ml oil in the engine, not 600ml as per the book. It's crazy coz you fill straight past the sight glass and it seems like your going to have the oil overflow out of the engine.

[racerfty]

At least KTM is attempting to fix the problem, That is why i ride Blue, never left me out in the cold yet.