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Nitpicking '02 520SX

MXFastGuy

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Joined
Aug 11, 2001
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#1
I've got 20 hours on my new '02 520SX and am very happy with it, even after coming off Hondas. A few things have surfaced that are are a little annoying; some help from you experienced KTM owners would be appreciated:

1. The return throttle cable frayed at the pulley.

2. Rear sprocket bolts come loose every ride, even with Loctite Blue.

3. Rear spokes break.

4. Sides of seat cover turned milky color (moisture under cover?)

5. Front and rear brakes squeal (fronts discussed elsewhere in this forum, but I had to mention it).

6. Rear brake master cylinder seal failed. Hopefully a fluke, dealer covered under warranty, but is this going to be a recurring problem?

7. Airbox fasteners come loose and fall out (band-aid fix is to cover the holes with duct tape).

Any suggestions? The bike is well worth these little things, but nevertheless, I'd like to fix them if possible.
 
Joined
Mar 19, 2001
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#2
Give your local dealer a call. The last I heard they were going to warranty all those seat covers.

As for the rest I'm not sure what to tell ya. Just got rid of a '01 400 SX with over 60 hours on it and I only had two problems all year.

1. Lost one exhaust spring.

2. Lost one rear spoke.

Coach
 
Joined
Dec 9, 2000
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#3
Servus MXFastGuy,

1. The return throttle cable frayed at the pulley.
A known problem the Yamaha YZ400 also had. Sometimes the cables (especially the pull-back cable) are not correctly aligned with the bracket on the carb and therefor rub on the metall. Take a close look a both cables and adjust (bend) the bracket if necessary.

2. Rear sprocket bolts come loose every ride, even with Loctite Blue.
I've heard this from the two strokes, but 'every ride' seems very strange. Replace the sprocket bolts AND nuts with new stock KTM parts!

3. Rear spokes break.
Only if you tighten them too much. I used to check and tighten the spokes after every other ride till I had them break also. Since then I just check for obviously loose ones and leave them alone otherwise. Problem gone!

7. Airbox fasteners come loose and fall out
They are supposed to be secured by a washer so that the can't fall out. Check for those little washers.


Michael
 
Joined
Dec 5, 2000
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#4
MXFastGuy,
You may want to check your chain tension. It could be contributing to some of your problems. Most new KTM owners tend to over tighten the chain. A good way to check is to take the shock off the bike and move the rear wheel through it's travel. This may sound time consuming but it's not. Just remove the two bolts holding the shock on and slip the shock out. Once you get the proper tension, find a place to measure the chain slack so you can quickly adjust the chain as it wears. I can't say this will solve all the problems as I still broke spokes after I correctly set the chain tension, but it's a start.
 
Joined
Jun 1, 2000
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#5
On the noisy front brake, the very best cure is an oversize EBC rotor and everything else stock. Out stops even Hondas! And no noise.
On the spokes, I've heard many theories/excuses but the only way to stop breakage is to replace the spokes. I've gone to Buchanan at each end.
On the rear sprocket bolts, I would also guess too tight a chain. I have almost 100 hours on my 01 520 mxc, 2 sprockets and 1 chain and no broken or loose bolts.
I recently rode a friend's new cr450f, the 520 still superior for an old guy like myself.
 
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Joined
Oct 3, 2000
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#6
WOW! Have not heard of any KTM owner with so many problems. My 01 400 EXC has had 1 problem, the seat cover. I'm on my third seat now, waiting for the fourth. My dealer found out CEET has a problem with their covers, and has replaced it every time. Since I got a 4 1/2 YEAR WARRANTY :cool: with my bike, any problems I have will be covered by my dealer. As for the squeaky brakes, mine did that for a few hundred miles, then just went away.
You may want to try pads with a different compound, the stock ones are for wet / muddy conditions I'm told.
 
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Joined
Oct 31, 2001
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#7
Originally posted by MXFastGuy
I've got 20 hours on my new '02 520SX and am very happy with it, even after coming off Hondas. A few things have surfaced that are are a little annoying; some help from you experienced KTM owners would be appreciated:

1. The return throttle cable frayed at the pulley.

2. Rear sprocket bolts come loose every ride, even with Loctite Blue.

Try putting very small zip ties on the inside of you airbox cover on the fasteners before the little keepers. Trim them clean and you will never lose another zues fastener. I have done this on 5 KTMs since 98 works great.
Your chain should be three fingers of play just behind the top guide when on the stand. Yes it looks too loose but it will be ok .You can verify this by removing the shock and raising the wheel through its travel. You dont have to remove the tire or anything else to take off the shock just move the flap out of the way.
When you put your tank on be sure not to bind the throttle cables.
It pulls the cable to the side and rubs just as it enters the carb .
The seat is junk and you should get an aftermarket cover or a gripper.
Your spokes can fail if you are not watching them and checking for proper tension. The bike is a torque monster and good aftermarket ones are better but really not needed. Wheel bearings will fail if you are one of those guys that over tightens the nut. Sand the brake pads every once in a while and this will end the squeal. Never had aproblem with any of the master cylindrs must be fluke.They have used the same design for the last few years .
You may have to tighten the fork seal springs. Look up my thread
KTM tricks.

3. Rear spokes break.

4. Sides of seat cover turned milky color (moisture under cover?)

5. Front and rear brakes squeal (fronts discussed elsewhere in this forum, but I had to mention it).

6. Rear brake master cylinder seal failed. Hopefully a fluke, dealer covered under warranty, but is this going to be a recurring problem?

7. Airbox fasteners come loose and fall out (band-aid fix is to cover the holes with duct tape).

Any suggestions? The bike is well worth these little things, but nevertheless, I'd like to fix them if possible.
 
Joined
Oct 31, 2001
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#9
Well I have tried three times to show the pics I have of the choke and the throttle on the members gallery.
No luck and I suspect the moderators must not want me to show them.
They are within the limits of the size of the file it must be a communist situation.
Sorry guys its another government bs deal.

Good thing these people arent in public government where they could do some damage. What a bunch of f-in bs. Cant even help a guy out.:mad:
 
Last edited:
Joined
Aug 11, 2001
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#10
can you post the pics or a web address where i can access them.
maybe even post to a alt.binaries.???? news group
and notify here where it is if it cant be done here.
 
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Patman

Pantless Wonder
Joined
Dec 26, 1999
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#11
rollingp I found your home page CLICK

Your member gallery is HERE and I see no pictures of what your trying to show.:eek: Keep in mind that there is also a maximum dimension on the pictures you can post in addition to the file size.

The black helicopters should be arriving soon, be sure to look at the light when they hold up the little flashy thing.:)
 
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Oct 31, 2001
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#12
Yea that was not to be taken seriously just kidding.
When I try to post them it says " your images uploaded successfully"
I will have to get a site established thats all .
 
Joined
Oct 31, 2001
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#15
Originally posted by rollingp
ok thanks I will try that.
I did put together a quick website with a few of the pics.
Well I quess I used too much space at geocities so I have to rework the page .
I will e-mail anyone interested in the picks.
 
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