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Message: [QUOTE="jeb, post: 142246, member: 16219"] The problem does seem very sporadic. I don't think anyone really knows why. Here's what I did to fix it. I declined KTM's offer to help. The problem is that my local dealer could no way handle the job and the other dealer is over 2 hours away and not real thrilled about working on a bike I didn't buy there, even though I've purchased 3 bikes from them in the last 3 years. Truth be told, I really prefer to do the work myself, anyway. I already had all the waterpump seal parts so all I needed was the bearings and a flywheel puller all of which I aquired Friday. I've already done the WP seal once so the steps, for the most part, were familiar. Drain and remove radiators and hoses. Lock the crank at TDC with the bolt. Unhook the head oil line. Remove the valve covers. Remove the left side rubber tank mount. Remove the waterpump cover and impeller. Remove the decompressor cable. Remove the rocker box cover. Now I can see the damage. The right (brake) side bearing is gone. The races are all that's left. Lot's of shrapnel in the top so I start in with the magnet before I go any further and get what I can. Remove the camchain tensioner bolt. Remove the flywheel cover (what a mess! oil all over the place.) and flywheel so I can unbolt and lower the plastic chain tensioner. Lift the cam chain off the cam and take the camshaft out. Close inspection shows no collateral damage to anything that I can tell. And I'm picky. The KTM bearings (2) I got are the updated parts. They're sealed and look just like wheel bearings. I'm sure the local bearing house ones would've been fine. Kind of odd to put sealed bearings on a cam that has an oiler right over the top of it. Pull the old bearings off, or what's left of the one. Press new one's one along with all new WP seal parts and reinstall cam, chain (watch those timing marks on the sprocket) and plastic tensioner. Clean all the gasket surfaces and apply a coat of gasket maker to rocker box cover and install. Set radial play on rocker arms before tigtening. Set valve gaps (they were off) and reinstall valve covers. Put impeller, pin and clip on and installed cover. Installed tensioner, flywheel, FW cover, etc. Drain oil and pull screens and filters. Flush engine with kerosene and let it dry. Fill with oil and fired it up. All right! Talk about a quiet running motor! I don't think it's ever been this quiet. Part of that may be that I left the CF skid plate off for now since I plan to change the oil several times in the next few miles to get all the junk out before it does any harm. This is when I'm happy that KTM put in 2 filters, 2 screens and a magnetic drain plug. Test ride was awesome. I have my bike back and all whole and I couldn't be happier. $30 worth of parts was the total bill. Flywheel puller was $45 but that doesn't count to me. I'll use it again so it's just another tool cost. Thanks to all that helped. I could not have done it without all the information. You guys are great! [/QUOTE]

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