Breaking spokes on 02 520 E

Has anyone had a problem with spokes breaking on 02 520's? I went on a 70 mile ride today in order to get ready for a desert race this weekend and broke two front spokes on the ride, bringing the total to 6 fronts, 1 rear. The bike has 650 miles on it and the problem started at about 300 miles. I tightend the spokes for the first time at the 150 mile mark. I owned a 99 300 E before this bike and never broke one spoke in the 2+ years it was around. I have tightend hundreds of spokes and even laced wheels as I was at one time a mechanic at a Honda dealership so this is not something that is new to me. I even tried to loosen them a bit thinking maybe had over tightened them but it did not make a difference. When I went to the local dealer to purchase some replacements I noticed that a new 02 520 M had different spokes that were not chromed and possibly had a larger diameter than the spokes in my bike. The dealer told me that maybe KTM was aware of a problem and made a change mid-year but he was not aware of any recalls or bulletins regarding the problem. Any ideas anyone? Thanks for your help !!!

Thanks for the info dstktmusa, I will check with my dealer on this and see if we can take care of the problem.

I got a copy of that tech (bull)etin from my dealer, it says to use a spoke torque wrench, what a joke. 99% of people tighten their spokes without one, I had a 01 YZ 250 with aluminum nipples and never had a problem with overtight spokes on that bike. all it does is cover up the fact that these spokes are faulty or KTM would not have changed them mid-year to a lager diameter non-cromed version. I know people have been also having problems with the KTM mini wheels. Didn't Grant Langston lose a National championship because his rear wheel came apart, that spoke torque wrench sure came in handy for him. So now I have to buy a set of aftermarket spokes for a Motorcycle that cost $7500 because on the tech (bull)etin it states not a warranty item. Lets just say I'm not a happy about this. Anybody have the number to KTM customer service handy ?

Bonehead, do you have aftermarket spokes and nipples ? Mine take a 6.8 spoke wrench.

Thanks for all your posts everyone. I was just pissed off yesterday and kinda blew a cranium gasket. I am getting ready for a 95 mile Hare&Hound and do not want to have my wheel come apart on loop 3. I re-checked the spoke tension and zip tied them where they cross (old school) so hopefuly this will help me get to the finish line. Only problem is it will be in the back of my mind the whole race. Since dstktmusa measured the spokes and they are the same size (they sure look bigger in a side to side comparison, must be an optical Illusion), I don't think I will even call KTM because I don't see any way they can help me with this problem since my dealer told me the non-cromed version of these spokes are breaking too. Must be a highspeed desert thing going on here. On monday I am going to have my dealer order some buchanan HD spokes which is what some of the local fast guys have done to remedy the problem. My dealer is going to give me a break on the price to help me out. Just stinks that a motorcycle that cost $7500 has to have this done to make it right. btw dstktmusa, thanks for that customer service number. I will keep it on file for future use if needed. Thanks again everyone and keep the rubber side down!!!