KTM 520 Cam Bearing Failure

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mcracer

Member
Jul 14, 2001
47
0
Please help. I have a KTM 520 MXC that came to me with a leaking water pump. Upon dissassemble to replace the seals I found all the ball bearings missing out of one of the cam bearings. I have read somewhere about others having this same problem, and that KTM has changed the bearings in the 2002 models. My local KTM dealer claims there is no problem and they have heard nothing about this. They actually insulted me by saying they know more about this because THEY are the KTM dealer and I am not. Any info,expieriences, etc that I can pass along may strengthen my case. Thank You ahead of time to anyone who may respond!
 
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OLD STROKER

Member
Feb 19, 2001
89
0
mcracer

1st off, you should post the name off the dealer so everyone can stay away from him. Yes there has been a few problems with cam bearings reported in other forums and KTM is aware of it. For 2002 they went to a sealed bearing. Go to your local bearing supply house an ask for a 6201 sealed bearing. Theyr'e $9.50 each.
When replacing the water pump seals you should read my recommendations on Holeshot, in the 4 Stroke Forum, under Water pump seal NO FIX on 2002, dated 11/19/01 You can find this site @....www.ktm-racetech.com
Good luck!
 
A

Anssi

Member
May 20, 2001
868
0
Your dealer (or their representative that you talked to) is a dork (I would've said something else on RMD). Try to get in touch with KTM USA.

What year was the bike in question? I had the rocker arm on my -02 520 SX come loose and it was all covered under KTM warranty and even this was admitted to be something that occurs on some of the bikes (the cam bearing problem is very well known).
 
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mcracer

Member
Jul 14, 2001
47
0
More Info. The bike in question is a 2001 EXC and is approximately 10 months old. Very disturbing is the fact that I have only found 2 of the balls (one in the head and one underneath the flywheel). If the original "cage" for the balls was metal, it and the others may be scattered throughout the engine. I would hate to have them lodge in the transmission gears! So.... I guess the motor will have to come apart to find the little darlings.:eek:
 
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JAMRACING

Member
Apr 21, 2000
55
0
I would try this first: Take the clutch basket off, and run parts washer through the motor. Sloshing it around should dislodge them from whereever they're hiding. Also, try getting a small magnet in there.:eek:
 

jeb

Member
Jul 21, 1999
633
0
Not every dealer has had a bike that has lost a cam bearing so his dealer just may not be aware of the problem. According to some good KTM USA sources, KTM hasn't had many problems with the cam bearings reported to them. We all know that a lot of us have had the problem, me included, but I guess not a lot of them are getting reported back to KTM.

Have any '00 RFS owner lost the cam bearings? It seems like this is mostly or entirely an '01 issue.

I'd flush the engine with kerosene and then just run it in short bursts changing oil in between for the first few miles. Use cheap oil for this. It took a while for my last two ball bearings to show up. I thought I had them all at first but two dropped out the bottom screen hole after several hundred miles.
 
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BCR-Bob

Sponsoring Member
Mar 8, 2001
104
0
Originally posted by jeb
Have any '00 RFS owner lost the cam bearings? It seems like this is mostly or entirely an '01 issue. [/B]
Click to expand...

I own a 2000 520 exc and have just gone through the engine after about 6000 miles on it. The cam bearings were in very good shape and showed no unusual wear. The weep hole occasionly seeped a little coolant for the whole life of the engine. I did of course change the bearings and seals anyway.
 

Shaw520

Damn Yankees
LIFETIME SPONSOR
May 14, 2000
1,082
6
Ditto,...except I havnt taken my down yet, and dont plan on it either, there is no reason for me to believe there is anything wrong with my cam bearings.
 
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Scoott

Member
Jun 1, 2000
37
0
I recently replaced the cam bearings on a friend's 2000 400 sx. The bearing opposite the chain had come apart and all the balls were gone except one lying in the top of the head.After pulling the motor and shaking upside down, fishing with magnets, etc. , we finally pulled the head and cylinder off, shook it upside down, and all the other balls came out of the crankcase. After inspecting the balls for damage and finding no pinch marks which might have indicated internal damage,, we re-assembled with new american sealed bearings and it runs fine.
I once owned the first 640 ridden by Greg Zitterkopf, and after seeing the damage caused by one 6mm bolt that came loose inside I would not run a motor with pieces loose inside.A retainer bolt came out of a bearing retainer, got into the oil pump gear and broke it.A short time later the rod, piston, and crank failed for lack of oil.
 
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PTCruiser

Member
Aug 25, 2000
73
0
You guys sound lucky! I just got onhere to see if anyone else had this problem 'cause my buddy's '01 400 EXC just completely grenaded becuase the cam bearing came apart and destroyed the entire motor! Somehow balls went thru the intake or exhaust, thrashed the piston and rod, locked up the motor and sheared teeth in the tranny too! Something even wore a hole thru one side of the center cases!

Anybody esle have catastrophic failure like this? He's going thru his shop right now to see if they'll do anything, but they're not sounding too hopeful :ugg:
 

Shaw520

Damn Yankees
LIFETIME SPONSOR
May 14, 2000
1,082
6
If KTM gets enough of these reports, hopefully they will begin to cover the damamges and possibly post a recall, but the latest word is that KTM has very few reports. So,....people who have had cam bearing probs......start YELLING!
 
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mcracer

Member
Jul 14, 2001
47
0
SUCCESS!! After talking to the owner they reviewed the situation, talked to KTM, and they are going to cover the repairs. Score one for the good guys!:cool:
 

James Dean

Member
May 17, 2000
137
0
KTM Support

My impression of this situation is that KTM wants to stand behind their customers with any of these serious problems, but dealers are often too quick to dismiss customers as ignorant and neglectful when it comes to maintenance. Be sure to keep records and show them what you have been doing to take care of your bike. Then DEMAND that they call KTM for their assessment.

Glad to hear of the outcome on this mcracer.
 

Strick

LIFETIME SPONSOR
Nov 8, 1999
1,782
2
Re: KTM Support


James Dean is 100% correct. I have gotten this out of the horse's mouth. Go to the dealer, have them call KTM service direct. Dealers have a number to get right in. Have them tell KTM your problem. They (KTM) will review the problem and get back to the dealer right away with their answer. This whole process never takes more than a day. Keep in mind KTM is the only dirtbike manufactured (that I am aware of) that offers a 30 day warranty on a race bike.

Good Luck

AND definitely post back how this process goes.

Secondly - any advice Old Stroker has to give - TAKE. I don't know of anyone who knows more about the rfs' bearing and water pump seal issues than him, except for maybe (and only maybe) KTM themselves.
 
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Geoff

Member
Oct 9, 2000
11
0
Great News. KTM did the right thing.

On my 520, the dealer was very good. They called KTM and requested thay pay for the repairs. KTM said no way, the bike is too old (6 months).

I think that they have heard the complaints loud and clear and have realized that many loyal customer have felt burned.
 
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dstktmusa

Member
Jan 5, 2001
179
0
geoff,

are you giving us ALL your information? i.e. are you the original owner? i have read on other boards that KTM has never denied a claim regarding cam bearing failures. are you sure that your dealer called KTM USA? i have read that KTM has sent out a tech bulletin regarding the maintenance interval of RFS' and cam bearings as well as the entire motor should be checked for wear at each 45hour interval. the same schedule is listed in my '02 owners manual.
 
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