KTM spoke Failures

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Jun 1, 2000
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#1
Does anyone know about the problems with the spokes on the 2001 KTM's? There seems to be a problem with spokes with an "A" stamped on the head of the spoke. They are a new design that are chrome-plated rather than nickel-plated as in the past. The older, better spoke is supposed to have an asteric stamped on the head. I have been running KTM's since 1990 and usually brag to japanese-bike owners that I don't hardly EVER have to tighten spokes, let alone have them break. This weekend we were trail-riding in the China Hat area near Bend,Or. A young man on a 2001 400SX mentioned that he had been breaking spokes and that he had been told that the new spoke design was the problem. He broke 5 spokes that weekend on the rear wheel, two on the front. He got to looking at my 2001 520 MXC and sure enough, I had two broken spokes!
There were no dings in the rims, no run-flats, and no loose spokes . The spoke snaps off just below the head that anchors in the hub. I was amazed and dismayed, to say the least.
Any info out there?


2001 520 MXC
1998 200 MXC
 
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Jan 5, 2001
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#2
I have heard that if you overtighten the spokes more than 4-4 1/2 ft.lbs the spokes are under to much tension and will break. KTM recommends 4ft.lbs of torque on the spokes and can be checked using a spoke wrench torque adapter.
 
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Oct 9, 2000
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#3
I have an 01 520. So far I have had three broken spokes. Seems every time I look, more broken spokes.
 
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#4
Your not alone, mine and a friend suffered the except same fate. Broken off at the hub on front wheel , they were not overtighned, so it's hard to say what happened. I've never broken a spoke for years, so its a good idea for 520 riders to zap strap the spokes where they cross to minimize damage.
 
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#6
The spoke are breaking at the front hub interface. Too much power? IT is strange that none of my rear spokes have broken, this would be easier to accept!

Geoff
 
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#7
borsy

Originally posted by dstktmusa
I have heard that if you overtighten the spokes more than 4-4 1/2 ft.lbs the spokes are under to much tension and will break. KTM recommends 4ft.lbs of torque on the spokes and can be checked using a spoke wrench torque adapter.
www.spokeheadtool.com
 
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#8
I would say if torque is the issue then KTM is producing bikes with over tight spokes. How many people loosen all the spokes on a new bike then re-torque their spokes. I have since checked for overtight spokes, and have not had any more failures.