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.1. The return throttle cable frayed at the pulley.
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!2. Rear sprocket bolts come loose every ride, even with Loctite Blue.
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!3. Rear spokes break.
They are supposed to be secured by a washer so that the can't fall out. Check for those little washers.7. Airbox fasteners come loose and fall out
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.
Originally posted by rollingp
ok thanks I will try that.
I did put together a quick website with a few of the pics.
Originally posted by Bud-Man
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.
Wow that's a late response. lol but at least it got me looking.
w*w*w.users.bigpond.net.au/Mr2/rpm/2002ktm400exc/2002ktm400exc.htm
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