I hate to continually gripe about my 01 520EXC but the thing has been a total nightmare up to this point. Here's the list of problems so far:
Mile 20:
=========
On the breakin ride the starter gear pin sheared off of the case. Complete lockup of all gears. Required an engine rebuild which was done by KTMUSA. 8 week wait. Required "unavailable to the public" parts to be shipped in from Austria.
Mile 30:
========
After I got the bike back from KTMUSA, I was experiencing overheating problems. Solved that myself by double checking all radiator hoses and changing fluid to Silkeline Pro Cool with a dash of Water Wetter.
Mile 70
========
I experienced problems with the bike coughing and then dying. Triple checked fuel level and determined I had about 1 1/2 gallons in the tank. I tried the usual YZ400 tricks of kicking the bike over with the decompression lever slightly open to clear out excessive fuel from the jug. No luck on starting the bike until the bike cooled down for about 15 minutes. Finally got it started by pushing it down a hill. Something felt wrong with the engine as it felt weak and unresponsive. At this point I took it to my local dealer where the verdict was that there was nothing wrong with the bike. Dealer did not open the engine but did put 10 miles on the bike. Grrr....
Mile 95
========
Started to get weep from waterpump. Wasn't sure of source and decided to keep a close eye on problem.
Mile 135
========
Weep got worse. Checked the waterpump area and found the impeller to have several surface scratches and a nearly broken off paddle. Looked like foreign object damage to me, but source is not known and could be from the thermoplastic impeller breaking down from earlier overheating problems.
Just got off the phone with my current local dealer which I'm pretty happy with since they've been customer focused, experienced, and responsive, but now the head doesn't want to torque down to spec. One of the head bolts keep striping out. Aack! I bought this bike in April on Friday the 13th! Is any one else here superstitious. (Once broke my collarbone on row 13 of an enduro)
Its been about 5 months of this stuff and I do like the bike and see many engineering aspects of the RFS that impress me, BUT I want ride the damn thing and not just work on it.
For the time being I'll just keep riding my mountain bike where the only thing wrong with the engine is that its fat and old.
Later,
Concho