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Thread: Bad noise

  1. 12-16-2011 01:54 AM #41
    ktmbill
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    You can send your Cylinder in to them they can fix it
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  2. 12-19-2011 03:02 PM #42
    harry_ss [OP]
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    they didnt have in stock....i bought a new cylinder from a forum member... now a looong wait.
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  3. 01-10-2012 07:21 PM #43
    harry_ss [OP]
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    Yesterday i recieved a brand new cylinder...I took some better pictures of the damage on the cylinder and piston.
    I havent split the cases yet because im waiting for a ktm extractor. The big rod end is destroyed.
    123.jpg124.jpg125.jpg126.jpg128.jpg
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  4. 01-10-2012 07:41 PM #44
    997GT3
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    Wow,the engine took a beating from the metal shavings.The big end bearing went out on mine last month.Just got my engine done and installed it back in last night.Fired right up! Good luck with your build!
    2009 KTM 505SX Pump Gas Guzzling Beast

    Web stage2 cams,12.5/1 comp,OEM piston,43.5mm taper bored billet insert carb with FastRanchero mods,DASA ported polished head,Carillo rod,ProX rod bearing,Hinson clutch basket,Hinson high temp clutch springs,Vortex X10,KTM high flow water pump,DASA full exhaust,FCI intake,Dyno tune..

    Skat Track Edge 20x10x8 8 paddle,Maxxis Razr Blade 21x7x10,Ohlins steering damper,Insert modded fuel tank,HID lighting,FourWerx Carbon bits,KTM Powerparts all around..
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  5. 01-10-2012 08:55 PM #45
    kiwi-craig
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    burning oil to by the look of it............
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / DJH cam chain tensioner
    Next round of mods: oil cooler........ the NEW TOP DOG

    KTM 560 XC: 560 sx style light weight 72mm crank by cut 7, balanced, with DJH pressure feed drive side main bearing setup, DJH stator main bearing oiler, light weight SXF flywheel, TT SXF stator - Swartfager billet stator adapter, DJH cam chain tensioner , Thumper racing 99mm CP with ceramic coating, DJH plus 1 ported head / Travis STG 5 billet cam, 44mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, Wp's front and Rear with Kiwi ZPS suspension, Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics.
    Next round of mods: PB oil cooler........

    gotta stop spending $$$ on these KTM's........

    LTR 450, My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / Yoshi cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head...... the clark kent of the ATV trio ! 150hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ Vets (40+) North Island MX champ 08 & 09
    NZ Vets (40+) TT champ 06, 08 & 09
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09 & 11

    hope to get a good season in for 2012.........
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  6. 01-10-2012 10:00 PM #46
    harry_ss [OP]
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    now i have doubt about the oil pump rotors...could be destroyed??
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  7. 01-10-2012 10:43 PM #47
    kiwi-craig
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    replace em, they are cheap
    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / DJH cam chain tensioner
    Next round of mods: oil cooler........ the NEW TOP DOG

    KTM 560 XC: 560 sx style light weight 72mm crank by cut 7, balanced, with DJH pressure feed drive side main bearing setup, DJH stator main bearing oiler, light weight SXF flywheel, TT SXF stator - Swartfager billet stator adapter, DJH cam chain tensioner , Thumper racing 99mm CP with ceramic coating, DJH plus 1 ported head / Travis STG 5 billet cam, 44mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, Wp's front and Rear with Kiwi ZPS suspension, Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics.
    Next round of mods: PB oil cooler........

    gotta stop spending $$$ on these KTM's........

    LTR 450, My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / Yoshi cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head...... the clark kent of the ATV trio ! 150hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ Vets (40+) North Island MX champ 08 & 09
    NZ Vets (40+) TT champ 06, 08 & 09
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09 & 11

    hope to get a good season in for 2012.........
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  8. 01-10-2012 11:35 PM #48
    harry_ss [OP]
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    ok,
    there is a better quality rotor to buy? or from another ktm model?? thanks!
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  9. 01-11-2012 12:07 AM #49
    harry_ss [OP]
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    how many rotors do i have to buy?? im looking the microfiche but im not sure....... im going to place an order from my dealer tomorrow, please help, thanks!
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  10. 01-11-2012 12:10 AM #50
    997GT3
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    3 total,2suction and 1pressure
    Last edited by 997GT3; 01-11-2012 at 12:13 AM.
    2009 KTM 505SX Pump Gas Guzzling Beast

    Web stage2 cams,12.5/1 comp,OEM piston,43.5mm taper bored billet insert carb with FastRanchero mods,DASA ported polished head,Carillo rod,ProX rod bearing,Hinson clutch basket,Hinson high temp clutch springs,Vortex X10,KTM high flow water pump,DASA full exhaust,FCI intake,Dyno tune..

    Skat Track Edge 20x10x8 8 paddle,Maxxis Razr Blade 21x7x10,Ohlins steering damper,Insert modded fuel tank,HID lighting,FourWerx Carbon bits,KTM Powerparts all around..
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  11. 01-11-2012 12:17 AM #51
    harry_ss [OP]
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    Ok, thank you very much!
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  12. 01-12-2012 01:08 AM #52
    harry_ss [OP]
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    other pictures127.jpg129.jpg130.jpgIMG00092-20111213-1816.jpgIMG00093-20111213-1817.jpg
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  13. 01-12-2012 04:33 PM #53
    harry_ss [OP]
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    wiseco 12.5:1autos 024.jpgpiston ktm 001.jpgpiston ktm 002.jpgpiston ktm 003.jpgpiston ktm 004.jpg
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  14. 01-13-2012 05:31 AM #54
    polaris bob
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    I would take a real close look at your air filter system. From the looks of your piston, it looks like you might be sucking a lot of fine dirt into your combustion chamber.
    2003 Polaris Predator / 2004 KTM 525 exc 6 speed motor.

    570 Thumper Racing kit w/ 12.5 - 1 CP piston.
    Head ported by Thumper Racing w/ new intake seats done by Pro-1 racing.
    Stage 5 cam ( Custom design by Thumper Racing )
    AC bearing mod.
    Oil system mod by DJH.
    KW valves ( stock size )
    * #100 CDI dirt bike CDI.
    42 mm FCR carb by Walt/ Fast64ranchero. ( SX carb = No TPS )
    Trail Tech -10 oz flywheel. ( Stock is 30 oz/ trail tech = 21 ozs )
    Mino water pump. Full flow set up, no T-stat.
    PB Oil cooler.
    Custom modded intake. Uni filter/ D2 moto adapter on a modded Predator intake tube.
    KTM Bill modded, CT racing full exhaust system.
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  15. 01-13-2012 02:03 PM #55
    harry_ss [OP]
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    I thought the way the piston looks is due all the crap from the destroyed big rod end...because im a picky with the air filter maintenance and fitment...but could be a posibility.
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  16. 01-14-2012 02:59 AM #56
    harry_ss [OP]
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    Today my dad recieved the extractor, pulled the flywheel and....the nut that hold the axial movement of the crank was completly loose, it wasnt even tight a little! This sucks...sorry but is the truth. The movement is like 2mm...
    Last edited by harry_ss; 01-14-2012 at 08:28 AM.
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  17. 01-14-2012 09:21 AM #57
    sticko2
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    the crank should not be able to move that much even without that nut on. the shims on the inside of the main bearing determine how much axial clearance there is. check the manual for setting axial clearance.
    505sx, 43.5 carb, hmf full system, Crower victory cam, DB CDI, Manual Tensioner, Hiflo waterpump, kiwi mod carb spring, ranchero mods for ap & adj leak jet, PEP PB1 all round on xc swinger (lower) & Walsh arms, Axcalibre Axle, Precision Pro damper, Flexxbars, honda throttle, custom relocated battery box, FourWerx hump seat, Quadtech hood525xc, 41 Carb, SX pipe, Hiflo waterpump, kiwi mod carb spring, ranchero mods for ap & leak jet, Rocket Ron Racing WP's on jb arms, Softbars.
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  18. 01-15-2012 11:19 PM #58
    harry_ss [OP]
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    ahh ok i will confirm the information about the clearance beacuse i was told by phone (im outside my city) maybe i didnt heard right or it wasnt measured properly.. I will recheck it and will let you know asap!
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  19. 02-08-2012 03:53 AM #59
    harry_ss [OP]
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    Well, after disassembly the rod/crank.. the rod bearing is like new!! but the crank pin ( dont know the real name) is destroyed.
    Is so strange... i always thought the bearing was the problem.
    what do you think?DSCF0004.JPGDSCF0006.JPGDSCF0198.JPGDSCF0199.JPG
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  20. 02-08-2012 07:19 AM #60
    sticko2
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    The bearing is the problem. It eats the pin as the bearing cage has sharp edges. Not a problem with aftermarket bearings.
    505sx, 43.5 carb, hmf full system, Crower victory cam, DB CDI, Manual Tensioner, Hiflo waterpump, kiwi mod carb spring, ranchero mods for ap & adj leak jet, PEP PB1 all round on xc swinger (lower) & Walsh arms, Axcalibre Axle, Precision Pro damper, Flexxbars, honda throttle, custom relocated battery box, FourWerx hump seat, Quadtech hood525xc, 41 Carb, SX pipe, Hiflo waterpump, kiwi mod carb spring, ranchero mods for ap & leak jet, Rocket Ron Racing WP's on jb arms, Softbars.
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