Bad noise

[harry_ss]

Yesterday after 5 month away of my quad I installed the DJH tensioner because the engine was making a bad noise (i thought it could be a bad cam chain tensioner) also I checked the spring (it was good) and added two 1mm washers, put new oil (motorex like always) and started the engine...and bad news..the noise still there. My quad has 10 or 12 hrs. and I have changed the oil 4 times with motorex, and I always keep my air filter as clean as posible. I am so disappointened of this engine..
I also bought (not installed yet): honda fibers and plates, HD barnett clutch springs, hi flow ktm water pump, Uptite fuel line filters..
I dont know from where this noise is coming, but i know this is not good i will post a video to show you ASAP!

[5lblmbn2009]

the ktm motors are pretty noisy to start out with, but the way it sounds that isn't the problem. does it go away when you pull the clutch in or anything like that or is it a one tiem deal you start it up and clank and then its good? or is it repeated like every time the gas explodes in the motor? never heard of it before unless it goes away with clutch being pulled in. figured id help some other guys out with more info on it. and maybe loose primary nut or whatever that is called? idk how that sounds either though. good luck

[branko]

5lblmbn2009, I'm friend of harry. A few days ago we instaled the manual chain tensioner of DJH, becouse we thought that was the problem. The engine has a noise that when yo rev the bike, its grows up. Is very dissapointing to us whats happening becouse the engine has 10 hrs app. And we always use motorex oil. We are going to open the engine to see the real problem. But i dont think that could be piston or crank bearings, becouse the quad is so new.

We are waiting for your answers and we will do a video to show you the noise.

[harry_ss]

Finally i will not going to post a video because i dont want to start the engine again. I forgot to tell you when i pull the magnetic oil drain plug it was FULL of metal!!!

[kiwi-craig]

okay Harry mate: metal, what colour and shape, can you take a picture, options include but are not limited to broken Gearbox gear dog / crank main / rod big end. Regardless yes it needs to come apart...........

[sticko2]

My money is on the big end. Brass colored shards/flakes by any chance? Did you say you've not used the bike in 5 months? Bikes don't like sitting doing nothing in my experience. Like to be used often to keep things nice inside. Both kiwi and I know what you are going through I had broken dogs in my gearbox after 9 hrs. We'll help you through this and by the end you'll have learned a whole lot about your engine. As kiwi said post some pics up. Also cut open your oil filter. Cut both metal ends of and spread the filter material flat and take pics.

[997GT3]

Sorry to hear about your troubles,let us know what you find.Good luck!

[harry_ss]

im uploading some pics of the oil filter

[harry_ss]

I dont have pictures of the magnetic plug, but i can tell you.. there was no space for more metal!!! it was full!! it was like little black pieces like very very thin threads and the oil filter with brilliant metal but in different shape like sand.
i just take some pictures to the oil filter but is dificult to see all the metal on it.
DSC07455.jpgDSC07456.jpgDSC07457.jpgDSC07458.jpg

[kiwi-craig]

hmmm I'd say a bad rod bearing......... maybe a main........... bugger............... thats bearing plating

at least it hasn't gone "bang" and wrecked a whole heap of other expensive parts...........

[harry_ss]

yes thats why i dont want to start the engine now...i want to split the cases, and i will be very greatfully if you guys can help me on what kind/brand of bearings is the best way to go with. Im sure is a bearing failure and i hope the piston is ok. I love this bike and now that im going to split the cases i want to put the best bearing and all the stuff necesary to get a strong and reliable motor.

[ktmbill]

Harry its the big end rod bearing . The you take the head off like for kiss marks in thr top of the piston Replace the main bearings too I have ben using pro X rods and have good luck with them. It does not take much wear on the rod bearing to make it knock. I have a 505 SX motor that they kept running it blow the big rod end took out the cases head cly.
Bill

[harry_ss]

Ok, and what is the best main bearing?

[ktmbill]

I use the stock KTM main bearings I have never had a problem with them . We have Dans SX with over 100 hours on it with 1 piston change at about 90 hours it's his practice quad. Chad's practice had to put a crank in at about 80 hour our fault sand track with dry and dusty try to run a 30 min practice moto suck in the dust run for a month started to knock.
Bill

[kiwi-craig]

Harry; peeled it open yet ???

[harry_ss]

No, i havent done anything yet.

[harry_ss]

Long time without updates.
Well i havent done anything yet in the engine because im too far away from my quad (studies). Due all the metal i saw in the magnetic plug, i decided to place an order.
Dont know what the real issue is but there is something wrong for sure
My plan is put some brand new main bearings, new con rod., and new piston.
I need your help on what is the best main bearing you will use on these enignes (sx). Also the best con rod and piston (i know from your comments the stock piston is the best choice but is too priced for me now.

Thanks for your help!

[ktmbill]

Well use prox rod kit, wiseco pistons, and stock main bearings And have luck with them

[harry_ss]

I found this kit but im not sure if the con rod of the dirt bike is the same on the quad..
PRO X PRO-X Connecting Rod: KTM 505 SX-F 2008 | eBay

[ktmbill]

I am sure it is the same. I can check tomorrow and get back with you