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February 24th, 2013, 02:01 AM   #1
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So my bergs cracked 200 hours

Was just wondering if there is any maintenance I should be doing to the engine. I've put over 100hrs on it in around 6 months, mainly highway use as I was doing around 45kms a day using it to get to work. (mostly highway at 100km/hr and I have since moved so it won't be racking up the kms anymore). The bike still runs perfectly fine, in fact the only thing I've done to it maintenance wise is oil and air filters. Changed the oil every 500km, haven't noticed any metal in the filter and only average chips on the plug.

I'm looking at doing the brake pads, rotors, chain and sprockets and my headset bearings as it seems to be sticking lately, that or my steering dampers dead. I'm just wondering how long the cam chains usually last, or the valve springs. Should I be doing a top end rebuild just incase or has it got plenty of life left in it? I plan on buying all my parts from the states so I'd rather get everything in one hit.
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February 26th, 2013, 12:25 AM   #2
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Re: So my bergs cracked 200hrs

There is no simple answer to these sorts of maintenance questions. Basically it comes down to how much money you have and what you feel comfortable doing. I took my berg apart and put a new top end in it for no obvious reason other than I wanted to, and i dont regret it, it was amazing!. Others will run the bike into the ground and get a new one in a few years.

Basically replace what is broken. If it doesnt sound broken and no evidence of worn bearings etc (knocking sound/filings on plug) it dont need fixing. (Exception to that is timing chain.) -is the tensioner completely used up? (Valve springs and chain are cheap IF you can do it yourself)

Ask questions of your local Berg/KTM mechanic, and speak to the mechanic (not sales). ask questions, usually happy to share their passion.

my biggest recommendation is to take your bike off road! 650 in the bush is categorically insane but you will have a much greater appreciation for it! and you will love it even more!

there is no simple answer.
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March 8th, 2013, 06:13 AM   #3
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Re: So my bergs cracked 200hrs

Bumping and borrowing this thread.

My berg just hit 100h and I had to tear the whole engine in pices because I tought I heard some noises from the gearbox. I didn't find anything wrong so maybe it was just my imagination. But anyways, I changed some of the bearings so the eventual soud should be dealth with.
what else is recomended to replace after 100/200(OP) hours?

the timing chain
timing chain tensioner
piston rings
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March 8th, 2013, 07:37 AM   #4
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Re: So my bergs cracked 200hrs

I've just clocked 195hrs and still going strong with no plans for a strip/rebuild. No abnormal noises, no smoke, runs and pulls like it always has. I replaced the CCT sometime ago with a DJH manual adjuster as the chain seemed noisy on occasion. Other than that (and the warrantied fuel pump change) it's had only routine maintenance. Oil & filter changed mostly @15hrs, occasionally gone out to 20hrs, synthetic 15/50 car oil & OE or FX filters. OE foam filters cleaned and re-oiled as necessary. Front brake caliper seems prone to sticking and doesn't seem to go long before it needs the pads out an another clean & re-grease. I put it down to the amount of salt they chuck down at this time of year.
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March 9th, 2013, 01:56 PM   #5
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Re: So my bergs cracked 200hrs

My 07 650 is at 263 hrs. A few water pump and oil seals plus I did the cam chain and DVSK kit at 156 hrs as preventative measures after reports of broken valve springs at +/- 200 hours. My cam chain was nearing the end of the adjuster travel, so due for replacement. Simple enough to get TDCC and pull the adjuster and check for travel with the spring removed. IWIS chain and DVSK from Taffy and all good. Not getting a lot of use ATM, but recent knee surgery means maybe in 4-6 weeks it might get a run.

Only other mtce item of note was a new battery last Dec, replacing the 6 year old original with a EarthX lithium.

Delo 400 every 5-7 hrs.
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March 10th, 2013, 11:07 PM   #6
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Re: So my bergs cracked 200hrs

Yeah my 08 650 is stock as a rock. Have only changed oil and filters for 200kms. Haven't checked the cam chain tension. Guess I'm going to have to do that as it and valve springs were my main concern. It only has a tiny weep coming out of the weephole (oil) and I have an orangeberg kit sitting there I just have to put it in. You say reports of broken valve springs at 200ish hours, that has me concerned now.

I use motorex oil every 500kms. (That is about 5hrs)

Also as far as asking my mechanic goes, I have had nothing but dramas the few times my bike has been in there. They didn't know how to bleed the coolant system for one example.
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March 11th, 2013, 03:50 AM   #7
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Re: So my bergs cracked 200hrs

Pegscraper, car oil? Most cars run a dry clutch, most bikes run a wet clutch. I believe this is one reason why there are different oils for cars and bikes, something to do with anti friction additives or something? Have you ever had clutch issues with your ride?
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March 12th, 2013, 07:22 AM   #8
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Re: So my bergs cracked 200hrs

It's time to refresh the valve train IMO. The cam follower bearings and timing chain at the least. My rt exhaust spring broke at 250 hours on my 05 650.

I put a dvsk in, timing chain, new CFB's, valve seals, and a new head gasket. It's got 400 hours on it now, oil changes getting more frequent as it ages. Started with 10 hours, filter every third change. Now it's 5-8 hours between oil changes, and valve adjustments at 30-40 hour intervals.

Been using "car oil" since 130 hours. Rotella T Dino oil and sometimes I'll use Rotella T6 (synthetic).

So... for sure, check the cam follower bearings, you will prolly find that they are worn out.
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March 12th, 2013, 01:54 PM   #9
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Re: So my bergs cracked 200hrs

Originally Posted by Idle
............

So... for sure, check the cam follower bearings, you will prolly find that they are worn out.
With the experience of my 501, I actually purchased some new follower bearings for my 650 when I did the DVSK etc, and I couldn't tell the difference between the old and new, so left the originals in. Valve clearances still don't change at 260 + hrs. If they do start to loosen though, its follower bearings ASAP.
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March 12th, 2013, 02:53 PM   #10
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Re: So my bergs cracked 200hrs

Originally Posted by akshun
Pegscraper, car oil? Most cars run a dry clutch, most bikes run a wet clutch. I believe this is one reason why there are different oils for cars and bikes, something to do with anti friction additives or something? Have you ever had clutch issues with your ride?
Been using the car oil (Shell 15/50) from around 30hrs and had no clutch issues at all. Personally, I don't buy into this car versus bike oil theory but that's just my choice. If they were the same price then maybe I'd use them but they can be 2-3 times more expensive and I'm yet to hear a valid reason why that is the case. I'm no oil expert. All I know is I've used car oils in the past on other bikes, even high performance road bikes and had no issues. I'm sure I've read somewhere, possibly on this forum?, of some owner's using diesel car oil in their bikes? JMO
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