approx FE570 miles before valves, top end rebuild etc?

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Just for the record, my FS570 is now at 280 hours. Lots of track time, WOT rides, wheelies, even offroad.

Valve clearances are still within spec. I bought a shim kit as one of the exhaust valve (the one for the auto decompression side) seems like on the tight end.

Anybody else with high mileage?
 
While I dont have high milage or hours, I've seen more stories of longevity and reliability than blow ups at low hours. I killed mine needlessly :(
 
my 570 has around 600hrs on it now, has had 2 sets of rings and now one new piston and rings. mostly high revving race and fast enduro stuff, does have a fmf ceramic coated powerbomb and headers also a fmf muffler,

but I have a complete rebuilt motor ready if i ever have a total failure

the original engine seems to run out of torque in the top end, with 14 x48 gearing im only scratching 160 kph on bitumen, 145 kph on hard gravel , am wondering if the comp map might be the next step to boost the topend??
anyone run a euro or comp map???
 
2012 fe 570. 550 hours, 35000 is and still no engine work. Not even a valve clearance adjustment. still does over 100 mph on the shingle. Just done 3000 ks of single track, shingle and road. have decided to pull it down for a look, if all is good I will throw a set of rings and a counter shaft at it. bike has not been flogged but ridden with the occasional whipping. This is the most fun bike I have ever owned, hands down. Cheers
 
My friend had his engine checked after ~210 h. The pistons tolerances was still within what KTM accepts when they sell them, and the gearbox and crankshaft were just fine needing no new bearings. He changed the piston anyway as the engine was apart.

I been told that the 570 engine survive so good due to thicker cast in crucial areas of the engine casings, leading to less flex and therefor less strain on moving parts. Also the 70 degree design doesn't fling the oil haphazardly around but spray them through the different nozzles exactly where oil are needed.

Amazing engine.
 
the original engine seems to run out of torque in the top end, with 14 x48 gearing im only scratching 160 kph on bitumen, 145 kph on hard gravel , am wondering if the comp map might be the next step to boost the topend??
anyone run a euro or comp map???


the bikes have no top end power because they have a MX cam in them.

Taffy
 
after 235 hours everything was still in spec on my engine to but the max piston/cylinder clearance is 0.08 and my piston was 99.92 (cylinder still 100.00).
AL the rest looked fine but I replaced most of it anyway also the camchain was still very good working smooth lined up beatifully to tdc markings so no stretch...

My bike is a 63hp supermoto so it has a harder life than someone who uses it for trail riding;)

I only dameged some gears but I think that is more riders fault than bike (I can't shift properly or use clutch :p )
 
Just though I would report on the condition of my 570 after a strip down after 35000 ks and 550 hours. Apart from the counter shaft wear the rest would have done at least another 300 may be 500 hours. Remember the bike has not been flogged and used for Adventure riding. Am replacing some parts for the reasons listed.

The Bore has no wear, measured it in 6 places and is in the lower range of the specs. piston is worn 0.03mm bore to piston clearance is 0.08 so will put another piston in. (Prox, They are cheap)

New timing chain, sounded like a good idea.

Countershaft, various clips, seals and gaskets.

All bearings look great, the oil has always come out clean.

Gear box looks great, shift forks no wear.

Not going to even look at the valves, the clearances are still in specification. and my budget, the bank (and the wife) wont let me have them.

The only problem was splitting the cases. the upper case dowel had slight corrosion. luckily the case has some tabs so gentle tapping and lifting the opposite side of the case sorted it.

For Adventure riding, in my opinion this one very strong engine that will last the distance.

Will post some pictures I took about an hour ago.

Cheers
 

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the original engine seems to run out of torque in the top end, with 14 x48 gearing im only scratching 160 kph on bitumen, 145 kph on hard gravel , am wondering if the comp map might be the next step to boost the topend??
anyone run a euro or comp map???

I've had my 570 to around the 190 on tarmac and would have probably squeezed a little more out of it if I had the road. Was accelerating ever so slightly. That was with 14 x 38 gearing I think (the rear sprocket that was delivered with the bike). I get to 180 pretty quickly, faster than my mates 696 Monster. He crawls past at that point. So I would investigate further. I was around the 100hr mark when I did those runs.

Currently at 115hrs and 5800k's. Motor feels strong and tight. Haven't checked the valves since the 50hr mark, but they hadn't budged then so will leave it until around 150 before I have another look.
 
My 2011 FE 390 has 312 hours and 12,000km on the clock. Other than the usual oil changes, valve clearance checks, DT CCT and a replacement fuel pump in 2012, it hasn't missed a beat. I was thinking it must be getting time for a new piston/rings, but after reading this thread, I might just keep riding it.
 
There's one on bikesales with 46k km on it wiggy, says has not been ridden since top and bottom end rebuild. Would be interesting to know what he got out of it..
2565ac58848e2eebd9d576d40bf0ed39.jpg
 
390/450/570 all have the same crank just different rods/pistons correct???
So I wonder what is the most reliable bike the 570 has the biggest weight connected to the crank but runs lowest revs... is a 450 more reliable than 570 or vice versa....:)
 
yes they must be slightly different to get a different stroke but the weight/design is almost exactly the same or not???
The 570 has a heavy full circle crank and the weight betweend the 390/450/570 is similar so I guess the bottom end is almost identical but I never seen a 450/390 in pieces so I am just guessing;)
 
This is from what I know/understand (it might be more differences as I haven't done proper research or taken all engines apart):

390/450 have the same bore, but the 390 has a longer rod with less stroke. 570 has bigger bore and different stroke. So all machines have different cranks. The intake lobe on the 390/450 is different from the 570, but outlet lobe is the same. The clutch springs on the 570 are harder than on 390/450 and they use different curves in the ECU. Apart from that the engines/bikes are the same.

So if this is correct you can rebuild a 390 to a 450 just by buying a different crank. And you can rebuild a 390/450 to a 570 with a new crank, cylinder/piston, cam and clutch springs (not sure about the head...).
 

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