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2009 Camchain tensioner failure 100hrs

H

husapye

Joined May 2009
108 Posts | 0+
South Island,New Zealand
Anyone have any ideas, as to reasons why?, my riding buddy has the KTM 400 (2009) :D the cam chain tensioner is an identical part to the 2010 Husaberg tensioner, he reckons. So he was warning to keep an eye out for it. The tensioner piston failed during a 4 hour ride. Symptoms were a knocking sound best heard on idle. Not an expensive part to replace, but strange it should fail at such low hours. KTM mechanic thought :shock: it could be a lubrication problem, oil pressure, or lack of ?
 
I'm assuming that the tensioner failed on your 2010 with low hours?

How many hours? Was there anything that happened and then it started knocking?

The 2010's were supposed to get an updated tensioner as with the KTM's. I believe the part numbers are the same, but, I'd have to check to be sure.

Is your bike still under warranty?
 
The Cam chain tensioner that failed was on a KTM 400 ( 2009)bike, not a Husaberg, but my riding buddy told me the part is the same as Husaberg Part # 77036003100. The cam chain tension piston failed approx half way through a 4 hour ride, so the engine was a maximum temp, but the day was not overly hot. It made no noticeable one-off noise to alert the rider while at high reves, or no noticeable performance changes. Was first noticed when the bike came to rest at idle, then the noise was so loud it was hard to believe it was not noticed while riding (metallic clacking ).The owner is a maintenance freak and uses only the best synth oils.The bike was out of warrentee and at 100 hours.
 
husapye said:
Anyone have any ideas, as to reasons why?, my riding buddy has the KTM 400 (2009) :D the cam chain tensioner is an identical part to the 2010 Husaberg tensioner, he reckons. So he was warning to keep an eye out for it. The tensioner piston failed during a 4 hour ride. Symptoms were a knocking sound best heard on idle. Not an expensive part to replace, but strange it should fail at such low hours. KTM mechanic thought :shock: it could be a lubrication problem, oil pressure, or lack of ?
Click to expand...

It's failing because it's poor design or implementation.... who knows. Mine (FE450 2009) failed one year ago at about 30 hours and I replaced it with Dirt Tricks chain tensioner. Have no problems so far.
 
Will replace mine as a precaution because who knows what further damage happened to the cam chain and sprockets riding for 2 hours back to the ride start with the cam chain thrashing and sounding like marbles in a baked bean can .Rather not have it happen mid-ride,cheers.
 
If your bike is 2010, it must be fine. There are no reports so far for 2010 chain tensioner failures.
 
sabink said:
If your bike is 2010, it must be fine. There are no reports so far for 2010 chain tensioner failures.
Click to expand...

Yur right, found out the part was modified for the 2010 bikes.
 
I am new here, but saw a post that I can contribute to.

There is a guy I know in Washington state that works on KTM's and Husaberg's, Dave H, or DJH as he goes by, that does a lot of performance engine mods and overhauls. He developed a fail-proof tensioner that is a bit cheaper than the dirt-tricks and doesn't use oil pressure. He has been great to work with.

His website where you can look at what he hashttp://www.djhcyclesport.com

He also has some videos that go through install if you are a newbe.
 
Dave is great to deal with

FWIW he has kibblewhite valves for the KTM RFS engines valve springs and steel guides that will fit in the pre 09 heads does carb boring and can help you get hold of just about any KTM cam you'd ever need, just have to cut the water pump shaft off
 

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