hey all! new to the forum and also a new berg owner. was on a ride today and somthing popped and the bike started to knock. Instantly i shut it off. my first thought was the cam chain tensioner so I am gonna order a new one none the less.. but if I try to start or even crank over the bike a bit there is nothing. just a click. this leads me to think something else happened.. any thoughts? was hoping to get it started to get the sound clip for help. and in the same go, no the head light and tail light are gone.. or they could have been gone prior but they were working on last ride. where do I start..lol thanks in advance
so i have begun the process of getting ready to teardown and figure this out. so far i have discovered you can not crank it manually all the way around.. goes one way and stops and then goes the other way and same thing. any thoughts? i know i prob have to fully tear it down just tryin to narrow the search
Joined Nov 2012
2K Posts | 821+
Iceland
Aw man, that sucks. Hope we can figure this out quick
So there has to be something in the combustion chamber right? Something got sucked in, or a valve dropped?
If you have a bore scope I’d have a peek down there, but I’d mostly just go for having a look in the head and then popping the head off and having a look down the cylinder.
So there has to be something in the combustion chamber right? Something got sucked in, or a valve dropped?
If you have a bore scope I’d have a peek down there, but I’d mostly just go for having a look in the head and then popping the head off and having a look down the cylinder.
ya there has to be something stuck.. i can crank it manually half way and it hits hard.. almost like the connecting rod broke and the piston is stuck half way. hauling the head off tomorrow id say.. sad thing is it was my second ride on it 
just gettin home from work here now.. prep time and then diving in.. i will update as i go along as I more than likely will have a few questions along the way. fortunately the fella i bought it from has every record and manual. both hard copy and disk.. and like most riders a few buddies willing to help.. wish me luck folks..
ughhhh. so due the the fly wheel not being able to crank the full way i can not get tdc. thoughts and suggestions? when i rotate clockwise i can build up some compression and then it will release as it roll it counter clockwise until it locks.
Joined Feb 2014
35 Posts | 6+
Victoria, Australia
Can you remove the rockers and spark plug on the motor and turn it over then? Just thinking that maybe one of the cams has jumped a tooth and the valves are opening at the wrong time and stopping it from doing a full turn....but only a possibiltiy, can still be something else too
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found the prob. valve stem seal blew up, fell into cylnder, piston hit head smash said bits.. new head, piston, gaskets, and valves..
Joined Feb 2014
35 Posts | 6+
Victoria, Australia
I was having the same thoughts? Maybe he meant the valve seat, but i cannot see how a stem seal would get in there unsless someone assembled the engine with it in the cylinder....
Just going by what the manual calls it.. its the metal cone looking piece at the bottom of the intake valve stem.. its a 10 dollar piece.. got shattered, valve opened, pieces fell in. Al i can think of.. also habe pics but havent sprted out how to post em here.. either way.. anyone wanna buy a parts bike.. lol gonna cost me 2500 cdn for new parts.. i will just buy a new bike at that point.
Curious. The stem seal actually fits onto the top of the valve guide... and the top of the valve guide is inside the valve spring. In other words, the stem seal lives in the same section of the engine as the camshaft. Its purpose is to stop oil from the cambox leaking into the intake. There's no way the seal itself can gain access to the inlet port.
Are you sure it's not some other part that's been inhaled by the engine through the intake? Have you recently dismantled any part of the intake or taken the spark plug out, such that some piece may have fallen inside the engine?
Whatever the cause, what a bummer... and particularly so on a new bike.
Cheers... Paul
Are you sure it's not some other part that's been inhaled by the engine through the intake? Have you recently dismantled any part of the intake or taken the spark plug out, such that some piece may have fallen inside the engine?
Whatever the cause, what a bummer... and particularly so on a new bike.
Cheers... Paul
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Part number 5 in the valve section of reapair manual. Thas whats missing, and busted up on cylnder head and piston
*edit- also spring retainer was also smashed up top, but still intact.
*edit- also spring retainer was also smashed up top, but still intact.
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Joined Nov 2012
2K Posts | 821+
Iceland
Man I’m sorry to hear this. I don’t remember hearing about this failure in these bikes before :/ Seems like a rare and unlucky occurrence.
In case it’s of interest then I think a rebuild I could be done for less than CAD 2500 in parts. The head might be repairable by a machine shop, or a number of alternate heads can be used - I believe they interchange between the 390/450/570, and then I also think that a number of KTM heads work too if modified a little (tapped for oil return line); see forum posts here. So there should be something used and good out there. Then Wössner and ProX make pistons. These also interchange between the 390 and similar years of the KTM 400. Those ought to be the biggest items right? And finally these motors are rather pleasant to work on, so it could be allright in the end - if you want to go that route.
In case it’s of interest then I think a rebuild I could be done for less than CAD 2500 in parts. The head might be repairable by a machine shop, or a number of alternate heads can be used - I believe they interchange between the 390/450/570, and then I also think that a number of KTM heads work too if modified a little (tapped for oil return line); see forum posts here. So there should be something used and good out there. Then Wössner and ProX make pistons. These also interchange between the 390 and similar years of the KTM 400. Those ought to be the biggest items right? And finally these motors are rather pleasant to work on, so it could be allright in the end - if you want to go that route.
2203.00 cdn plus tax.. just got my quote from the ktm dealer, unfortunately i am unable to fork that out after just buying the bike a week ago.. she will gonin storage i spose..thanks for all the help and support to everyone! Ur all legends.. hopefully i will revive her one day
Yessir! Needs a a new head, full valve kit, piston and cylinder kit, and according gaskets.. plus the ignition cover one as well.
**am at work so dont have the part numbers my friend.. but thats it in a nutshell.. whole entire top end..
**am at work so dont have the part numbers my friend.. but thats it in a nutshell.. whole entire top end..
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