Crawling first gear even when clutch is engaged? Any ideas?

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factor,

I think you will find your bike being an 05 still has the 32 mm crankpin/big end.

If the big end is shot and requires replacement I believe you can source a complete new 06 35mm crank for approx the same price as a 32 mm rod kit and assembly costs.

Do the research before spending your dollars- no point spending $800 on a rebuilt 32 mm crank when a new 35mm one is not much more $$$$.
 
factor,
For give for being rude but I seriously would consider going to another dealer, from what I have read I dont see much that instills confidence in the present repairer.
" THINKS IT COULD BE THE BIG END" ?, what if it isnt?, I would be going there as a last resort . I agree with nsman, check for damage to any of the gears behind the lhs cover especially as the noise only started after someone played around in there. I recently had some trouble with my 501 (posted here) and eventually found some slight gear damage, it was difficult to see but it was there and caused a noise that may be similar to what you describe. I would be willing to bet it isnt your big end (unless some one had it apart and forgot to put oil in it before they started it)mmm

Mick
 
i don't think he has many choices as far as dealers go .

but if i were you i would go the distance for a 2nd opinion .

i do have a 04 conrod kit which is in exceptional cond if you need it , you can have it dirt cheap .
 
I think you guys are right a few second opinions would be a good idea.
 
I also have a question are the steels in the clutch of an 05 the same as the steels in an 02 03 etc. As they only ordered me 5 x 2005 steels and said they had some others in stock from previous bikes (i am thinking what if they are different?)
 
Faktor,

Again, second opinion time....

are you taking it to Q.F. motorcycles ??

would be interested to know.....

the dealer I brought my Berg through, is extremely good, he is usually happy to yarn for a half hour to an hour if I have questions, he works on the bikes, he races, and he seems to know these things from the ground up. I know bendigo is a long way away, but at least you dont have a 16 km ferry crossing to negotiate....

try Bendigo Dirtbikes - Mick Hughes.

Good luck & hope its on the go again in June, keen for a ride ya' know.

Azza.
 
faktor said:
I am still wondering about the diff steel clutch plates etc...
Click to expand...

hi factor

03 bikes had thick and thin steels. the 04 on bikes have thin ones. want to know more ??

It gets a bit complicated.........
 
mm wonder what ones they mixed up with my 5 x 05 ones.

Wonder wether that could make the noises...
 
faktor said:
mm wonder what ones they mixed up with my 5 x 05 ones.

Wonder wether that could make the noises...
Click to expand...

04 - KTMs and Bergs use exactly the same steels- all X 1.00mm ones.

02/03 KTMs use 1.4mm and 1.0mm ones.

The 03 Berg has a mix of 1.4mm ones, and 1.0 mm ones as per the 02/03 KTMs

Maybe you have a heap of 03 1.4mm ones in your bike ???

If they are wrong and they cant supply the 1.omm steels, try KTM and then the aftermarket...........

You might be lucky, but in an unlucky sort of way ????? :wink:

Definetly worth checking.............
 
what engine oil do you use. I swithced from synthetic to chevron delo 15/40 and got better shifting and stopped the clutch drag immediatly. . I use johnsons baby oil in the clutch. pure mineral oil.
 
faktor said:
mm wonder what ones they mixed up with my 5 x 05 ones.

Wonder wether that could make the noises...
Click to expand...

Hey Factor,
I take it your clutch now works properly and the drag issue is gone ? Are you sure the noise was not there before you took it in for the repairs, ie, did you ride the bike without your helmet on before it went in? You can be pretty sure it wont be the clutch plates making the noise- with the clutch engaged (lever out) the plates are locked up in the basket and the whole clutch assy rotates as 1- eliminating the plates as a cause.
Still think it will be a gear mesh issue behind the clutch cover.

Mick
 
Yeah i still have the noise issue and the dealer thinks it is the big end maybe.
I have another mechanic having a look at it for a second opinion. either way i think someone will have to split it to see what is wrong.

:(
 
Factor,
Going back through the posts you describe this noise as a noisy rattle.You also suggest that the LH side cover of the engine has never been removed until you requested it.I was just thinking, did your dealer actually take the primary drive nut off to check the key and keyway when they checked the primary drive nut for tightness.These nuts have a habit of coming loose and the noise is very much like a rattle.If your big end is on the way out you would have seen increased ferous metal deposits on your magnetic drain plug as the bearing and crank pin were flaking away.
The primary drive gear and clutch hub gear are straight cut and these run very fine tolorences ,a very small imperfection in these gears makes quite a noise.Also have them check the gear for imperfections on the starter drive as again this is part of the same gear train and can cause the noise you describe.
Even if the LH side cover has not been removed,but the clutch drum has been removed it may be some gear damage has occurred.Refitting the clutch drum can be a little difficult as one cannot see the gear mesh to the primary drive and starter drive gears and these are a tight fit on many engines.
 
Thankyou very much for all that information I will pass it on to the second mechanic.

THe dealer mechaninc took side off and said the Primary drive was not loose then said he wanted to split it.
 
I am wondering what KTM parts i can get that will work for below ….?
Ok here is what I seem to need according to Mechanic ( if my bikes engine number has 5-820 at the start of it, is it 05 parts that i need. I would like 07 if can be done)
Counter Balancer bearings (can this be 2007 and work in my 05?)
Main Bearings (can this be 2007 and work in my 05?)
Conrod kit and Pin (not sure if it includes pin) (can this be 2007 and work in my 05?)
Piston Kit (is there after market)
Cam Chain and joining link (can this be 2007 and work in my 05?)
Cam bearings
Gasket Kit (does this include all seals etc (valve seals etc etc))
Any help would be great guys......
 
OUCH 8O @ 5000klms - no way baby

just find out what the cause of the noise is and repair it , no way do you need just about a full rebuild !!!

more opinions are required
 
oh yeah i was stunned and forgot to say

wait till you find out the cost of the quote + labour , you will enter into a world of hurt :evil3:
 

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