top end/rebuild interval? (05 fe550)

Interesting question on the maintenance overhaul issue. I don't know of anyone yet that has done one on the 04 and newer bikes. My theory is repair as needed.

Hey Velo,

I've got about 97 hours and approx 2000 miles on my 2004 fe550e.

I've done several valve adjustments, on all but the first one the valves have moved very little. IE, I could still get the .005" feeler in, but, it was just slightly tighter than before. I feel confident I could have left them completely alone for say 40 or 50 hours easy, and then it would have been a very small adjustment. And the only ones that have moved have been the exhausts, mainly the left side as you sit on the bike. Is that the one that moved on yours?? I would say that in the absence a large change of valve lash, perhaps indicating a follower going bad, I think bergers comment of "repair as needed", is excellent advice.


I know that the book says to pull the head at 45 hours, but, I haven't really seen the need to do so, and I'm very meticulous about the care and feeding of my bike. Like you, I'm easy on my bikes. I also keep a sharp eye on the oil, oil screen, and oil filter for any tell tale signs that something is starting to wear quickly. And change it often.

You're getting the same fuel milage that I get as well. What jetting are you running??

The only thing that I'll be checking in the near future which is mentioned in the Doc (thanks Taffy) is the cam chain tensioner, see red alerts. Seems that the 04's run out of throw on the tensioner, and should be replaced with an 05 spec tensioner, however the 04's have the good slider. It is also my understanding that the 05 tensioner is a constant tension type, and no longer the ratcheting style. If anyone has any comments on this please post.

Hope this helps,

Looks like the chain tensioner is still a ratcheting type. However, it is a new part number for '05. for sure. I have not had mine apart, I was just looking in the parts manual.

I have about the same time on mine as Velo, after the initial break in, the valves have not moved. Different than my KTM, where the soft intakes pound into the seat and require adjustment every time. I wonder if the 'Berg uses a different grade of steel than KTM for the intakes valves. It would seem so, but I don't know. Th heads are so close to identical, I'm surprised the valves are different?

I had to replace the intakes on my 520 ktm at around 150 hours. That was the weak spot there, the piston was good, and the rings were still in spec, barely.

I would guess 200+ hours on my Husaberg top end. That's what I'm shooting for anyway. Anything on the bottom end will be as necessary.

Johnf3 said:

Looks like the chain tensioner is still a ratcheting type. However, it is a new part number for '05. for sure. I have not had mine apart, I was just looking in the parts manual.

I have about the same time on mine as Velo, after the initial break in, the valves have not moved. Different than my KTM, where the soft intakes pound into the seat and require adjustment every time. I wonder if the 'Berg uses a different grade of steel than KTM for the intakes valves. It would seem so, but I don't know. Th heads are so close to identical, I'm surprised the valves are different?

I had to replace the intakes on my 520 ktm at around 150 hours. That was the weak spot there, the piston was good, and the rings were still in spec, barely.

I would guess 200+ hours on my Husaberg top end. That's what I'm shooting for anyway. Anything on the bottom end will be as necessary.

Click to expand...

Wasn't there a bad batch of Titanium that was causing all the KTM's valve problems a while back?

I'm pretty sure that the FE valves are stainless steel, and I believe that helps with the longevity of the valve train. I had even read that engine builders were going to SS valves in the CRF et al for the same reasons.

KTM only uses titanium on the SX models. The '03 450 SX had bad problems with their TI valves.

The EXC model like I have and all other Non SX KTM's have stainless valves like Husaberg. The KTM intakes are made from a softer grade of SS and are notoriously soft, which leads to the dreaded "tulip" shape after moderate use. The exhaust valves don't have the same problem, I guess they are a harder grade of SS.