| No. |
When |
What |
KM |
Cause |
Fix |
| 2006 |
| 53 |
May |
Rear subframe bolt sheared |
97,000 |
Overtightening and wear and tear. |
Replaced all 4 bolts. |
| 52 |
May |
Worn front wheelbearing |
94,000 |
Front wheel subject of KTM recall. |
Only 1,000 km to Sommer's and a new wheel. |
| 51 |
May |
1 broken front spoke |
94,000 |
Front wheel subject of KTM recall. |
Replaced spoke, new wheel to be fitted at Sommers next week. |
| 50 |
Mar |
Cracked tool box weld |
84,000 |
Vibration |
Not a structural item. Left as is. |
| 49 |
Mar |
Starter failed |
84,000 |
Corrugations |
Reconnected broken wire. |
| 48 |
Feb |
Rear shock - shaft was bent. |
82,000 |
20km at very slow speed on collapsed suspension. |
replace with secondhand shock |
| 47 |
Feb |
Chain damper- I threaded lower engine bolt. |
82,000 |
My fault. |
Helicoiled thread. |
| 46 |
Feb |
Rear hub - bearing broken by mechanic when removing it and hub damaged. |
82,000 |
Bad training and excessive force. |
New hub - the alternativ was for the dealer to butcher a new one
to remove the parts I needed.. |
| 45 |
Feb |
Rear wheel bearing |
82,000 |
Missing disc side spacer. |
Replaced both bearings. |
| 44 |
Feb |
Steering head bearings |
82,000 |
Wear and tear. |
Replaced. |
| 2005 |
| 43 |
Dec |
Clutch dragging |
78,000 |
Worn out clutch master cylinder |
New clutch master and slave cylinders. |
| 42 |
Broken rivet head in main clutch basket |
New clutch basket. |
| 41 |
Dec |
One rear wheel bearing knackered. |
76,000 |
Missing wheel spacer. |
Renewed both bearings. |
| 40 |
Dec |
Engine lost all compression |
75,000 |
No idea, presumably damaged when the inlet rocker arm was changed |
New piston rings. |
| 39 |
Dec |
Front brake keeps loosing feel by going soft. |
75,000 |
Wrong DOT used in Argentina |
Fitted master cylinder kit |
| 38 |
Dec |
1 broken front spoke |
75,000 |
Front wheel subject of KTM recall. |
Replaced spoke, new wheel ordered forward for Nairobi. |
| 37 |
Dec |
Front wheel bearing knackered. |
75,000 |
Wrong seals fitted front and rear. |
Replaced with correct sized seals. |
| 36 |
Dec |
Cush drive rubbers |
75,000 |
All knackered |
Replaced them all. |
| 35 |
Dec |
Carburettor main jet |
75,000 |
160 fitted in Joburg at 1,500 metres |
Changed to 157.5 at sea level as recommended by Sommer's. |
| 34 |
Sep |
Chain and sprockets |
73,000 |
Preventative maintenance. |
Replaced half worn ones to avoid problems in Africa. |
| 33 |
Sep |
Inlet rocker arm. |
73,000 |
Preventative maintenance. Life span is only 40,000 km |
Replaced inlet rocker arm to avoid problems in Africa. |
| 32 |
Aug |
Front forks and rear shock |
70,000 |
Wear and tear. |
Replaced all wear parts. |
| 31 |
Aug |
Rear Suspension Roller Bearings |
70,000 |
Lack of grease. Pressure washing. |
Replaced roller bearings and shaft. |
| 30 |
June |
Oil leak.
- Gearbox output shaft seal |
70,000 |
Poor work - Others.
Probably installed dry during the rebuild. |
Replaced 'O' ring and seal. |
| 29 |
June |
Rear suspension bushing worn. |
70,000 |
Wear and tear. |
Replaced bushing. |
| 28 |
May |
Clutch leaking |
65,000 |
Wear and tear. |
Fitted overhaul kits to master and slave cylinders. |
| 27 |
May |
1 broken front spoke |
65,000 |
Poor work - others.
Overtightened front spokes weakened them all. |
Replaced all spokes, rim also dented so new rim. |
| 26 |
May |
Engine -
felt slow & wouldn't run cleanly |
63,000 |
Vibration.
Dirty & worn emulsion tube. |
New emulsion tube & clean carburettor |
| 25 |
Apr |
3 broken front spokes |
58,000 |
Poor work - others.
See May 05 above. |
Replaced spokes, trued wheel. |
| 24 |
Mar |
Engine -
Dry bearing noise at less than engine speed.
|
53,000 |
My paranoia.
Originally thought to be dodgy gearbox bearing. |
Replaced all gearbox bearings. |
| 23 |
Mar |
Engine -
Large split in the gaiter between the carb and airbox |
53,000 |
Poor work - others.
Overtightened jubilee clamp. |
Mended with rubber tape then replaced with a new one.
Fit a new piston.
I now know I should have fitted a new barrel at the same time. |
| 22 |
Mar |
Front forks very stiff |
53,000 |
Poor work - others.
Forks overfilled with 600cc instead of 420cc of oil in Sao Paulo . |
Disassemble, clean & refill with 420 cc. |
| 21 |
Mar |
Engine -
Dry bearing noise at less than engine speed.
|
53,000 |
Wear and tear.
Cam chain tensioner not extending through lack of oil. |
New camchain tensioner.
|
| 20 |
Mar |
Steering head bearings worn |
53,000 |
Wear and tear. |
Renewed bearings. |
| 19 |
Mar |
Front wheel bearings. |
53,000 |
Wear and tear.
Stress from weight and sustained high speeds. |
Replaced for the second time.
The 2004 model has bigger fron wheel bearings. |
| 18 |
Feb |
Clutch still slipping. |
50,000 |
Cleaning didn't fix the problem. |
Replaced all clutch plates. |
| 2004 |
| 17 |
Nov |
Engine -
Clutch was slipping |
49,000 |
Poor work - Me
I used synthetic car oil in error. |
Changed oil.
Clutch plates cleaned and abraded. |
| 16 |
Oct |
Rear wheel rim was cracked in ten places |
41,000 |
Poor work - others.
Overtightened spokes when it was relaced in Cuenca, Ecuador. |
New Excel rim. |
| 15 |
Oct |
Rear suspension Bushing Cracked |
40,500 |
Wear and tear. |
Replaced. |
| 14 |
Oct |
Engine - inlet gaps increased again. |
40,500 |
Engine design fault.
Seized bearing on the inlet rocker arm. |
Replaced rocker arms and camshaft. |
| 13 |
Sep |
Engine - Gearbox output shaft seal. There was orange dust around
the sprocket bolt again.
|
37,000 |
Poor work - Me.
The 'O' ring was being squashed. |
Replaced it again.
Amazing proactive maintenance before the Salar Uyuni.
|
| 12 |
Sep |
Chain - broke because the connecting
link fell off. |
39,000 |
Wear and tear.
Circlip eventually falls off. |
Bodged twice, then replaced by DID Gold X ring chain with no circlip. |
| 11 |
Aug |
Exhaust bracket bolts - disappeared. |
33,000 |
Vibration and no Loctite |
Loctited replacements. |
| 10 |
Aug |
Engine -
Starter motor failure. |
32,000 |
Poor work - others.
The solonoid had been replaced in the wrong position. The feeder wires
were touching the side panel. Vibration had snapped off the feed wires. |
Rotated the solonoid so the feed wires did not contact anything. |
| 9 |
Aug |
Front wheel bearings |
33,000 |
Wear and tear |
Replaced by SKF ones. |
| 8 |
Jul |
Funny noise eventually traced to
missing and broken rollers on the chain |
30,000 |
Wear and tear.
Original KTM chain. |
Replaced with a second hand one. |
| 7 |
Jul |
Headlights -
Lights fused. |
29,000 |
Vibration wore through the insulation causing a short. |
Rotated the lamp cover 120 degrees anti clockwise so wires no longer
near the frame. |
| 6 |
Jun |
Steering - Top triple clamp
cracked. |
28,000 |
Poor work - Others.
I think this was caused by over tightening by an inexperienced mechanic. |
Replaced both top and bottom triple clamps to be safe. |
| 5 |
Apr |
Engine - Gearbox output shaft seal 'O' ring was disintegrating again.
|
26,000 |
Poor work - Me.
I installed the first one dry. |
Replaced it, but this time covered in oil. |
| 4 |
Feb |
Steering -
The steering head bearings were knackered. There was a big 'notch'
in the straight ahead position.
|
18,000 |
Wear and tear.
I went too fast over thousands of Mexican speed bumps. |
Moto Altavista
replaced the bearings.
|
| 3 |
Feb |
Chain -
The top roller guide under the rear brake master cyclinder disappeared.
|
18,000 |
Vibration. |
Replaced it using lots of Locktite. |
| 2003 |
| 2 |
Nov |
Engine -
The gearbox output shaft seal 'O' ring failed.
|
10,500 |
Poor work - others.
It was installed dry by the factory. |
Replaced 'O' ring and seal. |
| 1 |
Sep |
Engine -
The main gearbox bearings were noisy after 1,500 miles. They had no
brand name only the KTM part number.
|
1,500 |
My paranoia. |
Swampy
replaced all the bearings that did not have a recognisable brand name.
They are still noisy. Maybe it wasn't the right fix :) |
