Kawasaki Sportsbike Riders Club - Australia - Online Forum

[quote="aardvark Apparently there are documented problems regarding the main bearings in this model. I can't imagine that being a cheap fix. [/quote]

Ouch

I had the 650 and had the bearing colapse, it cost $3200 just in parts and that was trade!
BTW every part inside the motor is a KTM part

Allfixed07 wrote:I had the 650 and had the bearing colapse, it cost $3200 just in parts and that was trade!

One of the guys in the club had his 650 do the same thing. His cost $400 in labour and just under $600 in parts.... Did you buy a complete new engine?

Main bearings collapsing ?? that sounds like a manufacturing fault - I would be hunting the dealer for a warranty job. But either way, replacing mains is a big job alright......one for a workshop.

Whoever paid $3200 for parts got ripped off big-time, unless the 'parts' included a whole lot of other damaged stuff like everything inside the cases !!!

Gosling1 wrote:Main bearings collapsing ?? that sounds like a manufacturing fault - I would be hunting the dealer for a warranty job. But either way, replacing mains is a big job alright......one for a workshop.

It's an '05 mate. Pretty sure they aren't going to cover it under warranty.

I think I'm going to have a crack at it myself. How hard can it be?

Have a look, price up the parts, you may end up finding it cheaper just to buy a new engine once the parts have been priced up.

I completely rebuilt it while I had it appart, new crank, rod, piston etc.

Well, decided to have a bit of a look-see today. Here's what happened:

1) Drained the oil. Nothing to see here really. A couple of small metal filings on the drain plug, but nothing out of the ordinary. Oil filter and oil screen are both clean.
2) Removed the clutch cover and had a peep inside. Everything looks fine. No problems with any of the cogs in there and the timing chain looks to be ok.
3) Removed the valve covers. Again, no obvious problems.
4) Removed the headers. The exhaust ports are black and full of carbon, but I'm not real sure how gunked up they are supposed to be.
5) Took the rotor cover off and hooked a socket up to the main nut. Tried to wind the rotor clockwise but it was all locked up. Just like the kickstart lever. However, managed to wind the rotor anticlockwise a couple of turns. No weird noises and easy enough to turn. After that, it would wind either way.

The kickstart lever is now unlocked and I can hear the piston going up and down with no crunching noises.

Not going to try and start it at this stage, but wonder if anyone has any clues what the problem might have been based on this information?

Probably a broken tooth floating around so I wouldn't be kicking her over
Take the sump off and she should be at the bottom now

seiko1 wrote:Take the sump off and she should be at the bottom now

I think you mean - take the engine out, pull the head and cylinder off, then split the cases...

aardvark wrote:....It's an '05 mate. Pretty sure they aren't going to cover it under warranty.....

You might be surprised. I had the tank on the MFP12 replaced under warranty, 2 years after *warranty* had expired.

The standard manufacturers warranty is just that - a standard warranty. Goods have to be fit for purpose in accordance with the Trade Practices Act, regardless of any bullshit that the manufacturer may spin you about something being 'out of warranty'.

Especially if the problem is well-known and documented with recalls or service bulletins from the manufacturer......

If you have found the issue, and it sounds like you may have - that's great. But if the mains do shit themselves down the track (boom boom) - then I would be playing hardball with Husaberg.

On the off chance, I checked the coolant level. Took the radiator cap off and gave the bike a slosh around. Nothing to be seen!!

I wonder if it got too hot and the barrel seized up around the piston?

aardvark wrote:

seiko1 wrote:Take the sump off and she should be at the bottom now

I think you mean - take the engine out, pull the head and cylinder off, then split the cases...

OMG you poor bastard
Gos is talking about the Statutory Warranty.....it is the law that something should have a "reasonable life expectancy"
You may have trouble with a 5 yr old engine but
We get two and three yr old plasma's fixed now after taking LG and Samsung to VCAT
It was ruled that a $2000 (at that time) purchase would reasonably be expected to last more that a bloody year
and a half
They hate it and try not to let Joe public know it exists

entirely possible.....it may have just nipped up a bit after getting too hot, and freed up after cooling down....

if the motor is now spinning freely ( have you rotated it with the plug out and a drill attached to the end of the crank ?? don't. ) - but if it is spinning freely, with no obvious damage - mate I would fill the radiator and kick it in the guts. Chances are it will fire and run just fine....best outcome by far.

It's time to quiz your bro mate.......
How did it come to a stop ??
Did it lock the back wheel on him ? or did he fall off just prior to it stopping ? (may have hydraulically locked ?)