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Hi all, I'm Ben.. Been a total lurker for a while now, most of the info i've needed i could find using the search button. But after finally purchasing a beautiful 05 plate 625 SMC, I soon struck some serious trouble. Let me try and explain..

I bought the bike privatly about 2 months ago, Bike was mint, Nice bloke, even giving me a txt a few days after to see how i was getting on with it. So no gripes about that. Having not passed my test at that point it only went up and down a airstrip few times. After just less than a month I got it serviced. The bloke who did it mentioned some Fillings on the Sump Plug, He said that it has looked around and couldnt find the cause. I think his words were along the lines of; seems fine, if i notice anything come straight in.
Same week I took my Mod1 of the test.. Ran fine.. Passed of course. Next week Mod 2... Passed too.. BUT had it started getting a little louder. Engine noise i mean, along with slightly more vibration. As I rode it around (no more than 50 miles) it got to the point that the vibes were distorting my view.
Took it straight to the ktm dealer in my area. Mentioned it, he had a listen. His words were there could be a "serious problem, its not supposed to do that" "possible main engine bearing failure". At just over 6000 miles i had my doubts but I let them take it.
The next phone call described my bike as "totally fucked". The bearing had gone, along with generator, stator, crank, oil pump, the teflon coating on the piston had 'gone' and the cylinder was scratched.. Hmm.. £1500 quote.:mad:

£1500 was unaffordable for me just after buying the fookin thing, But i found a 625 Duke2,(2006 KTM DUKE 2 LC4 625 SXC) supposedly had 1 years use with the same high flow head. The dealership said £250 to put it in(and that it would fit fine) plus the engine cost me 850 delivered. Just about affordable as a whole...

What I am now wondering as i await delivery of my engine.. Have i done the right thing..? Is there much i am going to need to do? My SMC 'had' airbox mod, akrap full system, jetted to suit.. but as far as i am aware the carbs on the duke are not as good. (FCR carbs anyone??) Something to do with throttle response anyway.. The jetting i guess will need to be redone and the gear ratios are different.
Is there anything I need to worry about? Is my bike going to ever be the same again? Have i been ripped off? And most of all... What the hell would cause such a major failure at only 6000 miles!?

Any Info would be much apreciated.. and sorry for having to read my essay!

Thanks in advance guys.

Ben
 

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u have put a 640 engine in whitch is not the same animal as ur 625 so the bike will not be as powerfull some more peeps on here will shead more light on ur probs . not the best but get the virtual drinks in buddy
 

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id rather spent the cash on getting your engine fixed least you know its a good one then, your new motor could shit itself anytime now . changin mains aint a big job and the motor must of been fucked for a 1500 quid bill.
 

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Discussion Starter #4
hmm ok, the engine is still 625cc and looking at the specs its still showing 55bhp from the duke... mine cant have been much more than that.
 

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you are paying 1100 for an engine fitted you know nothing about, what garantee are you getting with engine? you should of spent extra few hundred then you know you got a motor fresh from bottom up, as for carbs fit your carb on new engine, if its an fcr why are you gona run the other shit cv on it? just use your carb no probs.
 

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Discussion Starter #6
The engine comes with a 3 month warranty, but i can see your point. If you really think this is worth it I may well consider selling it on. From what i gather they are fairly hard to come by..

Any ideas on the cause of the main bearing failing... along with the long list of other faults?
 

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The engine comes with a 3 month warranty, but i can see your point. If you really think this is worth it I may well consider selling it on. From what i gather they are fairly hard to come by..

Any ideas on the cause of the main bearing failing... along with the long list of other faults?
mains just wear mate, ive build a few around that miles just luck of the draw or bad servicing by prev owners. sumone on hear had same problems but fitted a new stator and it was fine, maybe worth asking:D :p :D :p jokes aside dont let it put you off ktm they good ikes and at end of day machines all brake and need love. what area are you as swampy at marsh perfprmance is the lc4 daddy:D
 

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Mmmm what a choice (a) Rebuild a knackered engine? or (b) Insert another engine of unknown condition?

If rebuilding the engine - get it done by someone with a solid reputation and experience of rebuilding these engines - otherwise you will probably just end up wasting your money. There are a number of folk on here who might be able to give you some tips, depending upon where you live?

If you spend your limited budget inserting the Duke II engine, who is to say that the whole thing won't go pop 50 miles later?

Either way, I'm genuinely concerned that someone is about to rip you off big time. Do some serious homework before you go any further.
 

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Reading through your sad epistle, your inexperience has been painful to read.

Firstly the person who carried out the first service and noticed the filings on the sump plug. If that person really knew about KTM's, then I'm surprised they didn't advise you that a major (expensive) problem was probably heading your way at high speed. If this same person wasn't experienced in servicing KTM's, did they bleed the lube system prior to you riding off?

You mention riding the bike on an airfield - were you ragging the engine from cold and tempting fate with a major failure?

The KTM dealer that you took the remains to - Are they simply sending the major engine components out to a local machine shop to be 'tidied up' - before seeing how many brand new parts from the KTM parts catalogue they can bolt on and charge you full list price, plus labour for? £1500 seems muckle expensive to me - unless you are in London or Surrey or somewhere full of rich people with more money than common sense.

As the impartial Mr Oggo suggests - the expertise and experience is available - if you want to access it.
 

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did the bike lock up ? if it did not i dont think it would have a 1500 quid repair bill ... take the bike back and get the motor rebuilt by someone recommended on here , as lee mentioned swampy or lee himself .
for 1500 sheets i would polish ur rifle too :D
Gayher, you'd polish his rifle for a fiver..
 

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did the bike lock up ? if it did not i dont think it would have a 1500 quid repair bill ... take the bike back and get the motor rebuilt by someone recommended on here , as lee mentioned swampy or lee himself .
for 1500 sheets i would polish ur rifle FOR FREE :D
:eek:
 

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Discussion Starter #18
Even though these hard times, and bad luck etc, your comments genuinely made me laugh! I’d feel a bit weird offering that sort of service during the first conversation though haha!
Really fucking wish I mentioned this here before i jumped into an engine sale. I could understand the comments about the condition of the duke engine but the warranty got rid of any of MY concerns. Sounds Like i jumped into that too easily. £1500 sounded like an engine write off, for a pretty much standard engine.
The general idea I’m getting.. the duke engine was a bad idea..
As this is now sounding like rebuilding is the right idea, any ideas for returning this engine under warranty, for a full refund? Dodgy question maybe, but as King Karl has been mentioning rivers...
Next question, can anyone recommended around the Norfolk area? Plymouth for Marsh is a bit too far!
@restitution. I feel the same way about the first company who did the service, I wish it had taken it more seriously. First real bike... That’s my excuse and I’m sticking to it. Oh and no not from cold, always hot before I rode it hard. Although in 2 hours or so it had probably stopped and started quite a few times, I guess that’s ok?
 

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Even though these hard times, and bad luck etc, your comments genuinely made me laugh! I’d feel a bit weird offering that sort of service during the first conversation though haha!
Really fucking wish I mentioned this here before i jumped into an engine sale. I could understand the comments about the condition of the duke engine but the warranty got rid of any of MY concerns. Sounds Like i jumped into that too easily. £1500 sounded like an engine write off, for a pretty much standard engine.
The general idea I’m getting.. the duke engine was a bad idea..
As this is now sounding like rebuilding is the right idea, any ideas for returning this engine under warranty, for a full refund? Dodgy question maybe, but as King Karl has been mentioning rivers...
Next question, can anyone recommended around the Norfolk area? Plymouth for Marsh is a bit too far!
@restitution. I feel the same way about the first company who did the service, I wish it had taken it more seriously. First real bike... That’s my excuse and I’m sticking to it. Oh and no not from cold, always hot before I rode it hard. Although in 2 hours or so it had probably stopped and started quite a few times, I guess that’s ok?
you could try to get a refund on the 640 if it was from a dealer; or if not sell it on..

Lee (Mr tatoo) would do you a good job on the rebuild; - he's Surrey; or i know someone in Folkestone

nearer to you is Terry Rudd ( TRM racing ) he is a specialist Honda dealer but may do the work??

Terry Rudd Motorcycles.Fen Road,Holbeach. Spalding Lincs.PE12 8QD.

http://www.trmracing.co.uk/acatalog/
 

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Even though these hard times, and bad luck etc, your comments genuinely made me laugh! I’d feel a bit weird offering that sort of service during the first conversation though haha!
Really fucking wish I mentioned this here before i jumped into an engine sale. I could understand the comments about the condition of the duke engine but the warranty got rid of any of MY concerns. Sounds Like i jumped into that too easily. £1500 sounded like an engine write off, for a pretty much standard engine.
The general idea I’m getting.. the duke engine was a bad idea..
As this is now sounding like rebuilding is the right idea, any ideas for returning this engine under warranty, for a full refund? Dodgy question maybe, but as King Karl has been mentioning rivers...
Next question, can anyone recommended around the Norfolk area? Plymouth for Marsh is a bit too far!
@restitution. I feel the same way about the first company who did the service, I wish it had taken it more seriously. First real bike... That’s my excuse and I’m sticking to it. Oh and no not from cold, always hot before I rode it hard. Although in 2 hours or so it had probably stopped and started quite a few times, I guess that’s ok?
Talk to Chris at Xbikes.


X Bikes Ltd,

The Paddocks, Mill Road, West Walton, Wisbech, Cambridgshire PE14 7EU
tel:01945 585 533 | fax:01945 585 593 | [email protected]
www.xbikes.cc/home/
 
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