MTC Failure Disaster

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Re: MTC Failure Disaster

Post by jfink » Fri Apr 20, 2018 1:53 pm

Status Update:

The dealer is starting the rebuild on the SD. The Service Manager called me yesterday and said they are committed to getting me out the door as quickly as possible. Hopefully, I will be riding the SD again, by next week. They still don't know what happened and still can't tell me it won't happen again.

They ran into a snag while reassembling, that may be some of you could enlighten me on. They could not get the Spark Plug insert out of the head. This is either #8 or #45 on the diagram below. My 990 has aluminum inserts but on the SD they were plastic. They ordered new inserts but had to wait on KTM to tell them how to install them. When I take the 990 apart, those little buggers are hard to get out but they eventually come out with a little bit of insistence. I plan to do much of the work on the SD myself (if I keep it), so I would like to know if the removal / installation is basically the same, grab hold of it and twist?

Image

Also, I contacted Kevin Peterson with USA KTM/Husaberg/WP customer support. I have to say I am a little disappointed. The only real consideration I am asking for is that they restart the warranty. It was originally purchased in 9/2017, so the warranty expires 9/2019. If they restarted the warranty, it would last until 4/2020. Given that we don't really know why this thing cratered, and the loss of months of riding it, I think it's a small concession to give me 7 more months of warranty.

Kevin's response was KTM's "protocol" is to not discuss such things until the bike is back on the road. I am not sure why, but it is very frustrating to be on the phone and not be able to get, what I believe to be, a reasonable request negotiated.

Anyway, I have to admit to being a little excited about getting it back.
Joe

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Re: MTC Failure Disaster

Post by jjscsix » Sun Apr 22, 2018 1:57 am

Joe, I think I must have misunderstood what a spark plug insert is when you sent me the e-mail. What does it do? I assumed it was what the spark plug screws into, but it can't be plastic if that's what it is. I'm confused :?:
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Re: MTC Failure Disaster

Post by jfink » Sun Apr 22, 2018 6:14 am

Jim, I don't know if you can see the diagram, but the spark plug insert (#8 or #45) fits into the head and basically forms a seal between the valve cover and the spark plug indent in the head. Mainly to keep the oil from blowing past the valve cover or filling in around the spark plug in the head. The Service Manager said there is no procedure in the service manual for removal or reinstallation, so they called KTM. I think KTM called them back and told them how to handle this. Like I said above, I would guess it is simply grab hold, twist and pull. Reverse to install.

They actually got the engine and the bike back together. They started engine and found that the cam chain tensioner on the rear cylinder would not release. I don't know how they could tell on a KTM, they all clatter like an old wash machine. Anyway, they removed it and tried to make it work but still couldn't get it to release. They have ordered a new one, and expect to get it in on Tuesday.

Meanwhile, I am still waiting ...
Joe

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Re: MTC Failure Disaster

Post by jjscsix » Sun Apr 22, 2018 2:00 pm

Joe, I did see the diagram. Your explanation was perfect. Thanks. Hope you get it back this week. Whenever this shit happens I'm glad that we have multiple bikes to ride. I'd stroke out if it were my only bike.
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Re: MTC Failure Disaster

Post by mick shere » Sun Apr 22, 2018 3:44 pm

Hope they get you back on the road soon, hopefully they will restart your warranty, these are not cheap bikes and fantastic service should be taken for granted

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Re: MTC Failure Disaster

Post by jfink » Sun Apr 22, 2018 6:55 pm

jjscsix wrote:
Sun Apr 22, 2018 2:00 pm
Joe, I did see the diagram. Your explanation was perfect. Thanks. Hope you get it back this week. Whenever this shit happens I'm glad that we have multiple bikes to ride. I'd stroke out if it were my only bike.
I agree, although given my luck, 5 bikes may not be enough! :-)
Joe

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Re: MTC Failure Disaster

Post by jjscsix » Sun Apr 22, 2018 9:45 pm

jfink wrote:
Sun Apr 22, 2018 6:55 pm
jjscsix wrote:
Sun Apr 22, 2018 2:00 pm
Joe, I did see the diagram. Your explanation was perfect. Thanks. Hope you get it back this week. Whenever this shit happens I'm glad that we have multiple bikes to ride. I'd stroke out if it were my only bike.
I agree, although given my luck, 5 bikes may not be enough! :-)
I need to try that line on Cherl.
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Re: MTC Failure Disaster

Post by jfink » Thu Apr 26, 2018 11:17 pm

Guess what followed me home today? I think it just wanted to play with it's other KTM buddies.

Image

Runs really good, better then I remember it ever running. A few little start up bugs, low tire indicator (cuz it was low), fuel gauge misreading (a new one is ordered), fans staying on for a prolonged period (but KTM says this is normal). Would like to say more, but today is really nice day and I am headed out for a ride. :D
Last edited by jfink on Fri Apr 27, 2018 1:54 pm, edited 1 time in total.
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Re: MTC Failure Disaster

Post by jjscsix » Fri Apr 27, 2018 12:45 pm

I cannot see the picture again, but I assume you got the GT out of the shop. Sure wish I could ride with you today!
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Re: MTC Failure Disaster

Post by jfink » Fri Apr 27, 2018 1:56 pm

jjscsix wrote:
Fri Apr 27, 2018 12:45 pm
I cannot see the picture again, but I assume you got the GT out of the shop. Sure wish I could ride with you today!
Hopefully the picture is fixed. It was a good ride, with the exception of the bugs. The weather is absolutely perfect, are you sure this is Texas??? Gotta go out now and clean up the bug carnage!
Joe

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Re: MTC Failure Disaster

Post by DaveW » Fri Apr 27, 2018 8:07 pm

Joe,
Photo up I can see it all the way to NZ.
Nice one..... 👍
you will be a happy man
Ride safe and look forward to your future updates

🍻DaveW
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Re: MTC Failure Disaster

Post by jfink » Mon Apr 30, 2018 9:34 am

DaveW wrote:
Fri Apr 27, 2018 8:07 pm
Joe,
Photo up I can see it all the way to NZ.
Nice one..... 👍
you will be a happy man
Ride safe and look forward to your future updates

🍻DaveW
Thanks Dave, I have gotten a little riding in over the past few days and it seems to be as good as new. No issues to speak of, no warning messages.

However, I have one question. There is a small hose hanging down from what looks like a connection to the radiator (or possibly throttle bodies). It looks like it should be connected to a overflow bottle or something. There is a 10mm screw in the end and a clamp holding it in. I suspect this is not the way it came from the factory. It doesn't look right, at speed it would clang back and forth and possible hit the radiator. Is this the way it is on others???

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Re: MTC Failure Disaster

Post by jjscsix » Mon Apr 30, 2018 5:56 pm

Joe, make sure it is not the hose that runs across the front of the gas tank from side to side that equalizes the tank. On each side it attaches to a fitting under the gas tank that has a knob for opening and closing the fuel flow. If you ride very far it probably would have run out of gas at some point prematurely.
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Re: MTC Failure Disaster

Post by jfink » Tue May 01, 2018 1:41 am

jjscsix wrote:
Mon Apr 30, 2018 5:56 pm
Joe, make sure it is not the hose that runs across the front of the gas tank from side to side that equalizes the tank. On each side it attaches to a fitting under the gas tank that has a knob for opening and closing the fuel flow. If you ride very far it probably would have run out of gas at some point prematurely.
Jim, good advice. It very well could be the equalizing tube. Thanks.
Joe

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Re: MTC Failure Disaster

Post by jfink » Tue May 01, 2018 2:10 am

Just now, I spent a few minutes under the bike. This is not the equalizing tube, although that was a good guess. After looking at a parts fiche, I believe it is one of two hoses off of the coolant expansion tank, although, I don't believe it should be routed here. KTM Part Number 60035067001
Joe

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Re: MTC Failure Disaster

Post by Superdave99 » Tue May 01, 2018 10:45 am

joe, if u want a side by side look, comparing it to mine let me know. think we live close to each other. if mine is even routed correctly.... ran into you afew weeks back at whataburger/ kroger in willis :D

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Re: MTC Failure Disaster

Post by jfink » Tue May 01, 2018 11:33 am

Superdave99 wrote:
Tue May 01, 2018 10:45 am
joe, if u want a side by side look, comparing it to mine let me know. think we live close to each other. if mine is even routed correctly.... ran into you afew weeks back at whataburger/ kroger in willis :D
Dave, that would be great. I have 'tucked' it into the radiator shroud for the time being, but knowing where it should be would be very helpful. I plan to stop today at Cycle Shack and ask them. I hope to ride with Jim soon too, so that is another option.
Joe

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Re: MTC Failure Disaster

Post by jfink » Thu May 03, 2018 3:00 am

I took the SDGT into the dealer and they placed the plugged hose in the bundle of wires and hoses, on the left side of the engine. It is indeed a drain for the expansion bottle. Needs to be drained during maintenance, otherwise it should remain plugged. All is well ...
Joe

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Re: MTC Failure Disaster

Post by jfink » Mon May 07, 2018 1:15 pm

I now have almost 500 miles on the bike after the rebuild. After this morning it will be 600 and I will take it in for a 600 mile service, as suggested by the dealer. I haven't spoke to anyone about this, but hope that this service is covered under the rebuild, as it wouldn't be necessary had this not happened.

While reassembling the bike, the fuel gauge showed no gas, even though the tank was 3/4 full. They disassembled again, meticulously reassembled taking note of the float positioning and got it to work. But they did say, don't let it run out of gas because it may happen again. I said ???. They have ordered a new sending unit and will replace once it arrives.

Received a call from the KTM Customer Service rep. No joy on extending the warranty. He did say they have the history on this bike and will 'make it right' for me should something else happen. That could be taken a lot of ways.

It was good to get out on the SD and meet up with my buddy Jim at 'The Hill' in Bellville, yesterday. I do enjoy this bike.
Joe

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Re: MTC Failure Disaster

Post by jjscsix » Mon May 07, 2018 8:48 pm

Good to see you as always Joe. Good luck on the free service. I’m skeptical!

I’m glad you finally have a bike that will keep up. You’ve always been a great rider, but now you have the bike!
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