FE/FC KTM 500 EXC

[A.A]

Hi guys , i have a 2012 KTM 500EXC, that has the FE 501 engine (i was told).
Engine has 200 hours and the piston was changed at 100 hs. valves adjusted / chain changed at 170 hrs
i took it to the dealership to check the valves. Dealership says that the valves were difficult to adjust cause the whole engine is worn.
he started the engine (cold) started accelerating hard and we could see a little black smoke which he said was oil consumption.
Said the piston/rod etc had to be changed which is gonna cost a lot so better off to sell it and buy a new one.
problem is my oil level is always perfect / lots of power and black oil means fuel mix.
is there a way to check if it is time to change piston/ rod??
my guess is the guy wants to sell another bike but still afraid to leave it and break the whole engine.
What should i do?
i bought it a 150 hs guy before wasnt that much of a maintenance guy
Help please

 

[Weantright]

Black oil doesn't mean fuel but carbon from something not sealing. Black smoke at startup usually is fuel and carbon blowing out. Blue smoke at startup can be causes by valve train issues. Blue smoke letting off throttle is rings either compression or oil. I would take it to another shop because you can't determine much just starting the motor. Did they do a leak down? Pull valve cover? Pull head??? At most a complete rebuild which would cost lot less then a new bike. If you go this route skip the dealer since they tend to have higher labor rates. At 200 hrs this motor is still young IF it was taken care of. First step is to remove the motor from frame. Then tear down verifying parts.

 

[A.A]

Black oil doesn't mean fuel but carbon from something not sealing. Black smoke at startup usually is fuel and carbon blowing out. Blue smoke at startup can be causes by valve train issues. Blue smoke letting off throttle is rings either compression or oil. I would take it to another shop because you can't determine much just starting the motor. Did they do a leak down? Pull valve cover? Pull head??? At most a complete rebuild which would cost lot less then a new bike. If you go this route skip the dealer since they tend to have higher labor rates. At 200 hrs this motor is still young IF it was taken care of. First step is to remove the motor from frame. Then tear down verifying parts.

Hi weantright!
i meant black smoke not black oil.
well the thing is we only have one ktm dealer in my country and i am afraid giving the bike to some other shop cause they wont know and dont carry parts.
i dont know exactly what he did open only what he told me that he was 4 bolts away from opening the piston.
he told me that the autodecompresser was worn , that he had to remove the chain to fix the valves and that took him time cause 'something' was too 'high'. that 'something' too high wouldnt let him fix the valves easily...
sorry i know its not too clear but the guy kept on pushing me to buy another bike
all i want to know is if i can still ride the bike for like 100 hours before i open it and change everything on it.
by the way i do not race it , i only ride on the dunes of sand , intermediate level
thanks man

 

[bikesparky]

My friend you have been conned! This is the easiest motor to do the valves on. Order yourself a hotcams shim kit and some feeler gauges and do it yourself!
Even if you never done one, it can be done within the hour.
Link here to is a very good youtube on the net which shows you how to.
These engines are very well build and I never heard of the auto decompression been worn. It's a centrifugal arm and a pin. If you take the valve cover off you can inspect it by hand.

Black smoke is excessive fuel and could have several reasons, get you bike out of that shop!

 

[A.A]

Thanks bikesparky!
i am gonna check your link. Ride a little before i do it myself!!

 

[A.A]

Here is another question!
The dealership told me that changing Piston/rod wasn't that good idea for a 2012 with 200hrs cause the bike will have too much compression and that will kill the starter and bendix. then i will have to change them aswell. Is that any true?
Thanks

 

[Brapman629]

Here is another question!
The dealership told me that changing Piston/rod wasn't that good idea for a 2012 with 200hrs cause the bike will have too much compression and that will kill the starter and bendix. then i will have to change them aswell. Is that any true?
Thanks

I've never heard of such a thing. I mean a weak starter and a high compression race motor probably don't mix, but your just freshening it up. Like Bikesparky said that dealer is trying to get some serious money out of you!

 

[Weantright]

No not really, true in the case you will have better stock like compression and the starter system is a bit worn. If this was the case 2t's would be replacing them after every start!

What was "too high"?? the tech??

 

[reveille]

New piston at 100 hours? Odd for an exc. These single cam engines will go much longer. Something is goofy with the dealership imho.

 

[Baddrapp]

It sounds like the dealer is screwing you over or does not want to work on your bike. He wants to sell you a new bike. Go pick up your bike. Take it to another mechanic. It does not have to be a KTM dealer. But, in the long run it's your bike and money.

 

[racemx904]

find another dealer lol

 

[juicypips]

Eff me! You need to take your bike else where! Im a 2stroke lad through n through but you are not sorting the wheat from the chaff!

A) your oil level is fine.
= rings fine
No leakes else where
B) black smoke on instant cold start up
= exhaust warming up -= no oil usage completely fine chill.

Remove your bike from that guy A.S.A.P. = now****************************************!

Yes check valves
Yes change filter
Yes change oil.

If it starts using oil or changes valve clearance then yes take it to someone who knows.
But your riding a KTM500 your a big boy so do the maintenance yourself if you don't know get to know!

A manual is a beautiful thing.
Tools 1 better.
Sorting it yourself. Priceless!!!

 

[bikesparky]

Here is another question!
The dealership told me that changing Piston/rod wasn't that good idea for a 2012 with 200hrs cause the bike will have too much compression and that will kill the starter and bendix. then i will have to change them aswell. Is that any true?
Thanks

Does this dealer has an exceptionally long nose and is his name is Pinocchio?
After this I would actually report this guy to KTM as he should not have a dealership! He is not only ripping off customers big time but also gives the brand a bad name.
The 500 engine is probably one of the more solid ones in the range, and in general KTM engines are pretty solid.
There is a 501 here that has well over 150 hours on it and besides oil and filter very 5 ish hours it has had two shims changed to adjust the valves and he just put the 3rd spark plug in.
The spark plug is precautionary as it was probably not worn, they come with Iridium tip originals.
For the rest the head never been off and it's inspected all the time to see how it does. No knocks, no play, no abnormal wear, no crap in the oil. I don't think the clutch has been changed neither, I'll ask when I see him.

This dealer is really doing a number on you!

 

[A.A]

Thanks for the replies.
From now on i am doing everything myself!
I downloaded the service manual but i couldnt find the repair manual. if anyone has a link please!
i changed oil this weekend after 500 km of use and i noticed that level is perfect and both oil screens are clean .
no residues at all i even used a piece of cloth to check all the oil for aluminum/steel residues but nothing.
So i guess i ll keep on riding some more!!