Time between overhauls

[Simmo737]

Speaking with other riders with way more experience than me the other day and the conversation concluded that:

Husky and ktm's trail ridden in:

1. Non competition (roughly meaning the engine spends most of it's life below 10,000 rpm and almost all below 9,000, especially at constant speeds)

2. Oil changed every 250km or 5 to 7hrs. Minimum of semi synth oil

3. Air filter changed every ride or day if multiple day riding in non desert/ dust environment and more protection if you are.

4. Valve clearances always maintained within spec.

5. Drivetrain maintained at all times (clutch, sprockets and chain tension)

6. Fresh fuel 98 Ron and not made by Shell.

You can expect minimum 200hrs plus from a top end and double from the bottom. Ktm's will burn through valves quicker, maybe 120 hrs subject to fuel. Husky is rumored to strip gears on occasion, but rare.

You will get more niggly ancillary system issues than japanese brands, but the faults are generally a known item with an easy and cheap fix or precaution to deal with them.

Japanese water-cooled engines won't always get these sorts of hrs, especially Honda.

Are these reasonable statements when considering huskies?

 

[Motosportz]

Short of a few bad Con rod bearings these are long lasting motors.

 

[be350ka]

Wow, what timing! I was just signing on to ask the same questions.

As you may know, I am considering a TE510 or a 530 EXC. After much research I am quickly coming to the conclusion that the KTM is a little more "needy" than the Husky. Some are saying that the older motor in the 525 was much "stonger" ie. read longer lasting and more durable. People seem to be doing MAJOR work on the Orange side at around 150-200 hours (top and bottom).

With fairly regular use (Sumo-70% and Trail-30%) and attention to maint, what kind of life can we see out of the Husky engine top and bottom? Any tricks that can prolong the life of the bike? I am used to Italian Sport bikes and when I first got involved with them I thought that $500 for a Valve and Belt check every 7,500 miles was a lot of maint. That thought has subsided, but the thoughts of 200 hours on a thumper requiring a FULL rebuilt is tough to swallow. I don't want it to sit in the garage, I want to ride it and not worry about the "hours" ticking away!

Thoughts?

 

[Slowpoke]

Over 350 hrs on my 07 TE250 so far(9700kms). Based on an inspection done in the spring, it should be good for many more hours. I think I've only ever had to adjust 2 or 3 of the valves once each. It's doing mostly commuting and lighter DS stuff now, with my 09 TXC doing the harder stuff(110+ hrs now). That being said, I know of an 08 TE250 that dropped a valve at 280 hrs, costing a bunch of $$$. KTM RFS motors can be at both ends of the scale. I know of a couple guys with 525s that have over 400 hrs on them, no issues. I know of others that have struggled to get 200hrs before doing the top end.
Not sure what kind of life the newer KTMs are getting.
I think RayRay has a crap pile of hours(over 500) on his TXC250.
Some of the Honda CRF-X's built 06 & later can get decent service lives. Some Yamaha WR-F enduro bikes also.

 

[Planepower]

I cant give you too much long term test info - but from what ive gathered so far is; (started with a 07 TC250 in 2009)
TC 250 has only 2 sets of rings and are prone to wearing (smoking) sooner i.e. piston and ring replacement.
The 250 bottom end shares much from its big bore brothers so should last longer.
The 450/510 SMR/TE uses 3 piston ring sets, so should last longer than the TC (or aftermarket hi-comp pistons).
I havent noticed mush in cylinder wear from any of my bikes.
The 450/510/530 will beat on the crank pin and that is the most likely reason rebuilds are required - if ignored, the pin will wear and allow interference with piston to vavles, thats when it gets costly!
Just an idea of costs (not including disassembly/reassembly labor) - crank / con-rod kit ~$250, piston kit ~$200, crank rebuild ~$100, Cylinder replating ~$165, gasket kits ~$200.
I dont think it matters what type of bike youre going to have, the only differences are OEM parts prices, they will all need rebuild - you either do it before it blows up or pay substantially more when it does. Any of these small displacement (under 1000cc) high output engines are designed for competition usage.
If youre looking for longevity, and minimum maintenance get a DRZ or XR, or one of the street designed Dual sport bikes.
My 250 have probably over 100hrs on it, it smokes when first started then clears up when warm, my 450 has been freshly rebuilt and is a monster (easliy pulls on SVX's and my friends Husa FS550) - it has a countdown timer instead of an hour meter.
Another friend has a 09 SMR 510 with over 7500 km and starts and runs fine, no clunks or clinks. (Its not a race machine, just his street play bike).
Be honest on how you intend to use the bike - the longer its life is towards redline will dictate its life.