07 Ktm 450 Xcw Help!

What to do, What to do?

I have spent a fortune on this bike, Scotts stabilizer, FC suspention, rebuilt just 300 miles ago, fuel screw, boyson qs2, the list goes on and on! I spent $3,000.00 3-400 miles ago, this bike is dialed in for me, my wt and riding style, or lack of it.

I rode the Classic and took some mud on in a mud hole. I am told I need a NEW engine and it will run approx $2,500.00-$3,000.

Here is where I need some advise.

I am a public servant and don't have money to burn again.

I can part the suka out, I have never done this and it sounds like a lot of work. What could i get for a blown up bike?

Anyone know where to buy a complete new engine?

How about a used engine. Can a 525 fit in the 450 frame?

If i could break even, I would love to switch to a cheap 2t. No more $1,000.00 rebuilds.

I am old and slow and nerotic about maintanance, I just have no luck.

Any and all advise is apreciated.




A little more info.

Yes the bike runs, smokes alot.

I just did a complete top end rebuild at Masons and it was around 800.00.

They took the filters and screens and saw mud in there and in the carb.

I was told once the dirt circulated through the bottom it is very bad.

They are looking into the cost of a new engine and thought it might be $2,500.00-$3,000.00.

I do the minor stuff, but rebuilding a 4 stroke is out of my league.

The bike was running better than new. I stalled in a mud bog on Saturday. I did not think it was all that deep and I did not fall over. My feet did not even get wet, I have been in worse. My electric start had already shorted out and I stupidly kicked away in the puddle. I finally gave up,put a new fuse in and it fired right up with the e-start.

It rode fine until near the top of the ledges where it stalled and then I was hearing some top end clatter. Bike cooled down and ran fine back to camp.

I rarely rev this bike and change the oil and air filter every 10 hrs.

At camp I could not see the oil in the window, well very low and I had to tip the bike to see it.

I put in a whole liter.

When I started it it was now smoking worse than a rich 2t.

I assumed that the sight glass was smoked and I could not see oil now either.

The bike rode fine, although I did let Lafferty pass me as I did not want to push the smoking beast. I assumed extra oil would burn off and not damage anything if I kept the rpms down.

I made it to the first reset, 10 miles and the bike started running like it was not carborated right. I dropped the oil and the brand new liter was black and smelled burnt. The magnetic drain plug was covered in what looked like mud. I assumed it was metal clutch material, the magnetic nipple was not visible.

I gave up and got a ride back to camp.

I spent all my $ in the last rebuild and decided to keep the bike and sunk $3,000.00 in motor, carb, plastics, tires, chain, sprockets etc...

Masons did a great job, but I am busted and my wife will leave me if I spend that much a second time 300 miles later.

Thanks for the help.


I am uncertain how the mud got in as the air filter was clean and I stuck a paper towel past it an it was also clean.

If my crank case breather hose was rerouted into the air box, where whould mud get in.

I did kick it numerous times in the hole. could enough mud get sucked up the carb hose to do it.

They did find mud in the carb.

I think Mason's is giving me the worst case scenario as they have not taken it apart yet. They are a great shop, not cheap, (like all shops) but definately fair and only sell KTM, so the know these bikes better than most.

I love a good mystery, just not an expensive one.



Kevin I agee, I love mud and am the idiot who goes back and forth through the mud holes. My feet did not even get wet. I did kick it a hundred times before pulling it out and starting it.

I trust the shop and they may be more interested in top performance right now than I am interested incheap just riding.


It Pays to Play!

Ow, That's going to leave a mark!!!

Ride faster and you will get farther.

Wow I can't believe that nobody chimed in to help this guy. Outthumped, I hope everything worked out. I would check e-bay for used engines, or better yet find a friend who will help you rebuild the thing. It's not that hard if you take your time and have a good shop manual.

As his problem was 17 months ago, I assume he either got a new engine or sold the bike. He has only posted one post ( in November this year ) since his problem. In my opinion, there was something strange going on with his engine, and it would be interesting to hear how things went. ??

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