So, I likely will never own another ktm after this bike, its been nothing but problems since I bought it, I fix one thing and up crops another.
My Son hasn't even gotten to ride it long enough to actually get fast on it.
First I bring it home from the dealer in 2013 as a slightly used 2013 model, someone supposedly bought it and it was too fast.
First night home all the oil leaks out all over my basement floor.
I find out the dealer had been into the side cover for some reason and destroyed the threads on the case using the wrong size bolt. I called them up and all they would do was sell me the case half at dealer cost... Mind you it was right after I bought it!! So I helicoiled that bolt hole instead of dealing with perhaps the worst dealer ever.
Next the rear shock breaks.
Next the kicker gets stuck down, so I replaced the little C spring after reading how common it was.
Next it starts overheating. So thinking it was running lean from sitting so much since it was new, I cleaned out the carb and checked for air leaks.
Then the ignition stator burns out. Replaced it with over priced ktm unit.
Then the reed valves break.
ALL of this has happened... in less than a liter of motul through it. I'm not kidding I still have the original liter of motul (half full) that came with the bike. He hasn't rode it because he lost interest because its always broken. Most of the premix I add ends up getting drained and used in my lawn tools so it doesn't go bad, since this is always breaking.
So today he wants to ride with his friend, so I take him out and all the sudden the thing sounds like the gear box is a buzz saw. The kicker lever tries to jump down and its making grinding noise.
I took it apart and I see nothing wrong, but the gears are making a terrible noise. When he rides it, it sounds like its about to explode and to top it off its running hot again.
So, any advise would be appreciated, I'm going to upload videos of the gear box and him riding in the field on it making the noise. Its intermittent so you have to listen for periodic grind noise.