Loose frame on KTM 640 - Anyone had this before?

[Kobus Myburgh]

After the last ride with the 640 the whole bike felt as if it was going to break in half with the centre of the bike 'pivoting'.

Over the weekend I stripped it down to the frame and was astounded to find that the entire frame at the top was no longer attached.  Has this happened to anyone before?

I also question the following:  I had my fork seals done end of last year with a reputable dealer and after the first ride found that one of the bolts on the triple clamps are missing!  Then I had my carburettor worked on at the same dealer to replace an o-ring and now that I stripped the bike to the bone (well, sort of) I can just imagine that the carburettor is removed a lot easier if the frame is loosened at this exact position.  I am no mechanic, but can my theory be correct that these guys just don't know how to tighten a bolt?

If so, I would like to share this experience with the dealer's guys (without getting nasty) to avoid this happening to someone else, which is bloody dangerous.

[sidetrack]

Or it just vibrated loose ?

[Kobus Myburgh]

Or it just vibrated loose ?

While the bike is open, I checked every other bolt and nut.  Unless this is the concentrated point of all/worst vibration, why is only this loose?

[Jughead]

Yes, the subframe needs to be removed or at least lowered in order to move the airbox back for the carb to be freed from the intake manifold.  My guess would be that they forgot to tighten them again.  Also check on the two lower subframe bolts.  They would also have had to be removed or at least loosened to be able to pivot the subframe.

[Kobus Myburgh]

Yes, the subframe needs to be removed or at least lowered in order to move the airbox back for the carb to be freed from the intake manifold.  My guess would be that they forgot to tighten them again.  Also check on the two lower subframe bolts.  They would also have had to be removed or at least loosened to be able to pivot the subframe.

This makes sense Jughead - come to think of it, the last time I cleaned the bike (prior to this incident), when moved onto the centre stand, I felt the bike was loose in the horizontal direction and actually fastened the bolts on the subframe, but never considered the top.  These were the only bolts that was loose.

I'll go and have a chat to the guys over the weekend - this is just not acceptable from a KTM dealer! 

[Kobus Myburgh]

This is how much the frame moved back when I took the tank off and pressed on the rear of the bike!

[Jughead]

This is how much the frame moved back when I took the tank off and pressed on the rear of the bike!

Yip, the exhaust is attached to the subframe so will pop out if the subframe is moved.

Loosen the exhaust from the frame and unclip the springs from the head to push it back in.  You will most likely damage the packing if you don't.

[Kobus Myburgh]

This is how much the frame moved back when I took the tank off and pressed on the rear of the bike!

Yip, the exhaust is attached to the subframe so will pop out if the subframe is moved.

Loosen the exhaust from the frame and unclip the springs from the head to push it back in.  You will most likely damage the packing if you don't.

All sorted, putting back together again the weekend. Thanks Jughead 

[Jughead]

This is how much the frame moved back when I took the tank off and pressed on the rear of the bike!

Yip, the exhaust is attached to the subframe so will pop out if the subframe is moved.

Loosen the exhaust from the frame and unclip the springs from the head to push it back in.  You will most likely damage the packing if you don't.

All sorted, putting back together again the weekend. Thanks Jughead 

 

[Kobus Myburgh]

So went to the dealer yesterday and ordered new parts, ie tail light and air filter boot that got damaged.

Showed the pics to the owner and his workshop manager and they admitted that the most probable cause is not tightening the subframe properly.

Very apologetic and said they would make it up to me. We'll see once I go to collect the parts and have to pay. Think I should take the bike there for them to reassemble?

[TheBear]

So went to the dealer yesterday and ordered new parts, ie tail light and air filter boot that got damaged.

Showed the pics to the owner and his workshop manager and they admitted that the most probable cause is not tightening the subframe properly.

Very apologetic and said they would make it up to me. We'll see once I go to collect the parts and have to pay. Think I should take the bike there for them to reassemble?

Where humans are involved, sh!t is bound to happen.  The true test is do they admit to the possibility that they caused the sh!t and how they plan to make up for it.  Seems your dealer is a good one.

[Kobus Myburgh]

So went to the dealer yesterday and ordered new parts, ie tail light and air filter boot that got damaged.

Showed the pics to the owner and his workshop manager and they admitted that the most probable cause is not tightening the subframe properly.

Very apologetic and said they would make it up to me. We'll see once I go to collect the parts and have to pay. Think I should take the bike there for them to reassemble?

Where humans are involved, sh!t is bound to happen.  The true test is do they admit to the possibility that they caused the sh!t and how they plan to make up for it.  Seems your dealer is a good one.

So, after what seemed like a lifetime of waiting for parts, I took a drive to the dealer on Saturday to find out if they even ordered it.  Low and behold, all the parts were there but they never even bothered to let me know - 3 weeks later!

Then it came to paying for the parts (which needed replacement because of their poor workmanship) and I started chatting to the owner of how they propose "making it up to me". 

His response:  "I'll give you 10% discount and then I only make 10%.  That way we'll meet each other half way."

This after I nearly came down at 145km/h because of their (admitted) poor workmanship!!

Needless to say, I told him where those parts could go and walked out with nothing.  Went to another dealer, ordered the parts and they even offered to install them for me at no cost, even though there is no affiliation between the dealers.

What a disgrace for the KTM brand.