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Discussion Starter #1
Hey Everyone,

You may all remember me from my recent posts regarding having a replacement engine installed under warranty after it failed. The bike was off the road for 13 weeks whilst KTM took their time un-crimping their buttholes to make a decision to replace my engine.

NOW there is another major issue. So I had the bike in at my local KTM dealer to have my warped discs replaced and the first 1,000km break in service. (KTM refused to honor the warranty on the discs).
The mechanic uploaded a new map for the Akra and updated software, etc.

The next day I embarked on a 4 day trip to Mt Hotham, twistie-heaven. I noticed almost immediately that the quick shifter wasn't responding well at all so I was using the clutch for most of the trip. The quick shifter only responded between 1st-2nd gear, and even with the clutch, 5-6 change was clunky.

So, back to the mechanic to take a look and after 2 days of KTM head office looking at the mapping (apparently they do it all remotely), they have confirmed that they cannot calibrate the QS. They cannot load in any parameters for the gear shift position sensor or QS sensor. They replaced the sensors, still no luck.

Now I'm in a quandary. I'm waiting to hear back from KTM Australia to give my mechanic the go-ahead to pull the motor again and strip it, to replace the internal GP sensor which apparently sits on the end of the shaft on the inside of the casing and can only be replaced by splitting the casing and removing the engine from the bike.

I suspect my bike will be off the road again for another month.

I use my bike to get to work every day and my local dealer doesn't have a loan bike.

What should I do? I am really at the end of my tether with KTM. I have spent a **** load of time and $$ on this bike. It's a lemon. What is going on with quality control KTM?

The only resolution I see now if this has to happen is I'm going to take KTM Australia to the ACCC and OFT and demand a brand new replacement bike, which I will then trade in with 0km on the clock for an Aprilia, Ducati or Triumph.

I'm so over this ****, it's blown my mind. I had an Aprilia Tuono V4r before this bike. I did 65K over 4 years and it never missed a beat. The quality was amazing. Reliable and fun bike.

I would really appreciate everyone's thoughts on this situation?

Cheers,
 

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Once you have ongoing issues with a bike it's hard to shake that frustration/disappointment/anger every time you ride it.
You also have the feeling of 'am I getting home today'.
I don't know the lemon laws here, I'd see what the ACCC say.
If the law allows for a full refund I'd go with that rather than trying to trade-in a new bike.
Good Luck
 

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Gee Mobcrimeboss, that is one big bunch of bad luck, did you run over a black cat or something.
Just so none of my mates buy yr bike 2nd hand where are you.
As for KTM Aust, dont forget they have just been through a transfer of ownership from an Oz company over to KTM, I hear things didn't go well with the changeover.
Personally I would put it down to "sh#t happens", leave the QS as is, fix the disk and sell the bike.
In my case the most unreliable bike I've ever owned was a Honda, so its not just KTM.
 

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After my first oil change, I brought the bike to my dealer to "calibrate the shift sensor" as it was on the first service and the tech looked upset. He said every KTM he hooks up to do that on, it's very finicky. Took about 6 tries on my bike following the instructions on the diagnostic tool exactly but we were able to do it.

I felt really defeated after having several warranty issues on my bike initially and was ready to throw in the towel. I can only imagine how you must feel after a blown engine. Certainly wouldn't blame you for moving on to something else.

On a side note, do you have the full Akra Evo exhaust? A decat? How does the Akra map feel? Was the bike modified before the engine blew?
 

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Discussion Starter #5
After my first oil change, I brought the bike to my dealer to "calibrate the shift sensor" as it was on the first service and the tech looked upset. He said every KTM he hooks up to do that on, it's very finicky. Took about 6 tries on my bike following the instructions on the diagnostic tool exactly but we were able to do it.

I felt really defeated after having several warranty issues on my bike initially and was ready to throw in the towel. I can only imagine how you must feel after a blown engine. Certainly wouldn't blame you for moving on to something else.

On a side note, do you have the full Akra Evo exhaust? A decat? How does the Akra map feel? Was the bike modified before the engine blew?
That's good to know. I was going to ask the mechanic to explore the option of changing out the ECU and/or pads cables, etc to see if it is an electronics problem first.
I have the Akra Slip-on and cat. KTM has released a map for the Akra slip-on. It's really smooth compared to stock. The bike had the Akra fitted from new running the stock map. The engine failure was bizarre. Basically was spewing all the oil into the airbox. Compression, leak-down and rings were fine. They put it down to some kind of failure in the casing causing extreme blow-by.
 

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That's good to know. I was going to ask the mechanic to explore the option of changing out the ECU and/or pads cables, etc to see if it is an electronics problem first.
I have the Akra Slip-on and cat. KTM has released a map for the Akra slip-on. It's really smooth compared to stock. The bike had the Akra fitted from new running the stock map. The engine failure was bizarre. Basically was spewing all the oil into the airbox. Compression, leak-down and rings were fine. They put it down to some kind of failure in the casing causing extreme blow-by.
Interesting. I was only aware of the map for the full Akra Titanium EVO system. I'll have to ask my dealer about the slip-on map.
 

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Now that I think about, there were quite a number of people that needed that shift sensor calibrated, and many did have a go at it a handful of times.
 

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After my first oil change, I brought the bike to my dealer to "calibrate the shift sensor" as it was on the first service and the tech looked upset.
My QS was not working at all until the 600 mile (1,000km) service. the schedule says: "Program shift shaft sensor".
 

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My QS worked beautifully prior to 1st service but afterwards not so good, lots of gear crunching.
Didn't worry me as I prefer the clutch anyway, clutch action is light and gear changes are as smooth as a knife in butter, so no big deal.
From 2nd gear onwards just pull the clutch in about 10 mm and gear changes are as smooth as can be.
 

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Sounds like u've had a sh1t run there mobcrimeboss. I'd be pretty pissed with KTM Australia not honoring warranty on the warped discs, let alone making u put up with not having a bike for ages.

I'd be seeking some form of compensation for KTM Australia and submitting a case to DFT.

Good luck mate.
 

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Interesting. I was only aware of the map for the full Akra Titanium EVO system. I'll have to ask my dealer about the slip-on map.
I doubt they've done a map just for the Akra slipon, sounds like the map they did for the standard bike which improved the low rpm response.
 

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Discussion Starter #13
That's what I'm thinking. Going to try to stop by my dealer sometime today.
That's what i thought. Apparently KTM has released a map very recently just for the Akra slip-on. I noticed it is definitely smoother down low. Don't notice a difference above 5K but i'm sure they worked out the fuelling.
 

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I had last week the 1.02 Up Date and had a little hope that there was a Quick Shifter Up Grade included. But not, the KTM 790 Duke QS is as the German MOTORRAD Magazine called a capricious item.
 

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I had last week the 1.02 Up Date and had a little hope that there was a Quick Shifter Up Grade included. But not, the KTM 790 Duke QS is as the German MOTORRAD Magazine called a capricious item.
It doesn't need a software upgrade, just re-calibration. Mine went from crap to perfect after re-calibration.
 

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Discussion Starter #17
Here is an update on the situation.

My local KTM mechanics (who are awesome btw) are still waiting for KTM Australia to authorize further action to be taken to get my bike fixed. They think they might need to pull the engine out and split the casings to inspect the gearbox. There is an internal sensor on the drive shaft that could be faulty but they aren't sure.

I have already waited for a week and still no action. The bike is running but not all parameters are loaded. I'm getting no gear indication, false neutrals, the gearbox is really clunky and yesterday for no reason my engine overheated and shut down in traffic. There was coolant spurting out of the overflow.

So I've had it. I have written to the manager of Procycles to ask for either a full refund or a new replacement. I would prefer a refund.

I followed up with a phone call yesterday to his personal mobile to explain the situation and to let him in the kindest possible way know that because I have no recourse with the manufacturer directly, fair trading wants me to follow due process to resolve this issue once and for all.

Let's just say that he wasn't very receptive on the phone and hung up on me.

If i don't get a positive response by tomorrow i'll be proceeding with the OFT and ACCC again. Will update this thread once I have an answer.
 

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Let's just say that he wasn't very receptive on the phone and hung up on me.

If i don't get a positive response by tomorrow i'll be proceeding with the OFT and ACCC again. Will update this thread once I have an answer.
I've heard some shocking stories about Procycles Hornsby and St Peters. Hence I bought my bike elsewhere. Hope it works out for you mate. Keep us posted.
 

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I guess I've been lucky. My local KTM dealer in Darwin is amazing and the mechanics have been awesome. I had a very minor oil leak from the valve cover gasket so they decided to change all gaskets on the engine (cylinder head and oil sump gaskets) at no additional cost whilst it's still under warranty. When they did the firmware update too I noticed an improvement in smoothness at the bottom end (not so jumpy anymore during low rpm's when idling along). The dealer up here loves his KTM's especially motocross bikes so he makes sure his mechanics are well versed and trained by sending them off to learn from KTM.



I also noticed a dead pixel on my TFT screen recently so mentioned that to my dealer and he's recorded it so that if it dies on me or gets worse it will be replaced even after the warranty period runs out. My QS runs very smooth too and I don't get any false neutrals now (I occasionally did but it might just have been me). Maybe the bike has run in well or I've just been lucky? I don't know. I'm getting close to 14,000KM on the clock so due for it's 2nd service very soon and I am always confident the boys will do a good job on my bike.
 
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