I've broken 7 spokes in my front wheel. After the first 3, I replaced all of them. Then replaced 4 more. It's always the disk side at the hub. The last one popped while I was sitting at a stoplight. Anyone else had this trouble?

There seems to be a problem with several wheels, almost apearing during the first 1000-6000km. Heard that some peopel were in serious troubbles after a pokes broke on the motorway. Best will be to ask on

http://www.reiseenduro.de/cgi-bin/forum/config.pl

those guys have an answer to most KTM problems and this topic was discussed there already. It's a german site but you can ask in english as well.

Thanks, I'll look in to it. I called ktm usa, they said they would get in touch with me. I'll see what happens.

yes! there are more.....
i found in germany 5 people with spokes ruptures, even with a broken leg when he hit the tarmac
these problems are from 2000/2001
myself had the same experiance on the highway with a blow out tire in the front, i dont have to tell you wat this means.my bike is from 2002 with 6000 km.
for me the problem is the bore holes in the hub, they are not in line with the spokes and rim, and they all braek on the place they leave the hub.
this is a safety item, and must have the highest priority for ktm, but there are NO service bulletins with the dealers.
KTM shame on you!!!!!!!!! must people get killed????

i wrote a letter to KTM 2 weeks ago, till now no reply.

greetings jos

Just to add my two penneth, the same front tyre blow out routine happened to me a week or so ago while travelling through Iran. A spoke snapped on nice flat tarmac for no apparent reason at 100 kph and mashed the innertube. It was the third spoke to go in three months and 10'000ks but the only one to hole the tube. It was a very scary moment and not one i wish to repeat.

Anyone any suggestions on remedial action on the bike or suggestions on getting together as a group and lobbying KTM to get them to sort it??!!

Will

All of mine have been on left side, closest to the disk. I'm still waiting to hear from KTM.Only suggestion I've gotten it to chanfer the soke hole on the hub.

the only thing you can do to avoid a blow out tire is to take some riggid tape[ducktape]
and wrap this around the inside of the rim,[2 or 3 times]the spokenippel is now unable to rip the innertube.

Best way to prevent the broken spoke form puncturing the tube is to keep it from flopping around in the first place.

I safety wire my spokes to each other. Just use stainless steel wire tightly wrapped around the junction where the spokes crossover.

This greatly strengthens the wheel, and reduces spoke breakage, and in the event of breakage, the spoke is tightly wired to another spoke, so no problem. Just remember to check it occasionally!

------------------
Grant Johnson

Seek, and ye shall find.
------------------------

One world, Two wheels.
www.HorizonsUnlimited.com

Safety-'wiring' the spokes is good enduro-practice. However, the wheel might get more rigid and thus LESS 'strong'. To stop the spokes from flopping around you can tie-wrap the crossings and this does not make the wheel less flexible. The age old enduro-practice was wrapping electricians tape around the crossings, but tie-wraps are far easier and quicker. The disadvantage they have in respect to tape is that the cut ends can be quite sharp and will cut your knuckles when washing the bike. I still use tape. Nowadays it's available in several colours so you can colour-match or -mismatch it.

Oh, to be complete: on the front wheel you only need to tape the ones on the disc side. If your bike has twin disc, well, you'll have to do all.
On the back it depends on wether your bike has a transmission-damper. With one, agian only the disc-side needs to be taped. If not, well, once again out of luck.

You'll need only 2" of tape per crossing and
start the tape in such a way that the end will be be with the direction the wheel turns on the outsine of the wheel. Less ends get flapping that way.
Pulling the tape is better then cutting it. For some strange but practice proven reason, the pulled ends stick better.

KTM wants to know what the spokes are torqued to. I don't have a torque wrench for the spokes. Talked to my dealer, funny thing they don't have one either! Love the bike, but this spoke thing is becoming a pain. How many spares do I bring on a ride?

Owfull to say "me too" but...

On my first '00 Adventurer 7 spokes were broken on the front wheel and 3 on the rear wheel in 33KKm... I almost falled out from a mountain gravel road on the alps when a spoke blow my front wheel...

With my '01 5 on the front and 2 on the rear.

the safety wiring seem useless... I allwais wire my spokes and they are allwais properly tensed by mi tire reseller...

Badwolf

I got a call from my dealer today. The spare spokes I ordered had come in. Then the service department called and said KTM is shipping me a new front wheel, should be in ina few days. They said they hadn't had any other complaints, but sent me a wheel. I guess I'll put the new one on and see what happens. A response in 2 weeks, not bed. I'll keep you posted.