Last week my bike developed a nasty noise from inside the engine and I took it into George White as is it still covered by the 2 years warranty, and the mechanic initial suspicion, having heard the noise was that perhaps the crank shaft bearings had worn out and so my bike was sent to their Swindon branch to be stripped and repaired, today I've got a call from them telling my bike it's fixed and it was something a lot less serious as what we initially thought, and what did happen was that the Primary Driven Gear (see manual section 5 page 47) had worn out and when it does that, it makes a nasty noise when the bike is idleing but then once you get it in gear and go its back to normal as this primary whatever gear is idle or not in use? anyway, the good news she is on her way back to me in a van either Sat or Mon so I am definately up for the Boxhill meet on the 30th.

woooohoooooo!!!

p.s. Kev, matey.... can you explain what the *blip* does the Primary Driven Gear do exactly and why, or how comes it wore out on my 20'000 miles? is there a way to avoid that to happen again? less wheelies, burnouts, heavily powering out of corners maybe?

The primary gear is the large gear on the clutch hub. The crankshaft rotational drive is transferred from the crankshaft primary drive gear to the primary driven gear through the clutch hub then to the gearbox.

Captmoto you must check with the bike shop, they must replace the drive gear on the crankshaft as well as the driven gear on the clutch hub. If one of these gears are damaged you always replace both gears. The large gear on the clutch hub normally comes as one unit, hub & gear together.

I would need to see the worn gears to comment, if you can get a photo Captmoto. In past experience with worn out primary gears it has been from low oil levels, bad oil quality or long service intervals & finally bad hardening of the gears. The hardening can be tested by a process called Rockwell testing, to see the depth & hardening strength of the tested teeth. Hopefully this is a one off, time will tell.

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
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My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946