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Old 03-09-2012, 10:21 PM   #1
HellSickle OP
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EXC Subframe cracks

I noticed my '06 450 and 300 EXC both have cracks in the upper subframe where it bolts to the main frame. Both bikes may have been like this for years. It looks like a hollow tube, that have a solid plug in the end.

Anyone else observed this? Should I yank the frames and have them welded up, or will the solid plug essentially make this unnecessary?

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Old 03-09-2012, 10:35 PM   #2
Hayden#69
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My friends 2002 400 SX is like that. My 03 450 EXC is like that and my other friends 04 450 EXC is like that. Doesnt slow us down any.

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Old 03-09-2012, 11:06 PM   #3
jrproper
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Every KTM sub-frame I've seen looks just like that... wouldn't worry about it.
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Old 03-09-2012, 11:08 PM   #4
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As is my '06 EXC and every KTM I've seen.

I think it's factory for less weight...

... hence the faster bike.

If someone has a pic of one not "cracked" please post.



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Old 03-09-2012, 11:17 PM   #5
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Thanks guys. What a relief. One less thing on the list to deal with this spring.
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Old 03-10-2012, 05:34 AM   #6
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Old 10-16-2012, 02:18 AM   #7
Safeman
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KTM 450 EXC Sub repair

I had the same issue with my sub which I modded so that I could carry more weight on it - take a look here at this link on our local (South Africa) av forum if you are interested:-) This solution works a treat!

http://www.wilddog.za.net/forum/inde...topic=108925.0
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Old 10-16-2012, 06:39 AM   #8
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Almost everyone I've ever seen is like that.
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Old 10-16-2012, 06:52 AM   #9
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Quote:
Originally Posted by Safeman View Post
I had the same issue with my sub which I modded so that I could carry more weight on it - take a look here at this link on our local (South Africa) av forum if you are interested:-) This solution works a treat!

http://www.wilddog.za.net/forum/inde...topic=108925.0
Thanks! Great fix.
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Old 10-16-2012, 06:58 AM   #10
Stphnw8
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Nearly all ktm's ( from 65cc upwards) I've seen at my sons moto x club have done the same in exactly the same place.
Most of them have never had any problem with the crack growing or opening up and these kids are jumping very large table tops with no probs at all.
My local ktm dealer says he's never seen it before..........

Ktm----- Sunday = ATM -------Monday
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Old 10-16-2012, 07:43 AM   #11
blake716
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Same here. All of my KTM's have had the exact same cracks.

No worries.
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Old 10-16-2012, 09:52 AM   #12
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The metal that's cracked is just the casing. The solid core is what's important. And like others said, every KTM I've ever seen has identical cracks.
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Old 10-16-2012, 01:16 PM   #13
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Originally Posted by blake716 View Post
Same here. All of my KTM's have had the exact same cracks.

No worries.
You are missing the point. Some folks have an irresistible urge to fix things like this, making them better, faster, stronger. (present company included)

If I had my own TIG, all three of my EXCs would be getting the same fix.
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Old 10-18-2012, 08:36 PM   #14
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I had an '06 exc 450 (which I wish I still had). Took it apart at about six months new to check thing out, It was not
cracked then. A year later I had the very same cracks and the plugs were just starting to loosen a bit. Being as I can TIG weld, I cleaned the offending crack, slightly V'd the crack and welded it back as well as ran a bead around the plugs and re-assembled. Never noticed anymore cracks up until I sold the bike a little over a year ago. My observation is that the plugs are slightly pressed into the end of the tube and being as the tube is extremely soft
alum, the press fit fatigues the material enought to cause a stretch crack over time due to vibratioin and riding.
Just my.03..........
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