Sad to say my new 525 Outlaw is in for repairs. With 6 hrs on the motor, after a quick ride today the motor started rapping loudly (not the music I wanted to hear). Took it to the dealer because it's still under warranty and he said it sounds like a rocker arm is slapping or broke, but he'll tear it apart and check it out. It was also bogging on quick acceleration. I thought these KTM motors were quality stuff. Is the motor normally noisey, my CRF450 was and it was normal. I broke it in nicely and changed the oil at 3 hrs. I put Belray Thumper 10w40 in it like all my other 'toys' and haven't really got on it. Does anyone else have or had this problem?

 

No problems with my 525 and I don't think the motor is that loud (maybe my exhaust) compared to others (the wifey has a KFX450R) sometimes each person has a bad personal experience with an item that most or almost nobody else has. My good friend drives his 525 EXC to many trips around town and his does not seem loud nor has he had any engine problems! Keep your chin up and be confident this should be your only problem!

 

The RFS KTM 510 engine is a very noisy engine, at least the tranny is. It starts out pretty quiet then at about the 15 hour point it will start to get louder and louder till it reaches that well known KTM gravel crusher sound we all love. If you go to some of the KTM specific web sites such as KTM talk or Predatorowners.com you will find quite a few threads about this. Not saying the noise your engine is making is this but something to be aware of.

As far as the bogging, it is caused by the way Polaris is having to release the engines in an extreme lean condition to meet California's emission laws. Installing a JD Jet kit and the parts included with it, adjusting the AP accelerator pump and a few other very simple things will eliminate that bog and give you a 1-3 HP jump.