'02 400exc reliability

[NYCdrz]

Looking at a used 400exc 2002 - any common problems I should look out for? Basic reliability issues, vulnerable parts in a crash, etc.?

How have these held up for those who have ridden them hard? Hare-scrambles, enduros, etc.?

And for those who have one with a license plate, how does it do on the street? (How horrible is it really?)

Thanks, all advice appreciated. Got a DRZ400S now, considering a trade in -- I've been riding more seriously off-road than I thought and the extra drz weight has become "a factor"

Thanks!

[^SQUID^_Thumper]

I rode a '02 400 EXC for an entire season this year, and I can honestly say it has been the most dependable and reliable bike I have ever owned. The only real problems I had were with leaking fork seals at the beginning of the year. Other than that, with basic routine maintenance, the bike has been top notch. I bought a new 450 EXC, so my 400 is now up for sale.

[flilawsa]

A friend of mine has an 01 400 and has rode the hell out of it with no problems. They are definetly more hi tech than jap bikes and will take a little more $ for maintenance,,but thats the price of technology. I am going to find out for myself. I just bought an 02 520 and have been on a TOTALLY reliable 93 xr 6oo for 10 years,,so im banking on the KTM being reliable.

[jrose]

I've ridden my '02 400 e for nearly a year and only have my previous bike to compare to...a '97 XR 400, but this pumpkin has been great. A bit more maintenance, but not as intimidating as it sounded before I actually got the bike. I don't race, just trail ride so maybe that's not a fair evaluation, but the bike's been VERY reliable and SO MUCH better than the XR in just about every respect!

[Nick2002]

NYC,

I had the DRZ400s model and changed to 02 400exc. Theres no comparision, the DRZ is bullet proof but a dinosoar to ride compared with the KTM.

After 2000 miles on the 400exc, oil changes and tyres aside, my total outlay was 1no. sidestand bolt and 3no. front spokes. I now have the 525exc and it just gets better. Go orange!

Nick

[EM_rider]

Mine is a little over one year old and has about 2500 miles. Coming off an XR4 I was used to virtually zero problems and maintenance. The KTM has been flawless thus far and an outstanding bike. Oil/filters are changed regularly as recommended and that is about it. I am not great at working on my bike so don't let the "heavy maintenance" stuff scare you.

[RidinDawgDoc]

After 2 years of hard riding, 18 harescrambles and 2 enduros my 01' 400 (now 450) has had the following issues. Had to replace starter switch(stop working, but was most likely the result of a crash). Left chain adjust bolt frozen. Had to rebuild transmission(result of Revloc clutch and clutchless power shifting while racing). Now have modified Revloc and shifts are much cleaner and not a worry anymore. I have no doubts this rebuild wouldn't have been necessary with stock clutch. But, I love that damn Revloc and Dave of Revloc has been extremely helpful in getting it set up right for my riding style. They are very adjustable.

To make this bike truely race ready I have had to spend a bit. Revalved forks and shock(I am currently having forks revalved again and going with the SXS shock). 18mm offset triple clamps, turned like a barge with the stock 20mms. Put the 450 kit on for more power (but it was plenty competitive as a 400, more is always better though! ?).

Rest has been maintenance,customizing and upgrade spending. Replaced cam bearings, autodecompression bolt, wheel bearings and seals, upgraded to better wheel spacers(highly recommended!), upgraded?? to 02 style water pump carrier(now leaks, never did before ), went with Enduro Engineering seat to replace covered 2X4 that came stock, taller bars and risers from Applied Racing, Fastway Lowboy pegs, had 5mm cut out of subframe posts for better turning, EBC brake pads, went to 13/52 sprockets, Flatland Racing radiator guards and other stuff.

The bike has been very tough and durable and reliable. If you want a really competant racer you are going to speed some more money, but the basics are very good.

[Durango_Dave]

I got a license plate so that I could ride on 4-wheel drive roads in the national parks, and we regularly ride 5-10 miles of pavement to hook up portions of forest service roads to make a loop. It's fine on the pavement - the only limiting factor is the knobby tires which you would have on any dirt bike. I estimate that my KTM is at least 30-40 lbs. lighter than a DRZe (depending on wether the DRZ has the optional kick starter or not) and certainly a lower center of gravity. Go orange, I don't think that you would be disappointed! ?

[NYCdrz]

Thanks ktm'ers for the info - still mulling it over, since going pumpkin would require some eating of cash spent on drz. The drz is still a good bike, especially since I ride road more than I'd like to...

Also seem to be some leftover new 02 400exc's around, which is a surprise since they were so popular. My dealer told me KTM delivered a bunch of them real late in the season, and since the 03's are out, they haven't been selling.