It was 12 months ago that we first started testing our 2015 KTM 450xcw. At that time I was starting to prep it for a Baja race. After a successful performance by the bike, it went on to be my regular mount for nearly all of my Baja riding for the year. It saw plenty of miles and very little attention.
Most of my riding is high mileage days, but not particularly stressful on the bike. I stretched oil changes out to 35-40 hours and oil filter only every other oil change. As for real maintenance, the 450 went back to KTM for service at 150 hours where it got a valve adjustment and new rubbers for the DDS clutch.
Since then another 100 hours have been logged, putting us up to 250 total. Our test time complete, I asked KTM to take apart the motor so we could look at the internals. It was an interesting project for them. The media department very seldom does a full motor tear down. The race department does, but never on motors with this many hours. So it was novel for everyone to take a look inside our high mileage bike.
I will leave most of the story to the photos. In short, here is what we found. The intake valves were tight (.05) but the exhausts were still fine (.15). The clutch rubbers were due for replacement again, noted by some motor vibration. I suggest changing these at 80-100 hours.
The only obvious wear anywhere was on the shift star, where it goes into neutral. The ring end gap was .48mm, spec limit is 1mm.
That was it, everything else looks near new. Take a look for yourself –