KTM 790 Valve Adjustment

[@DaneWentworth]

Great video, thanks.! Just did a tear down on a friend's 790 to fix an oil leak at the valve cover. Since I had the cover off, checked the valves, and found the exhausts in spec, but all intakes tight, 0.0025", with the right #2 at 0.0015" maybe. Closer to "0". Pulled the cams, and of course there was severe damage to the lobe and follower on the really tight intake... Showed the local KTM shop supervisor, and they agreed to replace cams and followers as part of the warranty step up on this problem. Said they will use the wider 890 followers in the replacement. 13,000 miles on a 2020, with full syndetic KTM oil changes at 4,000 miles, factory air filter changed at same intervals Hate to think what it would have looked like by the time he got to the recommended valve check interval! KTM probably should have set the expensive valve check interval to 9,000 miles or so, but I'm sure marketing wouldn't sign off! Swing arm bolts had also backed out and left the building on a ride... He loves the bike, but there is a serious maintenance price to pay to play with is.

[@Project_789T]

Thanks for producing this...I have a complete 790 rebuild to do and this will be a great point of reference.

[@craigwac5567]

Thank you for demonstrating the valve adjustment. There are plenty of videos for checking clearance, but none for adjustment. I'm a technician in a small shop and I suspect we will be seeing more of this engine. I did a clearance check on a 2019 Duke this summer. It was in spec and I didn't have to adjust either side. I own a 2020 790 Adventure R and I am guessing my intake will be on the right side in need of adjustment.

[@jamesal0]

Hi Andy. Not sure you noticed but at 1:48 you can see the inlet and exhaust cams are badly worn. This is the KTM 790/890 Warranty problem

[@anarchystick3765]

They are good, I show this in the video, I work on allot of KTM's the cams are good, the followers do make marks on the cams this is normal for this type of head. Thank you for watching the video I hope you found some value from it. I do have examples of bad cams but there are allot of videos that show that so I did not feel the need to show them.

[@sredju]

@@anarchystick3765 They are not good because there is at least 0.5 to 0.7 mm of material missing and that is the entire hardened layer that is missing. When the hardened layer is gone there is soft material underneath, At 2:51 is more cam wear to see.

[@anarchystick3765]

I would suggest on your bike you replace the cams this bike will make it to the next valve clearance check.

[@sredju]

, @@anarchystick3765 sir, i am riding 32 years old NX 500 with only 45000 kms, cams and rockers are shining like mirrors.

[@jesses1589]

Many guys in the ktm failed camshaft groups cry wolf is the cam doesn't have a like new polished finish. This is an example of it lol.

[@spa491]

Esos cabezales del arboles de levas se ven perfectos, que km tienen?

[@marklandgould6588]

Dang man, nice job and great video! This has helped me so much. All my valves are within spec and about to put valve cover back on, now I'm a little worried I might have dropped a shim. It's my first time and I left the radiator on and had a tough time getting a good reading on #2 exhaust. What are my options to check if it's still there? And if I did is there a way to fish it out? Thanks

[@anarchystick3765]

@@marklandgould6588 you can try a small mirror and light but like I said another way is to just double check the #2 exhaust clearance if it still in spec the shim is in.

[@marklandgould6588]

2022 890 Adventure R 9k miles

[@wXGuitarLoverXw]

I'm not a mechanic, but isn't it crazy that you had to completely change all the intake valves at only 16k miles?? You say it like it's completely normal in the video 😅 I would be mad as hell

[@anarchystick3765]

@@wXGuitarLoverXw yes you are correct but in the context of a dirt bike it’s common to change valves at 100-200 hours. The KTM 799-890 are designed almost the same as there dirt bikes. They are not BMWs or DRs these bikes need allot of attention but most owners are willing to deal with this for the high performance and they are amazing bikes to ride.