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Thread: Help me diagnose this leak

  1. #21
    KTMTalk Member Folie's Avatar
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    Default Re: Help me diagnose this leak

    The sprocket bolt has a boss under the head that is supposed to mate against the countershaft. The length of that boss is a bit less than the height of the dome washer so that the dome washer gets partly compressed to provide preload to the sprocket and the bushing & o ring behind it. You failed to insert the boss into the hole in the dome washer so the washer is now off center and pinched between the boss and countershaft. You can see by the holes in the sprocket some are partly covered by the washer and others are not. As a result you do not have the correct compression on the o ring which may be the cause of the leak. Also you have flattened the washer now so I suggest you get a new one. Or recup it between two sockets in a vice. Without correct preload of the dome washer you will accelerate wear of your countershaft which is no longer available from the dealer and hard to come by. Good news is it's a 10 min job.

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  3. #22
    KTMTalk Member Folie's Avatar
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    Default Re: Help me diagnose this leak

    On another note your chain guides are wearing in and I notice you are using a chain link with a spring clip. Soon your guides will start touching that spring clip and it will fling off. Some time later your chain will split and with any luck be jammed into the clutch slave by the sprocket.

  4. #23

    Default Re: Help me diagnose this leak

    Steelholder,
    I say the oil is definitely coming from the chain. Since you haven't oiled it, I'm guessing the chain is overheating from friction and allowing the factory lube to come out. Is it adjusted properly? Is the lower chain guide binding somehow?
    Since 10/2013 I love my 2005 540 EXC 12.5:1, welded crank, 8/06, +1KW, DJH 41mm carb, 14/52, Plated

    Past bikes
    1996 CR250R
    1985 Ninja 600
    1982 Virago 920
    1982 Virago 750
    1986 XR250R
    1971 SL125

  5. #24

    Default Re: Help me diagnose this leak

    Clearly the sprocket washer is off-center thus not effective


    Quote Originally Posted by Steelholder View Post
    Here are a few more pics. This doesnt seem to be oil it's very thick and tar like. Would that indicate it's the chain? I'm ashamed to admit I haven't replaced the chain in over 50 hours since I purchased the bike.





    [URL=http://www.djhcyclesport.com
    Former Husky Dealer in the '70's, currently Sell Real Estate, Seattle area and as a hobby business I manufactor cam chain tensioners for the KTMs, do Carburetor modification & setup and valve work on KTM & Husky 4 strokes. Full stock of parts for the KTM's. My rides are; Cadillac Escalade (the 1/2 pickup version), 72 ElCamino 454SS, and Triumph 1050 Sprint ST, Iron Butt member

  6. #25

    Default Re: Help me diagnose this leak

    I missed Travis's reply from Yesterday. I've changed my mind about the heat. I think Travis wins.
    Since 10/2013 I love my 2005 540 EXC 12.5:1, welded crank, 8/06, +1KW, DJH 41mm carb, 14/52, Plated

    Past bikes
    1996 CR250R
    1985 Ninja 600
    1982 Virago 920
    1982 Virago 750
    1986 XR250R
    1971 SL125

  7. #26

    Default Re: Help me diagnose this leak

    why does sprocket look like its flipped wrong, gap between washer and sprocket face

  8. #27
    KTMTalk Member Folie's Avatar
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    Default Re: Help me diagnose this leak

    Quote Originally Posted by surfref32 View Post
    I missed Travis's reply from Yesterday. I've changed my mind about the heat. I think Travis wins.
    You're wrong. Both of you owe me a beer now.
    Remove the sprocket bolt and it will be obvious. Travis will agree without a doubt after reading my post and looking at the picture again. DJH confirmed. t's not that I can not take being wrong. Just not used to it..
    Last edited by Folie; 03-25-2020 at 06:58 AM.

  9. #28
    KTMTalk Member kenpowell's Avatar
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    Default Re: Help me diagnose this leak

    Quote Originally Posted by Folie View Post
    You're wrong. Both of you owe me a beer now.
    Remove the sprocket bolt and it will be obvious. Travis will agree without a doubt after reading my post and looking at the picture again. DJH confirmed. t's not that I can not take being wrong. Just not used to it..
    To funny! And I think Folie gets the prize. Op also needs to fix the sealing washers (also identified earlier) on the clutch line.
    Ken Powell
    2018 KTM 250 XC-W
    2012 KTM 300 XC with YZ SSS cartridges in WP forks - Sold to son-in-law on 31 October 2014 due to injury - still ride it occasionally
    2003 YZ265WR (WR426 trans except YZ250 2nd gear) with 2005 Slavens revalved AOSS forks - backup bike
    2003 KX125 with KDX220 motor & 2006 YZ250F SSS forks - added Rekluse EXP 3.0 designed for YZ125
    1979 Maico 250 Magnum
    Many, many bikes until now...
    1963 Harley 175cc Scat - 1st motorcycle

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