Why did my KTM 525

[MysteriousR1]

Have something coming out of this overflow or whatever it is? Upper center in the picture...This is a little concerning with a track day on tuesday and then VIR. I started the bike, put gear on and when i came back there was something very very slowly coming out of there. I shut the bike off once i noticed. Anyone have any ideas

[Paul_E_D]

I can't tell what you mean. Can you mark the picture?

KTMs have a history of building crankcase pressure, sometimes enough to blow the seals in the bottom end. It's critical to get it breathing well for high rpm use. The motard racers around here will know what set-ups work...

[MysteriousR1]

Sure thing

[netra709]

Weep hole for the water pump. If its leaking, then you will probably be replacing that seal shortly.

[hammadown]

Weep hole for the water pump. If its leaking, then you will probably be replacing that seal shortly.

+1 did it on mine last year. Its not too difficult to do but here is a video:

http://www.youtube.com/watch?v=ynsdUY5QYvw

If you want some help or have questions, let me know, but its pretty easy if you have the 2 piece version which the 525 does since the vid is of a 525.

[richw]

1/2 a slug of bars leak

[Tricky Mike]

yup, don't sweat it. it's 10 minute job if done correctly.

[hammadown]

yup, don't sweat it. it's 10 minute job if done correctly.

and you dont have to break the cam chain to get the 1 piece version off

[Tricky Mike]

and you dont have to break the cam chain to get the 1 piece version off

Did we break yours? Can't remember.

[R7]

Make sure your water pump and the impeller shaft are ok as well, if they are warn, it could cause the leak.

For what it's worth, when I bought a new 04 Yamaha YFZ450 quad from the dealer, the waterpump wheap hole started to leak the next day. I brought it back to the dealer and they fixxed it on the spot. They put a quick blast of compressed air in the wheap hole, and it never leaked again. "could" be worth a shot to try it

[MysteriousR1]

That does not seem to tough at all, draining the coolent seemed to be the hardest part. Will be ordering parts from the dealer tomorrow and hoping they come in on time for tuesday. Seems like all i need is the O-rings and the cover gasket. Thank you all

[hammadown]

Did we break yours? Can't remember.

Make sure your water pump and the impeller shaft are ok as well, if they are warn, it could cause the leak.


Yuppa, it was fun!


For what it's worth, when I bought a new 04 Yamaha YFZ450 quad from the dealer, the waterpump wheap hole started to leak the next day. I brought it back to the dealer and they fixxed it on the spot. They put a quick blast of compressed air in the wheap hole, and it never leaked again. "could" be worth a shot to try it

Worth a try since free is good, but these seals are known to go on KTMs.

[MysteriousR1]

So everything is going so so, impeller was a total pain in the ass to get off. Dealer suggested i replace the gaskets inside in the carrier bearing, good thing one was torn. But how the hell do you get those bearings out?!?

[SVRACER01]

hammer and chisel

[Tricky Mike]

So everything is going so so, impeller was a total pain in the ass to get off. Dealer suggested i replace the gaskets inside in the carrier bearing, good thing one was torn. But how the hell do you get those bearings out?!?

You shouldn't have to. They're pressed onto the camshaft. That carrier should just wiggle out if you loosen the valve cover bolts. I use a big pair of snapring pliers.

[jbose]

when this happened on my 560, i just replaced the carrier, pressed a new bearing into it (maybe it had a seal on it as well?), and replaced the o-rings and seals.

[CEO]

while you're in there IMO replace the whole shebang... I did it on my CRF last race weekend... oil seal, water seal, bearing, shaft, impeller, washers, gasket, etc...

[R7]

Or you could just buy a Yamaha and put gas in it

[Crash Dummy Denno]

Or you could just buy a Yamaha and put gas in it

what mark was trying to say was...
"or you could buy a slow bike"

[Kurlon]

and you dont have to break the cam chain to get the 1 piece version off

So... does mine have the newer one piece style already? : )

[GixerJockey]

It's broke. Probably bad. Just give it to me and be done with the whole mess.