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Old 03-31-2013, 09:01 PM   #1
Dogtown OP
Gnarly Adventurer
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Joined: Apr 2008
Location: Marin County
Oddometer: 410

Getting the 07 990 adv ready for some long haul adventure rides and have a dilemma. With over 30K on the bike I still have the original water pump and fuel filter. As far as I can tell everything is within spec... no water in oil or vise versa and fuel comes out of the bike just as fast as i put it in!

On a 12 day trip I took last summer I took spares with me just in case but who the hell wants to take half a day to swap out parts on a vacation?

I'm not one for fixing things that ain't broken but with the 990's reputation with these parts I'm on borrowed time...Right??

How far have you all gotten with these items before failure or swap out???

What would y'all do?

OH 7 990

Marin County To Cabo!
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Old 03-31-2013, 11:00 PM   #2
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Joined: Mar 2012
Location: Portland OR
Oddometer: 823
I just bought a 06 950 and over the winter did the full maintenance, it has some of htefoam in teh clutch cover so I assumed it was due.. Turned out I caught it just right.. The shaft had significant wear and was definately starting to weep by. Bike has almost 31K on it..

Freedom is a delicate thing.
More easily lost than gained.
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Old 04-01-2013, 02:53 AM   #3
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Joined: Sep 2005
Location: Omaha, and I most definitely know why.
Oddometer: 309
At last years CJRacer Tech Days I did the water pump as part of regular maintenance. Mine is an '07 and then I was at about 18k miles.

Did a flush of the cooling system and what came out made dirty dishwater look good.

Pretty much a no-brainer to me. I'd do it for peace of mind before I left.
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Old 04-01-2013, 05:22 AM   #4
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Joined: Sep 2009
Location: Beautiful but often rainy North Yorkshire, UK
Oddometer: 1,733
Its pretty easy to do a coolant flush and just pull out the waterpump seal. Then you can decide if the shaft looks bad enough to go in further.

My 08 had 18,000 miles and the shaft looked fine so all I did was lube the lips of a new seal and pop it in.

As regards the fuel filter I pulled out the pump, removed the filters and rinsed them out in a jar of fuel a couple of times. Quite a bit of grit came out. I then let them dry and refitted.
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Old 04-01-2013, 06:08 AM   #5
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Joined: Feb 2008
Location: S.F. Bay Area
Oddometer: 743
Come know the answer. Besides, you'll feel sooo much better once you do it.
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Old 04-01-2013, 07:13 AM   #6
let's keep going...
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Joined: May 2008
Location: West-By-God Virginia
Oddometer: 1,034
Cool2 Do it & be Done

Go down to Scuderia West & buy the kit from Don & the gang

Take your time and follow the HOW if you need to

It definitely helps to freeze the new bearings (just leave them in a ziploc and put them in overnight) to shrink them to make installation easy- they will fall in. Just don't take them out and lay them on the bench, they are so small and have so little thermal mass they will warm up (& expand) quickly. I wait until the last second, which is why most all of these jobs have occured in the kitchen (shop has one)

With the case cover stripped of old seal & the case gasket remnants removed, put it on a piece of alum foil on a cookie sheet in put in the oven. This will expand it so the bearings will simply fall out. Just make sure the Mrs. doesn't know what you are doing on her kitchen floor, and run the vent fan to get rid of the hot oil smell. Use old oven mitts too!

If the case has a lot of corrosion or fowling under the seal, spraying contact cleaner directly on the (hot) soiled area will lift all but the most stubborn dirt right off the aluminium surface. Just pop back into the oven for a few to re-heat the bearing bores to re-expand them.

Have your quality snap-ring plier sized & setup to the circlips on the shaft.

I use a couple of pieces of 2x4 to keep the hot cover off the floor while you're working on it

The new seals are a lot tougher to get in than the older ones, so lube it with a bit of coolant so it goes in.

If you have the $, buy yourself the seal driver (installation) tool

KTM 950 990 LC8 Water Pump Seal Tool 60029082000

and the water pump shaft seal installation tool


which threads into the water pump shaft & allows the seal lips to slide easily over the new shaft end. You don't HAVE to have them, but for the price they offer foolproof installation (esp the sleeve tool) and damaging the seal means you have to re-do it all anyway. I have seen 3 seals now mis-installed & I re-did the job for the (frustrated) customers. Of course the oil had to be changed since it was contaminated, so it's more money lost as well as the time. I carry these tools along with my spare pump seal, snap rings & pump shaft with the bike at all times along with a cheap (Horrible Fright Toolz) pair of pliers ground to use on the snap rings.

One good thing is the new seals & shaft are higher quality than the originals so you should get 30-50K out of them.

CJRacer also makes a water pump shaft of his own that is harder even than the KTM offering, and he sells complete kits too
'06 KTM 950 Adv 'S'
'03 KTM 250 EXC
'87 KLR650 - <200K miles "Like the Energizer Bunny, just keeps going & going..."
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Old 04-01-2013, 07:57 AM   #7
Mmmm....Orange Kool-aid
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Joined: Jun 2007
Location: Knoxville, TN
Oddometer: 1,837
I'm in the same boat since I'm going on a 12,000 mile trip in July. Already changed the whole shebang once about 8,000 miles ago and my plan is to do the quick change like above: shaft and seals. CJ told me that he had 40,000 on his bike and he wasn't worried about it, just go ride. (He also said he ships if need be.)

I figure the bearings will do 40,000 miles so I'm just going to do the seals just for peace of mind.
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I am not the same having seen the moon shine on the other side of the world. - Radmacher

5 Cylinders vs. Moab..........My East Tennessee.........Internships may go to Hell and I will go to Alaska
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