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Old 04-05-2013, 04:13 AM   #1
Grantw OP
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Bluhduh Warning - Potentially Fatal KTM 990 failure

Thought I would post this as a warning to other KTM 990 riders or get alternative opinions on what happened.

On a recent 2000km trip on my 2012 KTM 990 Adv. I had the screw cap that provides access to the crank on the left hand flywheel cover fall out! Fortunately this must have happen just as I was entering a town ( slow speed) and only noticed it when I stopped for fuel. My left boot and the entire swing arm and left side of the tire was literally dripping with oil! If this had happened earlier in one of the high speed passes I would have gone down for sure.

Took 800ml of oil to refill to correct level after temporary repair was made and managed to complete a great trip!

I can only think that the mechanic must have over tightened the plastic screw cap and stripped the thread? KTM had repaired the motor under warrantee a few weeks earlier after the oil pump drive gear sheared in half. The replacement OEM gear that they supplied was a machined gear not cast metal like the original one that broke?

Still a great bike but I have replaced the plastic screw cap with a stainless steel plug and Locktite!
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Old 04-05-2013, 04:24 AM   #2
Orangecicle
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Yep. An issue that CJ has addressed: http://www.cjdesignsllc.com/products...ator-plug-kit/
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Old 04-05-2013, 04:34 AM   #3
johnno950
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Quote:
Originally Posted by Grantw View Post
Thought I would post this as a warning to other KTM 990 riders or get alternative opinions on what happened.

On a recent 2000km trip on my 2012 KTM 990 Adv. I had the screw cap that provides access to the crank on the left hand flywheel cover fall out! Fortunately this must have happen just as I was entering a town ( slow speed) and only noticed it when I stopped for fuel. My left boot and the entire swing arm and left side of the tire was literally dripping with oil! If this had happened earlier in one of the high speed passes I would have gone down for sure.

Took 800ml of oil to refill to correct level after temporary repair was made and managed to complete a great trip!

I can only think that the mechanic must have over tightened the plastic screw cap and stripped the thread? KTM had repaired the motor under warrantee a few weeks earlier after the oil pump drive gear sheared in half. The replacement OEM gear that they supplied was a machined gear not cast metal like the original one that broke?

Still a great bike but I have replaced the plastic screw cap with a stainless steel plug and Locktite!
more like warning dickhead worked on my bike,not a oem ktm issue
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Old 04-05-2013, 04:49 AM   #4
gefr
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Well such a big screw cap shouldn't be plastic in the first place.

I had this cap broken by my mech on my KTM , so yes it is a OEM KTM problem IMHO.
Cheers.

gefr screwed with this post 04-05-2013 at 07:45 AM
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Old 04-05-2013, 07:34 AM   #5
rossguzzi
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Same type of plastic bung in Aprilia Rotax motors. Ive been on the AF1 Aprilia forum for 8 years and never herd of one going missing. Not that it is impossible. I may well buy one off CJ too.
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Old 04-05-2013, 03:07 PM   #6
felixblack1
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there are aluminium plugs on ebay from china that are great quality and even comes in genuine parts ktm packaging for about $16 delivered. unfortunately i can't post the link up due to forum rules
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Old 04-05-2013, 03:23 PM   #7
Alleycatdad
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Quote:
Originally Posted by johnno950 View Post
more like warning dickhead worked on my bike,not a oem ktm issue



While I'm sure the plastic may bother some folks, if you treat it right, it shouldn't be a big issue. If you're worried about it slap a patch of gorilla tape over whatever you have and it'll be ugly but secure.

My experience with my KTM dealer mech leads me to believe that he could destroy an anvil by just looking at it...

S
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Old 04-05-2013, 05:45 PM   #8
Nowwhat
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Sooo dramatic........


I am off to go run wit scissors now....
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