KTM 530 EXCR- More better!

[FlyingDutchman]

Originally Posted by FlyingDutchman

I have a bit of a leak under my waterpump cover.

I have only drained 600ml from the transmission the last few changes.

How much can I ride before big problems? I've got a big enduro next weekend...

KTM Talk I guess...

[Country Doc]

Originally Posted by FlyingDutchman

KTM Talk I guess...

What are you leaking? Oil? Coolant?

Is the engine side ok, or are you transferring oil?

dc

[terry.mc]

Does anyone else see these marks on the inside of their fork protectors?





I was riding with another 530 rider this weekend and it looks like we both have them. Not sure if the marks are rocks that get picked up in the side knobs or actual wheel deflection causing the contact...

[FlyingDutchman]

Originally Posted by Country Doc

What are you leaking? Oil? Coolant?

Is the engine side ok, or are you transferring oil?

dc

Pretty sure it is coolant...seems all around the gasket though.?

Re: Tranny Oil loss - Engine side seems normal...as it ever is but if it is transferring, it seems to be evacuating through one of the typical 530 ways - 1) rings 2) venting 3) valve seals

How common was the oil transfer issue...I thought they addressed that with the 09 models?

I must admit that it was on it's side more than usual last weekend...maybe 10 times.

[Deseret Rider]

" I must admit that it was on it's side more than usual last weekend...maybe 10 times."

That's one more than the required 9 times Dutch----indicating that you are riding fast enough. Anything less than 9 denotes that you weren't really trying.

[Hugerush]

Originally Posted by FlyingDutchman

Pretty sure it is coolant...seems all around the gasket though.?

There is a weep hole on the bottom of (an inboard of) the water pump cover to indicate the coolant seal under the impeller is leaking. This leak is fairly common from what I can read. Also, a lot of people INSIST that seal is installed backwards by KTM and this is the cause of the leak. Quite a few people claim to have rectified their leak by reversing the seal. I changed the impeller out to the high flow model and did reverse the seal, based on the argument put forth on KTMTALK that it is backwards. The easiest way is to hit it with compressed air through the weep hole and it will slowly POP out (with the impeller off, of course). Good luck.

[RuckedUp]

Well I did it again went nuts with the wrench and now Im sitting in the garage scratching my head about what length the new chain should be. I had stock gearing on the bike, 15/45. I am now in the process of putting on 14/48 combo with new chain.

I laid out the new EK chain its a 520x120 O Ring chain and when I lay it next to the chain that I just took off the bike it is 3 or 4 links longer than the stock chain.

Should I just break the chain at the length of the original chain or just put the chain on as is?

[Davebert]

Originally Posted by RuckedUp

Well I did it again went nuts with the wrench and now Im sitting in the garage scratching my head about what length the new chain should be. I had stock gearing on the bike, 15/45. I am now in the process of putting on 14/48 combo with new chain.

I laid out the new EK chain its a 520x120 O Ring chain and when I lay it next to the chain that I just took off the bike it is 3 or 4 links longer than the stock chain.

Should I just break the chain at the length of the original chain or just put the chain on as is?

I would make the new chain 2 links longer than the oem.
DB

[FlyingDutchman]

Originally Posted by RuckedUp

Well...

I am now in the process of putting on 14/48 combo with new chain.

....break the chain at the length of the original chain .....?

Cut it to 118....again

[FlyingDutchman]

Originally Posted by Hugerush

There is a weep hole on the bottom of (an inboard of) the water pump cover to indicate the coolant seal under the impeller is leaking. This leak is fairly common from what I can read. Also, a lot of people INSIST that seal is installed backwards by KTM and this is the cause of the leak. Quite a few people claim to have rectified their leak by reversing the seal. I changed the impeller out to the high flow model and did reverse the seal, based on the argument put forth on KTMTALK that it is backwards. The easiest way is to hit it with compressed air through the weep hole and it will slowly POP out (with the impeller off, of course). Good luck.

I ordered the water pump gasket:


GASKET WAPU-COVER 08
78035053000

I can't imagine how that could be put on in reverse?? Are you talking about this part?

[Yardstick]

Originally Posted by FlyingDutchman

I ordered the water pump gasket:


GASKET WAPU-COVER 08
78035053000

I can't imagine how that could be put on in reverse?? Are you talking about this part?

I think he's talking about the water pump shaft seal. I know they had some issues in the RFS bikes with those being installed backward. I hadn't seen any reports of it on the XC4's.

[Hodakaguy]

Originally Posted by Yardstick

I think he's talking about the water pump shaft seal. I know they had some issues in the RFS bikes with those being installed backward. I hadn't seen any reports of it on the XC4's.

Yep the outboard water pump seal (located directly behind the impeller) is installed backwards from the factory in our 530's compared to how the rest of the world installs them. Usually the spring side of the seal is towards the pressure side, the pressure in the system and the spring helps press the lip of the seal down on the shaft for a good seal. KTM installs our outer seal with the spring towards the weep hole (non pressure side), the pressure in the system try's to expand the seal and leak past it leaving only the spring to counteract the pressure in the system and keep the seal on the shaft.

My 530 started leaking about 80hrs or so, replaced the outer seal and installed it "backwards" with the spring on the pressure side...haven't had any problems since.

Hodakaguy

[Yardstick]

Originally Posted by Hodakaguy

Yep the outboard water pump seal (located directly behind the impeller) is installed backwards from the factory in our 530's compared to how the rest of the world installs them. Usually the spring side of the seal is towards the pressure side, the pressure in the system and the spring helps press the lip of the seal down on the shaft for a good seal. KTM installs our outer seal with the spring towards the weep hole (non pressure side), the pressure in the system try's to expand the seal and leak past it leaving only the spring to counteract the pressure in the system and keep the seal on the shaft.

My 530 started leaking about 80hrs or so, replaced the outer seal and installed it "backwards" with the spring on the pressure side...haven't had any problems since.

Hodakaguy

Good to know! I'd only connected that issue to the RFS bikes. I'll be watching mine. Thanks for the confirmation/correction!

[Country Doc]

Originally Posted by Hodakaguy

Yep the outboard water pump seal (located directly behind the impeller) is installed backwards from the factory in our 530's compared to how the rest of the world installs them. Usually the spring side of the seal is towards the pressure side, the pressure in the system and the spring helps press the lip of the seal down on the shaft for a good seal. KTM installs our outer seal with the spring towards the weep hole (non pressure side), the pressure in the system try's to expand the seal and leak past it leaving only the spring to counteract the pressure in the system and keep the seal on the shaft.

My 530 started leaking about 80hrs or so, replaced the outer seal and installed it "backwards" with the spring on the pressure side...haven't had any problems since.

Hodakaguy

I had the same small leak from the WP hole. I ordered the new shaft seal planning to install it backwards, but was sent the inner seal not the outer one. I popped the original one out with my fingers and just reversed it on the spot. That was 60 hours and some hard riding ago, and no issues since (with respect to that leak )

Dutch, I have heard of transferring issues on some 09s, particularly early 09s. Not sure if that is your issue but if the tranny is not leaking and dropping 300ccs but the engine is staying constant, it must be going somewhere. I would guess it's transferring and then blowing by the rings, like mine was.

dc

[FlyingDutchman]

Originally Posted by Country Doc

I had the same small leak from the WP hole. I ordered the new shaft seal planning to install it backwards, but was sent the inner seal not the outer one. I popped the original one out with my fingers and just reversed it on the spot. That was 60 hours and some hard riding ago, and no issues since (with respect to that leak )

I have coolant around the bottom and sides of my waterpump cover...Is this the gasket leaking as I assumed or is the seal the known cause of the leak. Does anyone have a pick of the weephole? I checked my coolant, it needed a bit

Originally Posted by Country Doc

Dutch, I have heard of transferring issues on some 09s, particularly early 09s. Not sure if that is your issue but if the tranny is not leaking and dropping 300ccs but the engine is staying constant, it must be going somewhere. I would guess it's transferring and then blowing by the rings, like mine was.

dc

I'm still hoping my tranny is venting the oil and burning it through the carb. Or hoping that it will survive until winter....I guess I will be doing frequent oil changes...

How is your re-build treating you? Any issues? How's the performance?