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Old 11-21-2010, 01:29 PM   #61
Steverino
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Mine engine is completely apart right now. What do you want a picture of?
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Old 11-21-2010, 01:47 PM   #62
AdvGa
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Quote:
Originally Posted by viola-tor
Hopefully you got it sorted by now, I JUST fixed this leak on mine a few days ago.

Hope that helps.
Thanks for your info... so far the Formagasket has been holding up until I locate the O-Ring replacement. (Really an Odd Size and not easy to find)

St..Dave was nice enough to give me the dimensions of his replacement but been too busy to find one yet.

Glad your worked out well.
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Old 11-21-2010, 03:07 PM   #63
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The spec's AdvGa refers to are the O-ring I picked up from Ace Hardware. The KTM spec's are for a 27.5mm x 2.5mm but the local dealer didn't have one in stock. I headed to Ace and couldn't find anything in the metric O-rings but I did find one in the standard O-rings that converted to very close to the size needed. The Ace package was for a 1 1/4" x 1 1/8" x 3/32", #77 O-ring, stock no 35716B.

Dave
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Old 11-21-2010, 03:31 PM   #64
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FOUND MINE


removed the tanks and skid plate
cleaned all the grunge off it with 2 stroke gas and a parts brush, then detergent followed by water and dried it real good with compressed air then some brakecleaner spray
put the left tank on, dusted it with talc and ran it up to 5,000 rpm for a few minutes
and found it right away

embarrassingly it is dripping from the oil filter cover , what a relief to find it. I must have buggered the Oring ....oooFh
All the other leakeage is ooze this is a steady drip
the ooze ran right down to the cover and threw me off because I suspect the highest leak first and my test was after no cleaning and a 200 mile hi speed , hard to find in all that wet looking grunge
and its all clean under the hood now
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Old 11-21-2010, 04:58 PM   #65
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I figured out what I did wrong
I used a pick to pry out the old oil filter last time and left a burr on the O-ring mating surface

evidently it only leaked at high pressure not idle

removed the burr and stopped the leak

i cant believe how much grunge had built up, it took a lot of cleaning
it kinda looked like the bottom of an 18 wheeler all the way up to the heads
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Old 11-23-2010, 03:42 AM   #66
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Glad you got it sorted and it didn't cost you a load of cash.

Happy days.
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Old 11-23-2010, 05:56 AM   #67
erappaport
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Quote:
Mine engine is completely apart right now. What do you want a picture of?
Just the cover assembly and oil seal for the starter motor, when you have a minute. Thanks.
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Old 11-24-2010, 07:58 AM   #68
Steverino
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Starter itself has an oring. This is the only seal to replace in the generator cover.



Whole thing.



Hope this helps...

Steve
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Old 11-26-2010, 03:08 AM   #69
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Don't think he meant that but the O-ring which is behind the startermotor, located inbetween the V.

Think that Pyn had a picture on that one somewhere in his thread. Will try and find it...

Cheers,
Zappa
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Old 11-26-2010, 03:15 AM   #70
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Wasn't sure, but he said seal and not o ring. It is an o ring on the starter motor.

I'll dig that out of the box today. IF the case gasket comes in and motivates me to start reassembly.
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Old 12-09-2011, 08:58 PM   #71
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Just in case while your doing your winter maintenance and have an Oil Leak, take a look at your Oil Pressure Switch.... sure enough, mine was Leaking:

Taken from DeeGee's Post:
And the oil pressure switch is damp and oily




http://www.advrider.com/forums/showp...8&postcount=16
 
Parts list from for my '06 Adventure:

ktmamerica.com
 
60038091100 OIL-PRESSURE SWITCH LC8 04 $10.00
Taken out with a 13/16" or 21mm Deep Socket

This is the
Oil Vent Crankcase Seal in case you need this too:
http://ktmtalk.com/index.php?showtopic=408017

0760122050 SEAL 12X20X5 B $10.00

AdvGa screwed with this post 12-09-2011 at 10:14 PM
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Old 02-04-2012, 01:40 PM   #72
AdvGa
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Quote:
Originally Posted by StmbtDave View Post
I had the exact same leak. Don't mess with Formagasket. There is no gasket between the sensor and the case, only an O-ring. You can pull the cover and very little oil will leak out. The local dealer didn't have the proper O-ring in stock so I picked one up at Ace Hardware. Seems to me the proper one is 27.5mm x 2.5mm and the one I used was 27mm x 2.5mm. So far, no leaks .Dave
Well, it started leaking again, the Gear Shifting Sensor, so I found this O-Ring at Ace Hardware

1 3/16 x 1 3/32 #20 O-Ring Stock # 35737B that seems to be working in addition I Cut a Gasket from Flat Gasket Material to cover the Plastic Flange.... also,

I had to Epoxy the Exit Wires out of the Plastic Sensor since it appeared Oil was Leaking out of the Wire Exit Area.

It appears this Plastic Sensor is too flimsy with only 2 screws holding it in place.

When I did the Valve Check, Replaced the Oil Pressure Sensor that appeared to be leaking out of the Plastic area where the Wire Connects.

Thanks for your help !!
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Old 02-05-2012, 12:48 PM   #73
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Had to exchange my Gear Position thingy a few months back and KTM have updated the design and added an extra wire... It's a ground wire... But I thin kit looked alot more sturdy and hope it will do the trick and at only $30 I think it's worth it.

I got a 05.5 (or 05 here in Sweden).

Cheers,
Zappa
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Old 02-05-2012, 01:53 PM   #74
AdvGa
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Quote:
Originally Posted by TA-Zappa View Post
Had to exchange my Gear Position thingy a few months back and KTM have updated the design and added an extra wire... It's a ground wire... But I thin kit looked alot more sturdy...
Thanks for letting us know....

this does not surprise me and glad to see some warrantted changes were made on this item. Next time, I will have to get the New Model.
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Old 02-05-2012, 02:09 PM   #75
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Man you've gotta love the OC and this forum
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