Oil leak at counter shaft on KTM 450

marin ktm · 10-09-2011, 10:22 PM

I have a slight oil dribble at the counter shaft on my '07 KTM 450 EXC. Does anyone have any advice on replacement?

Off the grid · 10-09-2011, 11:39 PM

Quote:

Originally Posted by marin ktm

I have a slight oil dribble at the counter shaft on my '07 KTM 450 EXC. Does anyone have any advice on replacement?

Pretty common if you run your chain too tight. Rule of thumb...chain should look loose, then loosen it some more. It should look almost TOO loose.

The seal is easy to replace and get out. Use an awl or similar to get it out (gently!) and a large socket to put it in...make sure it's seated correctly.

Albie · 10-10-2011, 10:00 AM

The seal probably doesn't need replacing, the bushing is what really gets worn. Unfortunately, it's much more expensive then the seal, but it's easier to replace. Just slide it out and slide the new one in.

ChrisC · 10-10-2011, 11:57 AM

If the 450 is anything like the LC4 in this regard, then part number 17 (o-ring) is often at fault for the weepy countershaft...

LukasM · 10-10-2011, 12:05 PM

Check the bushing for wear as Albie said, and also check if you have an OEM countersprocket on there as the aftermarket ones are sometimes too thin.

Otherwise it's probably the O-ring as Chris said, they flatten out over time, especially if you unbolt the countersprocket and put it back on.

I like to use the O-Ring from the two strokes, it has very similar outside dimensions but is a bit thicker and seals better. Don't have the part number handy but you should be able to find it by searching here and on KTMtalk.

Cheers

wrk2surf · 10-10-2011, 08:52 PM

and keep that chain LOOOSE..

marin ktm · 10-11-2011, 10:15 PM

Thanks for the replies. I have always run my chain loose. It looks pretty simple. Although it is hard to tell from all of the input what parts I should order. Seal? Bushing? Washer? O-ring? All of the above? I am sure that once I start taking things apart, it will become obvious. I may as well get another new chain and sprockets while I am at it. I hope it is easier than wheel bearings/spacers. Those things have been a real pain to remove on this bike.

Any recommendations on where to get the parts?

It has 241 hours and 5600 miles and has been an awesome performer on 95% singletrack trails for almost 5 years.

Albie · 10-12-2011, 07:17 AM

I just got mine at the local KTM dealer. The seal and O-ring are cheap. The bushing will run you around $20-$24. They're parts that most dealers should have in stock. When mine started leaking I picked up the seal and O-ring and changed them out but it still leaked. Had to go back and get the bushing a couple days later and once I swapped it out I was golden. You'll probably save a couple bucks if you order on line from some place like Munn or Cycle Hutt.

I've got a little over 6K on mine and it's been one of the best bikes I've ever owned!

r'elise me · 02-11-2013, 10:11 PM

Thought it worth reviving this thread to ask if there are any tricks to removing the bushing without removing the seal and vice versa. I'm kind of worried about scratching the case when I yank on the seal with an awl. I'm thinking it would be easier to pull the seal after pulling the bushing, but not sure if that's possible.

BTW, I see Moose Racing sells a complete kit. Anyone have experience with that kit? I like their bearings and steel-sleeved front wheel spacers better than OEM, but wondering if OEM is better in for the countershaft seals.

Thanks!

BogeyMan · 02-11-2013, 10:29 PM

Quote:

Originally Posted by r'elise me

Thought it worth reviving this thread to ask if there are any tricks to removing the bushing without removing the seal and vice versa. I'm kind of worried about scratching the case when I yank on the seal with an awl. I'm thinking it would be easier to pull the seal after pulling the bushing, but not sure if that's possible.

BTW, I see Moose Racing sells a complete kit. Anyone have experience with that kit? I like their bearings and steel-sleeved front wheel spacers better than OEM, but wondering if OEM is better in for the countershaft seals.

Thanks!

I've used the Enduro Engineering kit with success. If your seal is good, you should be able to grab the bushing with your fingers and pull it out. Then use a pick or needle-nosed pliers to pull out the O ring.

Albie · 02-12-2013, 09:37 AM

Quote:

Originally Posted by r'elise me

Thought it worth reviving this thread to ask if there are any tricks to removing the bushing without removing the seal and vice versa. I'm kind of worried about scratching the case when I yank on the seal with an awl. I'm thinking it would be easier to pull the seal after pulling the bushing, but not sure if that's possible.

BTW, I see Moose Racing sells a complete kit. Anyone have experience with that kit? I like their bearings and steel-sleeved front wheel spacers better than OEM, but wondering if OEM is better in for the countershaft seals.

Thanks!

The bushing should just pull right out then fish out the o-ring with a pick. I've used a sheet metal screw to remove the seal, just screw it in and yank it out with a pair of pliers.

Haven't tried the MR kit but I have tried the All Balls one and that kit works fine.

10-09-2011, 10:22 PM	#1
marin ktm ^OP Gnarly Adventurer Joined: Feb 2008 Location: Marin County, CA Oddometer: 317	Oil leak at counter shaft on KTM 450 I have a slight oil dribble at the counter shaft on my '07 KTM 450 EXC. Does anyone have any advice on replacement? __________________ Current: '07 990 Adventure '07 450 EXC Past: GS550E Saber1100 VF700F XR350 KTM MX500 KTM mxc350 XL600 XR650R KTM MXC400 VFR800

10-10-2011, 11:57 AM	#4
ChrisC Molon Labe Joined: Feb 2003 Location: Prescott, Arizona USA Earth Oddometer: 6,286	If the 450 is anything like the LC4 in this regard, then part number 17 (o-ring) is often at fault for the weepy countershaft... __________________ Chris '03 KTM Adventure 640 '43 BSA M20WD

10-10-2011, 12:05 PM	#5
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,915	Check the bushing for wear as Albie said, and also check if you have an OEM countersprocket on there as the aftermarket ones are sometimes too thin. Otherwise it's probably the O-ring as Chris said, they flatten out over time, especially if you unbolt the countersprocket and put it back on. I like to use the O-Ring from the two strokes, it has very similar outside dimensions but is a bit thicker and seals better. Don't have the part number handy but you should be able to find it by searching here and on KTMtalk. Cheers __________________ Proud member of the HUSABERG ADVENTURE TEAM! '12 Husaberg FE570, 09 KTM XC-F/ 450 RFS hybrid, 07 KTM 450 SMR, 08+09 BMW F650GS twins/F800GS conversion, 03+05 YZF-R6

10-10-2011, 08:52 PM	#6
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,309	and keep that chain LOOOSE.. __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

10-11-2011, 10:15 PM	#7
marin ktm ^OP Gnarly Adventurer Joined: Feb 2008 Location: Marin County, CA Oddometer: 317	Thanks for the replies. I have always run my chain loose. It looks pretty simple. Although it is hard to tell from all of the input what parts I should order. Seal? Bushing? Washer? O-ring? All of the above? I am sure that once I start taking things apart, it will become obvious. I may as well get another new chain and sprockets while I am at it. I hope it is easier than wheel bearings/spacers. Those things have been a real pain to remove on this bike. Any recommendations on where to get the parts? It has 241 hours and 5600 miles and has been an awesome performer on 95% singletrack trails for almost 5 years. __________________ Current: '07 990 Adventure '07 450 EXC Past: GS550E Saber1100 VF700F XR350 KTM MX500 KTM mxc350 XL600 XR650R KTM MXC400 VFR800

10-10-2011, 10:00 AM	#3
Albie Kool Aid poisoner Joined: Mar 2004 Location: NWA Oddometer: 4,838	The seal probably doesn't need replacing, the bushing is what really gets worn. Unfortunately, it's much more expensive then the seal, but it's easier to replace. Just slide it out and slide the new one in.

10-12-2011, 07:17 AM	#8
Albie Kool Aid poisoner Joined: Mar 2004 Location: NWA Oddometer: 4,838	I just got mine at the local KTM dealer. The seal and O-ring are cheap. The bushing will run you around $20-$24. They're parts that most dealers should have in stock. When mine started leaking I picked up the seal and O-ring and changed them out but it still leaked. Had to go back and get the bushing a couple days later and once I swapped it out I was golden. You'll probably save a couple bucks if you order on line from some place like Munn or Cycle Hutt. I've got a little over 6K on mine and it's been one of the best bikes I've ever owned!

02-11-2013, 10:11 PM	#9
r'elise me Gnarly Adventurer Joined: Nov 2011 Location: Venice CA Oddometer: 123	Thought it worth reviving this thread to ask if there are any tricks to removing the bushing without removing the seal and vice versa. I'm kind of worried about scratching the case when I yank on the seal with an awl. I'm thinking it would be easier to pull the seal after pulling the bushing, but not sure if that's possible. BTW, I see Moose Racing sells a complete kit. Anyone have experience with that kit? I like their bearings and steel-sleeved front wheel spacers better than OEM, but wondering if OEM is better in for the countershaft seals. Thanks! __________________ 08 KTM 690E / 06 GSA / 07 450EXC / 05 Lotus Elise Lotus Cup Open Class 10 Audi A3 / '12 Land Rover LR4 / bicycles for every terrain 11 year old boy - baddest-ass toy I've ever had

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