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Old 10-20-2014, 05:18 PM   #1
sweetlou OP
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KTM 990 Valve Cover Oil Leak

Greetings,

It seems I have developed an oil leak from the right side rear cylinder valve cover. Bike is a 2013 Ktm 990 Smt with 3800 miles. I bought the bike brand new in June. Here's my feeble attempt at pics:









This can't be normal... Could it? It's a decent amount of oil dripping down. I use motorex oil. Level is good.

Advice?

Lou
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Old 10-20-2014, 05:39 PM   #2
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It looks to me like that oil ran down the side of the cylinder when you were stationary. Is it coming out of the air box? Anyway check your cover bolts are tight, looks like you can get a spanner to them easily. Verify exactly where it's coming from. Not a huge job to renew the gasket if need be. Good luck.
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Old 10-20-2014, 06:09 PM   #3
sweetlou OP
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KTM 990 Valve Cover Oil Leak

It's coming from the front right side of the rear cylinder, I tried to picture it.

I did the SAS mod, I plugged the main hose before it splits to each cylinder. Maybe crank case pressure is off? I really don't want to go back to the dealer... I just left 1000 miles ago for replacement rotors. Ugh.

I checked valve cover bolts and they are tight. Leak is definitely through the gasket and not from air box
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sweetlou screwed with this post 10-21-2014 at 06:55 AM
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Old 10-21-2014, 08:47 AM   #4
sweetlou OP
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KTM 990 Valve Cover Oil Leak

I'm going to pull the tank and check the crank case breather. I hear they are known for being on backwards from the factory. They are designed to release pressure OUT right, not suck IN?

Also, should I vent the throttle body vacuum hoses that are plugged from charcoal canister removal? Or keep them sealed?

Thanks
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Old 10-21-2014, 09:23 AM   #5
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Quote:
Originally Posted by sweetlou View Post
I'm going to pull the tank and check the crank case breather. I hear they are known for being on backwards from the factory. They are designed to release pressure OUT right, not suck IN?

Also, should I vent the throttle body vacuum hoses that are plugged from charcoal canister removal? Or keep them sealed?

Thanks
Yes... breaths to the airbox.
I routed mine together from one TB to the other, like it was done from the factory. Many have sealed them like you did with success i guess.
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Old 10-21-2014, 09:40 AM   #6
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At the risk of being master of the obvious, had the exact same thing on my 990 when I first got it. Thought the valve cover gasket was leaking. turned out I over serviced the oil by about .2 liters. Just something simple to double check. Don't just let it idle to warm up, ride the bike and get it hot, then check the oil level.
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Old 10-21-2014, 10:23 AM   #7
sweetlou OP
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KTM 990 Valve Cover Oil Leak

Hmm, maybe the oil is overfilled, I did run into this issue when I changed the oil I put in too much. I'll check again when "hot" should be in the middle right?
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Old 10-21-2014, 10:33 AM   #8
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Quote:
Originally Posted by sweetlou View Post
Hmm, maybe the oil is overfilled, I did run into this issue when I changed the oil I put in too much. I'll check again when "hot" should be in the middle right?
Middle of the full/low marks more or less. Once you get the bike warm by riding it, it should be obvious if its over serviced. If you need to remove some oil just get a big syringe with some tubing attached and draw it out of the tank.
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Old 10-21-2014, 04:33 PM   #9
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Ok I didn't ride the bike but I let it idle and warm up to 6 bars as described in the manual. Level is between the lines. Odd, the cold level was the same as the warm level?

I also loosened and retightened the valve cover bolts.

What should I do next if the problem persists? Remove the plugged throttle body hose and let breathe? Stock they are connected to the canister which let's it breath...

Lou
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Old 10-21-2014, 05:23 PM   #10
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The corners of the half moon plugs are a common place to get leaks. The 'oriental' bikes have you always put a drop of sealer there.

I can see you have a big problem though, you're bike is too clean.
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Old 10-21-2014, 05:29 PM   #11
sweetlou OP
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KTM 990 Valve Cover Oil Leak

It's only a few months old and the seal around the half moon does appear to be wet

I've been rethinking the canisterectomy. Right now the suction tube is plugged. When connected to the charcoal canister it can "breathe" through the canister and also suck vapor from the tank.

Maybe the plugged suction like is causing increased crank case pressure?
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Old 10-21-2014, 07:29 PM   #12
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Quote:
Originally Posted by sweetlou View Post
Odd, the cold level was the same as the warm level?
Not odd at all. simply idling to warm does no good. You have to go ride it. Its a dry sump motor. Because of this, folks new to the bike tend to over service the oil. Here's what happens. you do an oil change, put in the required amount following the manual, etc. You idle it warm per the manual, finish the procedure all by the book, and when you check the level its barely on the dipstick, so you do what anyone would do and add more oil to get it in the middle of the dipstick, thus over servicing it. The bike will puke it out. Personally, if my bikes oil level was in the middle of the dipstick cold, I know its over serviced, BTDT.

Just to be sure, go ride it then check the level. My 07' 990 reads quite a bit higher level after I get it good and warmed up by riding it. It never has liked extra oil and will always puke it out. Been that way for well over 20 oil changes. If you find the level OK, then, might be a good idea to open up the air box next and see if its wet in there.

Since you said that you over serviced the oil, I would eliminate this possibility first before tearing the bike apart. Well, thats what I would do anyway. Simple shit first, and if that doesnt work, then work deeper.
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Old 10-22-2014, 09:32 AM   #13
sweetlou OP
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Good plan. Just for fun I removed 12oz of oil from tank and ran bike until fan kicked on. Id take it for a ride but it's raining. Oil level is at bottom mark. I'll go for a ride when rain stops and report back.

Thanks
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Old 10-24-2014, 06:40 PM   #14
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Have you had a chance to check it out yet?
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Old 10-24-2014, 07:08 PM   #15
sweetlou OP
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KTM 990 Valve Cover Oil Leak

Came back from a ride to get new tires put on, oil level is below top mark after removing 12oz oil so obviously it was over filled. Valve cover gasket was slightly wet but no drip. Didn't ride today (rain) but going for a ride in the AM so will report back.

Thanks
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