KTM 450 - 530 Oil Pump Upgrade! How To Article with Pics

Discussion in 'Thumpers' started by Hodakaguy, Jun 14, 2011.

  1. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    Did the upgrades on my friends 530 tonight.

    This picture shows the correct direction of the bevel spacer more clearly.

    [​IMG]


    Hodakaguy
    #21
  2. dirtRiderGuy

    dirtRiderGuy Adventurer

    Joined:
    Feb 7, 2010
    Oddometer:
    79
    Location:
    on a trail somewhere
    Well, to my eyes, the way it is in the bike and the way it's pictured in the diagram look opposite to me.

    I don't get it.

    Hey Hodaka guy...you don't see it???? Maybe it's me. Dunno at this point.
    #22
  3. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    Sorry, The diagram agrees with the pictures to me. :1drink

    Hodakaguy
    #23
  4. dirtRiderGuy

    dirtRiderGuy Adventurer

    Joined:
    Feb 7, 2010
    Oddometer:
    79
    Location:
    on a trail somewhere
    Ok, let's approach it this way:

    Look at the rings inner and outer diameters. The ring is beveled, so that the inner diameter is off plane with the outer diameter.

    In the diagram, the inner diameter is away from the engine center line and the outer diameter is closer to the engine center line.

    The way it's pictured (in reality) on the bike in the actual pictures taken is such that the outer diameter is away from the engine center line and the inner diameter is closer to the engine center line.

    Upon very close inspection this is what I see.

    They appear opposite to me.
    #24
  5. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    I'm not following.....we have a disconnect in communication I think lol. Ok...this pic isn't the best but maybe this will help.

    [​IMG]

    Hodakaguy
    #25
  6. husqvarna

    husqvarna Been here awhile

    Joined:
    May 29, 2007
    Oddometer:
    166
    Location:
    Darkest Efrika
    Great write up, thank you for your time.

    Two little comments:

    Did you check the O Ring material? As for below the quality is not always the best and you may consider sourcing a premium quality O Ring of the same size if the OEM one is not at least Viton. I'm on thin ice here as I don't know the materials but we've had some marginal specifcation O Rings on the engines we've worked on,

    An off topic note; we work on some big (1000kW) Austrian made engines and it's clear they are under cost pressure to have parts made in the East and Eastern Europe, often with quality issues. Also the Austrains are not the easist to deal with as many of them (the salesmen for sure) having a know it all attitude, particularly when dealing with us Africans. And they do not always know it all. KTM's should be evaluated with the same critical attitude (I've got 3, I sort of know). Spares are a major rip off for both brands (spark plugs for the big engines run to around $US700 each and last about a year; 20 per engine)..
    #26
  7. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    The material is Viton

    What large engines do you work on? I work on some large engines as well and the parts can be expensive for sure.

    Hodakaguy
    #27
  8. Stellar_D

    Stellar_D n00b

    Joined:
    Apr 13, 2012
    Oddometer:
    1
    Sorry for the noob question, but does the updated oil pump cover also address the oil migration issue?

    Outstanding write up. I'm having troubles with the estart on my 08 exc 450 and was going to try to use the torque limiter fix to try and resolve it. Going to update the pump while i'm at it.

    :freaky
    #28
  9. JTOP

    JTOP Tree Top Flyer

    Joined:
    Jan 19, 2012
    Oddometer:
    15
    Location:
    Olympia, WA
    First off, great write up. It's threads like these that make these forums such a valuable resource for idiots like me.

    I picked up an 09 530 EXC this winter and have been gone for work most of the time I've owned it. It only had 400 street miles when I picked it up and is pretty much a new bike. I bought a Rekluse clutch for it and decided that while I was intaslling that, I might as well do all the upgrades for the oil pump while I had it apart. Everything went well with the clutch and oil pump, but now I have a oil seep coming from the clutch cover (the bigger one). I'm not really sure why this has developed. Both surfaces were clean, I installed a new gasket and torqued the bolts to spec. Upon inspection I can see that the gasket is in the correct place. Today I went out and tightend all the bolts securing the clutch cover about a 1/4 turn more hoping that would stop the flow, but it hasn't. My question is, do I really need the gasket? Could I just take it off and use some kind of gasket maker or would that be a bad idea? Any sugestions would help. I would hate to buy another gasket just have that one leak too.
    #29
  10. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    The updated O-ring that goes behind the cover can address some oil migration issues...if thats where it's leaking from. It can transfer at the O-ring, the crank seal and even through the case halves (Friends 08 just had that happen).

    Hodakaguy
    #30
  11. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State

    I had the same thing happen once and had to remove the gasket and install a new one...second one held just fine. Not really sure why my first one didnt seal up, and it hurts when a stupid gasket is that expensive! :eek1

    I would use a gasket instead of sealant, bits of sealant inside the case have a way of finding their way into small oil ports and pluggin them up :deal
    #31
  12. CalKev

    CalKev n00b

    Joined:
    Nov 2, 2012
    Oddometer:
    3
    Hodakaguy,

    If I order the part # for the 2011 530 will it be the new improved version? I've called KTM Hutt and KTM World and neither know about the upgrade. KTM notes the superseded part number for the oil pump shaft for the 2011 but the pump gears (both 17 & 27 tooth) remain the same. Neither had in stock to look at and compare and both kept repeating that they should be the same part since the part numbers are the same and not superseded. My fear is that I get the same non upgraded gear and have to wait all over for the parts to be returned and look elsewhere.

    Where did you order from?

    My 2008 530XCR-W broke (27 tooth) while at idle with a piece getting caught between two gears which stalled the bike about 1/2 a mile from our camp. Thankfully I was wasn't rippin' through the gears which would have chewed the piece up and eventually seize the bike. We were on our way to a 10k altitude ride in Bishop California & would of had a tough time getting her back 60 miles out and up high.

    Thanks in advance and great write up. Actually awesome as well as the others!

    CalKev
    #32
  13. Y E T I

    Y E T I Unpossible

    Joined:
    Apr 26, 2007
    Oddometer:
    8,335
    Location:
    San Diego
    You might want to consider the Blais racing aluminum gears. You can get them HERE
    #33
  14. CalKev

    CalKev n00b

    Joined:
    Nov 2, 2012
    Oddometer:
    3
    YetiGS,

    Thanks for the reply! Would prefer them but can't justify the $90 at the moment. For $70 + shipping I can replace the oil pump cover, o-ring, pump shaft, both gears, circlips etc. According to what I've read here and elsewhere on the net the new gears seem to be doing well. I wish KTM would cover the update costs or at least the parts. As I said in my original post the consequences could have been worse. Thankfully I was at idle when the gear broke.

    CalKev
    #34
  15. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,222
    Location:
    Eastern WA State
    Yep, order the part numbers listed in the first post and you'll get the new parts :thumb

    Hodakaguy
    #35
  16. CalKev

    CalKev n00b

    Joined:
    Nov 2, 2012
    Oddometer:
    3
    Thanks Hodakaguy! Apparently there is a 2 week back order. If anyone knows of a dealer that has the updated parts in stock, please let me know. I have a Thanksgiving weekend trip coming up.

    CalKev
    #36
  17. Nijntje

    Nijntje The Riding Dutchman

    Joined:
    Aug 4, 2010
    Oddometer:
    28
    Location:
    Southern Oregon
    Wow, what a great write up! As I need to tighten the e-start torque limiter, my plan is to do this as well in the next couple of weeks, but I'm curious if there is any actual difference in the oil pump covers. Maybe just size to accommodate the larger o-ring perhaps?
    #37
  18. SmashingPumpkins

    SmashingPumpkins Dinah-Mo-Humm

    Joined:
    Jul 18, 2006
    Oddometer:
    287
    Location:
    Coldwater MI
    I've wondered this too.

    Also, can the new o-ring be used on the old pump cover?
    #38
  19. dieselcruiserhead

    dieselcruiserhead Long timer

    Joined:
    Jul 25, 2008
    Oddometer:
    1,622
    Location:
    Park City, Utah
    thanks for this. I did this last night in about 2-3 hours tops, it was super easy. I only wish you could pull the water pump, clutch, and oil pump gears in 2-3 hours in a car.. It was actually a pleasant job..

    2010 450 XC-W Six days.
    This is a unique model a lot like your 530 six days where some parts of it are a 2011.

    It had the newer gears, old oil pump cover and o rings, and new shaft. Only difference between my '10 450 six days and your '10 530 six days was that yours didn't have the newer shaft...

    things for me:

    old oil pump cover had same part number but there was a "2" on it instead of a "3"
    [​IMG]

    shafts appear to be the same, measured the same in thickness...
    [​IMG]

    decided to bling it up also...
    [​IMG]

    the whole side of it, super pleasant. I also didn't use a clutch basket tool, I just put in gear with the rear tire on the ground, and used the air gun. It should be OK I figure...
    #39
  20. ARZ

    ARZ Adventurer

    Joined:
    Jan 26, 2010
    Oddometer:
    75
    Location:
    Mesa AZ
    I read this thread forward and back and didn't see any details on tightening up the E-start Torque limiter. Or even how to check it. Anyone have a link?

    Im in the process of a full rebuild, on a 2010 530 XCW, and my pump gears failed, along with a few other things. Any chance any of you have seen another thread that documents a full rebuild on one of these motors?
    #40