KTM520 metal shavings in oil = gearing

Discussion in 'Thumpers' started by Datan556, Mar 7, 2013.

  1. Datan556

    Datan556 Adventurer

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    Good day everyone

    Drained the oil on my KTM520exc recently and found metal shavings in the oil. I opened up the ol girl and had a look. It appears its the gearing behind the clutch plates. The teeth on one of the gears are stripped of, only a few, and there was another gear that just fell out. Not connected at, sat on the top right hand of the casing that I removed. I cant upload any photos cause I'm a boob. (dont know how and no i do not have a smugmug or pocketpic:rofl whatever)

    Should that gear be loose and topple around in the engine side? dont think so, its my first hand experience with KTM and 4strokes for that matter. Wont be offended if anybody reply and say I'm a twat.

    Please help so I can find out if I can just chuck that gear if its not in use
    #1
  2. crazybrit

    crazybrit Long timer

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    If you are going to the trouble of posting pictures, you'll get much better answers over at ktmtalk in the "racing four strokes" forum (they allow you to post pics there without needing a smugmug account or similar). This is where all the engine builders hang out and there is probably one thread a week about "what are these bits in my oil". good luck!
    #2
  3. Navin

    Navin Long timer

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    Is there a groove on the gear shaft for a circlip?
    #3
  4. Datan556

    Datan556 Adventurer

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    NOTED

    Thanks
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  5. Foot dragger

    Foot dragger singletracker

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    Gee,I dont think tossing gears out because they came loose is a good idea.
    Maybe find a mechanic or workshop manual.All those gears tend to be there for a reason.

    Any metal shaving loose in an engine will destroy the rest of the engine at some point in time,unless your really,really lucky.
    #5
  6. Datan556

    Datan556 Adventurer

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    does anybody know what this gear is and does? Is it the estart gear?

    A buddy said its the idler gear. Im not sure on reading up on internet. click on link to have a look please...

    http://t.co/zxONNuruyn
    #6
  7. Foot dragger

    Foot dragger singletracker

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    You need a manual,tearing into a high dollar 4 stroke engine and asking what parts are on ADV isnt going to work well.
    #7
  8. Escaped

    Escaped Been here awhile

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    :nod:nod
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  9. Datan556

    Datan556 Adventurer

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    Do have a repair manual, asking for hep to make sure im not twatting the thing any further. Thanks for input
    #9
  10. tundradirtbiker

    tundradirtbiker Been here awhile

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    The 520 has some bad history with starter gears. KTMtalk mechanics DJH,Caflash & Kev have the best handle on KTM issues. Look for their posts, and post the pics. RFS hx is pinned at the top for bike problems to check and fix for better service.
    #10
  11. Datan556

    Datan556 Adventurer

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    #

    cheers, have got a post on KTMtalk, my manual says one part and the parts book says another...nice and confused at the moment.
    #11
  12. Navin

    Navin Long timer

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    A pic would help.
    #12
  13. Datan556

    Datan556 Adventurer

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    #13
  14. MKJ

    MKJ Married w/ Children

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    The intermediate gear is the one that has lost teeth. Pull the clutch and you can get to the clip that holds it on. Replace the gear with another. There are other options you can do, but this is the simple, stock fix. The gear that "fell" out fits in the the hole in the case just forward of the intermediate gear. It has a needle bearing on the shaft. The other end of the shaft fits into the hole on the side cover. Try a fit up, you will see what I'm talking about. Easy fix.


    Ohhhh...... I forgot.












    Your a twat.
    #14
  15. Droptarotter

    Droptarotter Long timer

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    Hey Twat;
    It's an easy fix........pull the clutch and change the intermediate gear.......order parts from Munn's and all will be well!

    Cheers
    #15
  16. Datan556

    Datan556 Adventurer

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    Thanks, didnt replace it, just ripped it out for now, KTM dealership in Dubai doesnt have it and oredering online is a because nobody ships to this part of the gulf

    yours truly

    Twat
    #16
  17. Datan556

    Datan556 Adventurer

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    sorted, not easy as in a western world though... o well

    regards

    his royal twatness
    #17
  18. Foot dragger

    Foot dragger singletracker

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    I shipped a Norton part to Dubai once,it took 6 months to show up but it did get there.

    I cant believe KTM put any gear in there just for laughs and giggles.
    #18
  19. Datan556

    Datan556 Adventurer

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    its for the e-start actually

    6 bloody months!!!!! dont have the patience for that :rofl

    Im on KTMtalk and there are some really helpful chaps. GOt a contact in UK that will order and send through private comp.

    O well, such is life in middle east!
    #19