Oil leak at counter shaft on KTM 450

Discussion in 'Thumpers' started by marin ktm, Oct 9, 2011.

  1. marin ktm

    marin ktm Been here awhile

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    I have a slight oil dribble at the counter shaft on my '07 KTM 450 EXC. Does anyone have any advice on replacement?
    #1
  2. Off the grid

    Off the grid Unsmooth Operator

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    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.
    #2
  3. Albie

    Albie Kool Aid poisoner

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    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.
    #3
  4. ChrisC

    ChrisC Amal sex?

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    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...

    [​IMG]
    #4
  5. LukasM

    LukasM Long timer

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    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
    #5
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  6. wrk2surf

    wrk2surf on the gas or brakes

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    and keep that chain LOOOSE..
    #6
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  7. marin ktm

    marin ktm Been here awhile

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    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.
    #7
  8. Albie

    Albie Kool Aid poisoner

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    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!
    #8
  9. r'elise me

    r'elise me Been here awhile

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    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!
    #9
  10. BogeyMan

    BogeyMan Been here awhile

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    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.
    #10
  11. Albie

    Albie Kool Aid poisoner

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    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.
    #11
  12. jms415

    jms415 KTM disciple

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    Anyone know if the 2010 450 EXC engine oil would leak thru the counter shaft seal?
    #12
  13. Grreatdog

    Grreatdog Flamed out

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    AFAIK it uses the same o-ring, bushing and seal setup that KTM has always used. So, yes, that does go bad over time.

    All three parts total maybe $20. So do them all. It is just a few minutes to install. Most dealers and all on-line places are going to stock them.

    And buy yourself a seal puller. Seriously, they are less than $10 at any auto parts store and save a lot of aggravation (and possible case damage).
    #13
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  14. wsmc831

    wsmc831 Been here awhile

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    ...and a Dirt Tricks washer. My oem flattened out after just a few hours, better one fixed the weep.
    #14
  15. jms415

    jms415 KTM disciple

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    Thanks for the suggestions, I picked up some parts.

    I have oil leaking out from the engine sprocket area and just wondering....

    Does anyone know if the engine oil leaks out the countershaft seal or is it the gear oil?

    I think it is the gear oil.
    #15