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Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by DeeGee, Jul 8, 2009.
Mine engine is completely apart right now. What do you want a picture of?
Thanks for your info... so far the Formagasket has been holding up until I locate the O-Ring replacement. (Really an Odd Size and not easy to find)
St..Dave was nice enough to give me the dimensions of his replacement but been too busy to find one yet.
Glad your worked out well.
The spec's AdvGa refers to are the O-ring I picked up from Ace Hardware. The KTM spec's are for a 27.5mm x 2.5mm but the local dealer didn't have one in stock. I headed to Ace and couldn't find anything in the metric O-rings but I did find one in the standard O-rings that converted to very close to the size needed. The Ace package was for a 1 1/4" x 1 1/8" x 3/32", #77 O-ring, stock no 35716B.
removed the tanks and skid plate
cleaned all the grunge off it with 2 stroke gas and a parts brush, then detergent followed by water and dried it real good with compressed air then some brakecleaner spray
put the left tank on, dusted it with talc and ran it up to 5,000 rpm for a few minutes
and found it right away
embarrassingly it is dripping from the oil filter cover :eek1 , what a relief to find it. I must have buggered the Oring ....oooFh
All the other leakeage is ooze this is a steady drip
the ooze ran right down to the cover and threw me off because I suspect the highest leak first and my test was after no cleaning and a 200 mile hi speed , hard to find in all that wet looking grunge
and its all clean under the hood now
I figured out what I did wrong
I used a pick to pry out the old oil filter last time and left a burr on the O-ring mating surface
evidently it only leaked at high pressure not idle
removed the burr and stopped the leak
i cant believe how much grunge had built up, it took a lot of cleaning
it kinda looked like the bottom of an 18 wheeler all the way up to the heads
Glad you got it sorted and it didn't cost you a load of cash.
Just the cover assembly and oil seal for the starter motor, when you have a minute. Thanks.
Starter itself has an oring. This is the only seal to replace in the generator cover.
Hope this helps...
Don't think he meant that but the O-ring which is behind the startermotor, located inbetween the V.
Think that Pyn had a picture on that one somewhere in his thread. Will try and find it...
Wasn't sure, but he said seal and not o ring. It is an o ring on the starter motor.
I'll dig that out of the box today. IF the case gasket comes in and motivates me to start reassembly.
Just in case while your doing your winter maintenance and have an Oil Leak, take a look at your Oil Pressure Switch.... sure enough, mine was Leaking:
Taken from DeeGee's Post:
And the oil pressure switch is damp and oily
Parts list from for my '06 Adventure:
60038091100 OIL-PRESSURE SWITCH LC8 04 $10.00
Taken out with a 13/16" or 21mm Deep Socket
This is the
Oil Vent Crankcase Seal in case you need this too:
0760122050 SEAL 12X20X5 B $10.00
Well, it started leaking again, the Gear Shifting Sensor, so I found this O-Ring at Ace Hardware
1 3/16 x 1 3/32 #20 O-Ring Stock # 35737B that seems to be working in addition I Cut a Gasket from Flat Gasket Material to cover the Plastic Flange.... also,
I had to Epoxy the Exit Wires out of the Plastic Sensor since it appeared Oil was Leaking out of the Wire Exit Area.
It appears this Plastic Sensor is too flimsy with only 2 screws holding it in place.
When I did the Valve Check, Replaced the Oil Pressure Sensor that appeared to be leaking out of the Plastic area where the Wire Connects.
Thanks for your help !!
Had to exchange my Gear Position thingy a few months back and KTM have updated the design and added an extra wire... It's a ground wire... But I thin kit looked alot more sturdy and hope it will do the trick and at only $30 I think it's worth it.
I got a 05.5 (or 05 here in Sweden).
Thanks for letting us know....
this does not surprise me and glad to see some warrantted changes were made on this item. Next time, I will have to get the New Model.
Man you've gotta love the OC and this forum
Speaking of the gear selection thingy, that seems to be where mine is leaking from as well. Just lean and support the bike to the right side and replace O ring? Would like to avoid draining all that clean oil I just put in...
When you do this, take out the Gear Position Sensor, Oil may Drip but not gush out.... you should not have a problem.
Just installed a New GEAR-POSITION SENSOR #60011023100 on the '06 Adventure... the Old One was Leaking Oil out of the potting material and out of the Wires.
The New One has Brass Nurling around the Screw Holes, has better Potting Material, and is made in Japan.
However, it DID NOT COME With an O'Ring...just to let you know.
I got a 950SE '06, that is leaking from that spot also. What sensor is it? Problem to replace?