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

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

  1. akarob

    akarob Rob

    Joined:
    Apr 8, 2009
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    9,141
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    Skuncasville, CT
    I tight5ened mine once, it worked for a little while, then I was back to kicking it again. I recently got a top end job done (260 hours and valves were still in spec) and I had that part replaced as well. It's been superceeded so hopefully it's an improvement. So far, e-start heaven.

    Here's a link to that thread.

    http://www.advrider.com/forums/showthread.php?t=667644
    #41
  2. booniebasher

    booniebasher Been here awhile

    Joined:
    Dec 29, 2009
    Oddometer:
    712
    i am in the midle of doing the same mod on my rf4 2008 (450xcf)

    does the larger oil jet apply to my motor as well ?
    strange my bike has 50 hours on it and the gears are metal ?

    can anyone give me advice on this?
    munn sold me the three pumps and plastic gears with no mention of larger oil jet ?
    #42
  3. Hank.SD

    Hank.SD Jet Measurer

    Joined:
    May 15, 2007
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    1,376
    Location:
    Sodak
    Does anyone know if an 09 400 XC-W would benefit from the same upgrades? I'm assuming the bottom end is the same?

    I plan to install a Rekluse, and if I'm in there that far...
    #43
  4. resqd1

    resqd1 Been here awhile

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    if you have metal gears someone already put the blais kit in
    #44
  5. booniebasher

    booniebasher Been here awhile

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    Dec 29, 2009
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    Interesting ?
    thanks
    keith
    #45
  6. NWMotohead

    NWMotohead Motojunkie

    Joined:
    Dec 31, 2007
    Oddometer:
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    Location:
    PNW
    I just did this upgrade to my 09' 450 XC-W that has 4,200 miles on it. All the parts were still the original "old style" components. Wasn't having any transfer issues, but decided to upgrade the gears/cover/seal just in case. Thanks Hodakaguy! :D
    #46
  7. B-Rod

    B-Rod RubberNecker

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    Jul 28, 2007
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    I'm considering doing these updates to an '08 and my own '09 530. Any idea why the shaft is superseded or required? It's listed a few places as out of stock, and my pea brain can't imagine how the only dimension that is different, and only 1/3mm different, would actually have an implication. :dunno

    Anyone do the updates without doing the shaft?

    #47
  8. dieselcruiserhead

    dieselcruiserhead Long timer

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    Jul 25, 2008
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    Park City, Utah
    I have the shaft that came out of my 10. There was differing info about whether it would be the upgraded and it was. If you want, you can just have it for shipping...
    #48
  9. B-Rod

    B-Rod RubberNecker

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    Sent you a pm
    #49
  10. KTMLes

    KTMLes n00b

    Joined:
    Dec 3, 2013
    Oddometer:
    2
    I just bought a 2008 KTM 450XC-F. Do these upgrades apply to this model also? Is it the same engine as the XC-W?

    I really enjoyed the quality post. Nice job!
    #50
  11. Navin

    Navin Long timer

    Joined:
    Sep 22, 2009
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    21,464
    Different engine but you should rebuild the oil pump in that and get a DJH manual CCT and use the oil galley plug to direct more oil to the cams. I had that engine too. Rebuild the oil pump every year, change the oil very often and they are very good. If it loses oil pressure the head it junk and the bike is basically finished.
    #51
  12. joca400

    joca400 n00b

    Joined:
    Oct 19, 2014
    Oddometer:
    7
    Location:
    Croatia, Pula
    Large pump doesn't have an o ring am i right? I chaged all the seals and o-rings and pump cover and my bike still transfers a 1dcl of oil to transmission only when the engine is cold, when the engine gets hot i pour in that 1dcl and i ride it the whole day with the same engine oil level, any ideas? :/
    #52
  13. alongat

    alongat Fesh Fesh

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    Windsor, United Kingdom
    If you've updated your oil pump housing, you should use the o-ring specified for that housing (in hodakaguy's tutorial's parts list).


    #53
  14. RiderJCGone

    RiderJCGone n00b

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    Sep 21, 2009
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    Michigan
    I have an 08 450 SXF and need to know what size the oil jet is, and if it needs to be upped to the 125 jet.
    #54
  15. KTM Explorer

    KTM Explorer Dirt Whore

    Joined:
    Oct 6, 2011
    Oddometer:
    212
    Location:
    Kirkland, WA
    What the heck IS the gasket part number for the OUTER cover - the circular cover gasket?? I cannot figure this one out.. MUCH THX in advance!
    #55
  16. KTM Explorer

    KTM Explorer Dirt Whore

    Joined:
    Oct 6, 2011
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    Location:
    Kirkland, WA
    Under the black PC cover:

    [​IMG]
    #56
  17. Night Falcon

    Night Falcon Broke Engine Supporter

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    New Zealand
    78030027000 gasket outer clutch cover ​

    #57
  18. vintagespeed

    vintagespeed fNg

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    that's cuz it's an o-ring. :D
    #58
  19. BHTravis

    BHTravis n00b

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    May 30, 2015
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    grande prairie, ab
    I need some help please. I did the gear updates and the torque converter tighten for the e start and all that great stuff. Totally fixed the problem that the starter would just whine and not turn anything over, so thank you very much for that. But now that it starts right up, it sounds like a supercharger. I took everything back out again and looked for anything poping out at me but everything looks fine. It is pretty loud, could it be the new gears? It certainly doesn't seem right. There was a missing shim in my bike behind the torque converter, could that be it? I also pulled the water pump cover off to inspect and make sure i had lined that gear up correctly and it does spin. Anyone with any ideas? Thank you
    #59
  20. vintagespeed

    vintagespeed fNg

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    did you over-tighten the torque limiter clutch on the starter? aka torque convertor...

    the new gears do not increase running noise at all.
    #60